Engineering Failure Analysis 15 (2008) 445457

www.elsevier.com/locate/engfailanal

Computational and experimental failure analysis

of continuous-annealing furnace radiant tubes
exposed to excessive temperature
Ghasem Dini a,*, Sayed Mahmoud Monir Vaghe a, Mostafa Lotani a,
Majid Jafari a, Mohammad Safaei-Rad b, Morteza Navabi b, Shahram Abbasi b

a
Department of Materials Science and Engineering, Isfahan University of Technology, 84154 Isfahan, Iran
b
Mobarakeh Steel Company, 84815-161 Isfahan, Iran

Received 9 February 2007; received in revised form 22 March 2007; accepted 18 May 2007
Available online 5 June 2007

Abstract

Radiant tubes of a continuous-annealing furnace at Mobarakeh Steel Company failed after a fraction of their rated
service life. The tubes were manufactured from INCONEL alloy 601 superalloy. In this study, a failure analysis of the radi-
ant tubes was performed by careful visual inspection of the failed tubes, scanning electron microscopy observation of crack
region samples, energy-dispersive X-ray spectroscopy and X-ray diractometer analysis of the tube metals and oxide
scales. The temperature distribution for steady-state heat transfer and the structural stresses induced by the weight of
the tube material were also studied in this paper. The nite element method (FEM) was employed to compute the eect
of increasing temperature on tube service life and to dene the critical regions.
The experimental results showed that the mode of tube failure was a combination of creep damage and high-temperature
oxidation attack which led to cracking. Signicant growth of carbide precipitates was also observed in the failed zones; these
precipitates result in both the drastic reduction of material ductility and the propagation of creep cracking. The simulation
results showed that the damaged region in radiant tubes is susceptible to high-temperature creep. Tube failure occurred as
a result of bending in the tube length, which may be responsible for subsequent hot-spot formations and high-temperature
oxidation. Furthermore, the tube failure veried experimental results. Moreover, a simulation indicated that modication
in radian tube installation is necessary because utilization of supports in specic locations can extend creep life.
2007 Elsevier Ltd. All rights reserved.

Keywords: Failure; Radiant tube; Creep; Oxidation; Finite element method

1. Introduction

For the continuous annealing of moving steel plates undergoing galvanization, the plates are usually
allowed to pass between two radiant tube rows that are located above and below the pathway. The plates
*
Corresponding author. Tel.: +98 311 3915741; fax: +98 311 3912752.
E-mail address: gh_dini@ma.iut.ac.ir (G. Dini).

1350-6307/$ - see front matter 2007 Elsevier Ltd. All rights reserved.
doi:10.1016/j.engfailanal.2007.05.007
446 G. Dini et al. / Engineering Failure Analysis 15 (2008) 445457

are heated by radiation from the radiant tubes with inside burners. Since the burner is located inside the tube
and hot ue gas passes through the tube, the radiant tubes are continuously operated at high temperatures.
Due to this prolonged exposure to high temperature, the radiant tube material is subject to degradation.
Despite careful selection of the materials, design and operations, failures can hardly be avoided because of
complicating factors such as overheating and creep. As a result, thinning of the tube and crack initiation occur
frequently. Gas leaking through the developing crack often causes both operating problems and serious sur-
face nish problems on the galvanized plate product [1]. Since the operating temperature of the tubes is
expected to be well above 900 C, they are generally fabricated from 3- and 5-mm wrought heat-resistant
alloys having high contents of Ni and Cr. Wrought alloys for radiant tubes include types 309, 310, RA
330, 800H, 601, 230, and 214. Most radiant tubes are red with natural gas in the inner diameter. Therefore,
the inner diameter of the radiant tube is subject to oxidation and the outer diameter of the tube is exposed to
the furnace atmosphere [2].
In this study, a failure analysis of fabricated radiant tubes was performed and the nite element method
(FEM) was employed to compute the eect of increases in temperature on the tube failure mode and to dene
the critical regions.

2. Background

These radiant tubes were used in the continuous-annealing furnace of Mobarakeh Steel Company (MSCo)
to produce galvanized steel sheets. The galvanizing line at the MSCo was built in December 2003. The lines 13
heating zones contained 156 fabricated radiant tubes (P-type) from another manufacturer. The arrangement
of the radiant tubes is shown in Fig. 1a. Radiant tubes are designed to operate at 960 C; the furnace temper-
ature is maintained between 750 C and 850 C by a design requirement based on the sheet thickness. After
about 26 months in service, the rst radiant tube damage was reported. The rst tube failure occurred in zone
6. During the line shutdown in May 2006, 30 tubes were replaced. By the end of 2006, 29 additional tubes had
failed and been replaced.
In general, the damage style of a number of the tubes is almost the same. The failure mode of the tubes
appeared to be in the surface of the tube, about 6590 cm from the burner-mounting ange (Fig. 1b).
Failure of the inner surface of the tube appeared to cause the failure of the outer surface of the tube,
which allowed the combustion products into the furnace chamber and consequently required shutting
down the burner.

3. Experimental and results

3.1. Visual examination

Visual inspection revealed that the radiant tubes usually failed at the same location (about 6590 cm from
the burner-mounting ange). Investigation of all failed tubes indicated that most of them failed completely
with a big hole through the tube wall (Fig. 2a). In some tubes, however, cracking in the same location was
responsible for the tube failure (Fig. 2b). In these failed tubes, the cracking direction was not random, but
was related to the principal stress direction. From this observation, it can be argued that the stress generated
in the tube due to tube weight and creep is the major cause of cracking.
Generally, all failed tubes showed similar banding and evidence of localized wall thinning, i.e., metal wast-
age by high-temperature oxidation and erosion. Also, a scale developed on the tube as a result of exposure to
elevated temperatures; this appeared to be adhered to the surface, with no evidence of aking [3].

3.2. Materials

Chemical analysis by energy-dispersive X-ray spectroscopy conrmed the radiant tube material to be a
nickel-base superalloy (INCONEL alloy 601). An energy-dispersive X-ray spectrum representative of the tube
material is shown in Fig. 3. Table 1 illustrates the results of quantifying the spectral data of Fig. 3 in compar-
 G. Dini et al. / Engineering Failure Analysis 15 (2008) 445457 447

Fig. 1. Illustration of a radiant tube: (a) for an annealing furnace; (b) top view; (c) side view.

Fig. 2. Failed radiant tubes with (a) big hole or (b) cracking.

ison with the nominal chemical composition of INCONEL alloy 601 [3]. The material specication and design
parameters are also given in Table 1. The composition of the tubes is in agreement with the requirements of
the specications for INCONEL alloy 601.
448 G. Dini et al. / Engineering Failure Analysis 15 (2008) 445457

Fig. 3. EDS spectrum from the tube material.

Table 1
Nominal and measured chemical composition (wt%) of INCONEL alloy 601 and design parameters
Tube material INCONEL alloy 601
Element C Si Mn S Cr Ni Al Cu Fe
Nominal 0.027 0.30 0.26 <0.001 22.6 59.38 1.3 0.13 Bal.
Measured 0.1 0.6 22.5 61 1 Bal.

Design temperature 960 C

Tube size Outer diameter 200 mm
Thickness 3 mm
Length 134 cm

3.3. Microstructure of specimens (failed and unfailed)

In order to compare the microstructure between the damaged zone and the normal zone, SEM metallo-
graphic samples were prepared from the dierent sites. Sample No. 1 was cut from an unfailed zone and sam-
ple No. 2 was cut from the zone that was immediately adjacent to the failed zone.
In Fig. 4a, sample No. 1 shows an austenite matrix and a network of primary carbides, which is the typical
microstructure of alloys with high chromium and nickel contents [4]. Fig. 4b shows the microstructure of sam-
ple No. 2. The carbides have obviously increased and coalesced, which indicates overheating.
The energy-dispersive X-ray spectroscopy of sample No. 2 revealed that the grain boundary constituent
consists of Cr-rich carbide as illustrated in the EDS spectra of Fig. 4c. Wrought heat-resistant nickel-base
superalloys such as the INCONEL alloy 601 consist of austenite matrix (face-centred cubic solid solution
of Fe, Cr and Ni) and carbide precipitates. Such austenitic superalloys are characterized by good creep
strength so long as the carbide precipitates are properly distributed throughout the austenite matrix. To pro-
mote creep strength, the carbides must be in the form of a ne dispersion in the austenite matrix, which can be
achieved by exposure to a relatively low temperature. However, as the temperature increases, the carbides
become coarser and lose their eectiveness as a source of strength. Continuous networks of grain boundary
carbides are undesirable because they embrittle the alloy and promote cracking [5]. Evidence for overheating
or hot-spot formation can thus be provided by the size of the carbide precipitates.
As mentioned above, massive carbide precipitates at grain boundaries and throughout the austenite matrix
of the failed zone are illustrated in Fig. 4b. From the rather large size of the carbide precipitates, it could be
concluded that the tube was exposed to an excessively high temperature [6]. As can be seen, the carbides
formed a continuous network at grain boundaries, which is detrimental to creep strength. Voids at the car-
bide-austenite interface could be distinguished as indicated by the arrows in Fig. 4d.

3.4. Analysis of the scale formed on the failed tube

To investigate the cause of the severe oxidation, microstructural and chemical analyses were performed on
the oxide scale. A piece of oxide scale was detached from the tubes interior surface and analyzed.
 G. Dini et al. / Engineering Failure Analysis 15 (2008) 445457 449

Fig. 4. SEM images showing the microstructure of (a) unfailed and (b) failed tube materials. (c) EDS spectra obtained from grain
boundary precipitate in (b). (d) SEM image of failed tube illustrating voids at the carbide-matrix interface.

Fig. 5 illustrates the results of scale analysis. As can be seen from the secondary electron SEM images of
Fig. 5a, the surface scale consisted of an aggregate of granular particles and an underlying oxide. Both X-ray
diraction (Fig. 5b) and energy-dispersive X-ray spectroscopy (Fig. 5c) revealed that the surface scale con-
sisted of oxides of the major elements in the alloy, i.e., Fe, Cr and Ni.
Analysis results of the oxide scale showed that the Cr content increased and the Fe content decreased con-
siderably. Thus, it can be predicted that Cr2O3 is the oxidation product in the oxide scale. Although the alloy
was capable of developing an oxide scale, the presence of voids and cracks provided evidence that this was not
suciently protective [7].

3.5. Fractography

Since the surface of the primary crack (crack which penetrated the entire thickness of the tube) was covered
with the oxide scale, it was not possible to clearly identify the fracture mode. To determine the fracture mode,
some of the early phase cracks were propagated to complete separation and the freshly exposed surface was
450 G. Dini et al. / Engineering Failure Analysis 15 (2008) 445457

Fig. 5. (a) SEM image of scale morphology; (b) XRD pattern; and (c) EDS spectra derived from the surface scale.

examined, as illustrated in Fig. 6. Figs. 6bd show the SEM photograph of the initial and fresh fracture sur-
faces. The general view shows ductile fracture and crack propagation along the precipitates.
The mechanism of fracture can be explained as follows. Since the matrix metal around the precipitates pos-
sesses good ductility and toughness, when the fracture takes place due to creep along these precipitates, the
surrounding metal matrix presents with ductile fracture. So, the fractography looks like ductile fracture in
a general view [8].
 G. Dini et al. / Engineering Failure Analysis 15 (2008) 445457 451

Fig. 6. (a) Photograph of the failed tube with the primary crack indicated. SEM image showing: (b) the initial and fresh fracture surfaces;
(c) the fresh fracture surface; and (d) the initial fracture surface.

To summarize, the mode of failure of the radiant tube was a combination of creep damage and oxidation
attack.

4. Finite element method

As mentioned previously, the radiant tubes are subjected to high temperatures in continuous-annealing pro-
cesses. Their mechanical characteristics are subjected to deterioration during long-term service exposure due
to microstructural degradation and damage accumulation. For example, the experimental results indicated
that precipitates coarsening during service leads to progressive loss in both creep resistance and ductility.
One of the main concerns in the high-temperature design of radiant tubes is the estimated service life of the
tube under creep condition. Many methods for life prediction have been proposed. When evaluating the ser-
vice life of a well-known material, one simple strategy is to calculate the structural stresses applied to the com-
ponent under design and operation conditions. Therefore, the nite element method (FEM) was employed to
compute the eect of temperature increases on the tube service life and to dene the critical regions. The tem-
perature distribution for steady-state heat transfer and the structural stresses induced by the weight of the tube
material were also studied in this simulation.
In general, there are three steps in the development of a nite element model [9]:

(1) developing a geometrical model, selecting an element, determining material properties and nally con-
verting the geometrical model to a nite element model by griding;
(2) applying boundary and initial conditions, loading and performing calculations based on the model; and
(3) extracting results.

4.1. Modeling

The nite element model of the radiant tube was developed using the available plane of a tube (Fig. 7a) and
the modeling facility of ANSYS software. Visual inspection revealed that the radiant tubes usually failed at the
452 G. Dini et al. / Engineering Failure Analysis 15 (2008) 445457

Fig. 7. Radiant tube: (a) sketch and (b) model.

same locations. Therefore, in order to simplify the model, the initial part of the radiant tube was not consid-
ered in the model development.
With respect to the physical condition of the tube, the thermal and structural elds have important eects in
this model simulation. For this reason, the thermal and structural elements with specications given in Table 2
were selected for model griding [9]. The properties of the tube material (INCONEL alloy 601) are also given in
Table 3 [10]. Fig. 7b represents the model and its grids.

Table 2
Element specications of radiant tube for thermal and structural analysis
Name of element Geometrical consideration Degree of freedom
Thermal 3D solid 70 8 node 3D space Temperature
Structural 3D solid 45 8 node 3D space Transition (ux, uy, uz)

Table 3
Properties of INCONEL alloy 601
Temperature (C) 500 600 700 800 900 1000
Thermal conductivity (W/m C) 19.5 21 22.8 24.4 26.1 27.8
Specic heat capacity (J/kg C) 578 603 632 657 686 712
Youngs modulus (GPa) 178.2 170.8 161.3 150.2 137.9 124.7
Poisson ratio 0.308 0.327 0.34 0.35 0.37 0.395
Expansion coecient (lm/m C) 15.19 15.62 16.11 16.67 17.24 17.82
Density (g/cm3) at 25 C 8.11
 G. Dini et al. / Engineering Failure Analysis 15 (2008) 445457 453

4.2. Loading and model calculations

In order to analyze the model, the method of indirect solution of coupled elds was selected since there are
simultaneously two eective elds [9]. In this indirect method, calculations of the model can be performed in
two steps.
First, the thermal conditions are analyzed and results of this analysis are saved in a le. In the second step,
the model simulation concludes by applying the structural conditions and combining those results with ther-
mal analysis.
In the thermally developed ow of a gas with constant properties, the heat transfer coecient, h, is constant
[11]. In order to determine h, the temperatures at several locations in the tube were measured. The tempera-
tures and measurement positions are given in Table 4.
In addition, at the initial end of the tube, the displacements were kept to zero in all directions (x, y, z) and
the tube was allowed to elongate in the longitudinal direction (y-direction). After applying the weight force of
the tube and performing the structural analysis, the thermal analysis was reloaded at dierent burner temper-

Table 4
Radiant tube temperature and position of measurement
Distance from burner-mounting ange (cm) 10 20 30 40 50 60 70
Temperature (C) 870 910 915 920 935 940 940

Fig. 8. Results of a simulation at 1100 C: (a) total displacement in the y-direction; (b) temperature prole; and (c) maximum displacement
in the z-direction.
454 G. Dini et al. / Engineering Failure Analysis 15 (2008) 445457

atures. Finally, to estimate the creep life of the radiant tube under those operating conditions, the distribution
of internal structural stresses as induced by the weight of the tube was determined.

4.3. Results of modeling

The total displacement in the y-direction, the temperature prole and the maximum displacement in the z-
direction were determined through the tube model using ANSYS nite element software at dierent burner
temperatures. For example, Fig. 8 shows the results of a simulation at 1100 C.
In Fig. 9a, the eect of the burner temperature on the total displacement of the tube in the y-direction is
presented. As expected, the total expansion increases with temperature.
Fig. 9b shows the length of the computational region with a temperature higher than 960 C. As can be
seen, the length of the critical region increases with burner temperature.
The maximum displacement in the z-direction versus the burner temperature is presented in Fig. 9c. As can
be seen in this gure, the maximum displacement values increase to about 2.1 mm at 1100 C.
Fig. 10a shows the distribution of structural stresses through the tube model. In order to estimate the creep
life of the tube under creep conditions, the stress values obtained from Fig. 10a are presented in Fig. 10b. As
expected, the maximum value of stress (4.8 MPa) is located in the damaged area, where the temperature is at
a maximum.
As reported, the crack at the damaged area (Fig. 1b) caused the leakage of combustion products after about
14,000 h. The creep crack initiation life is estimated using experimentally generated average stress rupture
curves, as shown in Fig. 10c [10]. From this gure, it can be seen that by increasing the temperature, the esti-
mated life decreases at constant stress (4.8 MPa). It is also noteworthy that the estimated life at 1095 C is
nearly equal to the service life which initiates the crack in the failed radiant tubes.

Fig. 9. Results of a simulation at dierent temperatures: (a) total displacement in the y-direction; (b) length of region with temperature
higher than 960 C; (c) maximum displacement in the z-direction.
 G. Dini et al. / Engineering Failure Analysis 15 (2008) 445457 455

Fig. 10. (a, b) Distribution of the structural stresses; (c) creep rupture property of INCONEL alloy 601 [10].

It can be concluded that if the operating temperature exceeds the recommended temperature range, the ser-
vice creep life of tube decreases and creep rate accelerates. Therefore, a radiant tube should be operated within
the recommended temperature range. In order to increase the furnace eciency by increasing the burner tem-
perature, modication of the radiant tube installation is necessary and utilization of supports in a specic loca-
tion could reduce the structural stresses induced by weight and extended creep life.

5. Discussion

Abnormal oxidation problems of high-temperature Ni-base superalloy are generally caused by improper
operating temperatures exceeding the recommended temperature range. The material of the radiant tube in
this study is similar to the well-known INCONEL alloy 601. This material is known to have excellent high-
temperature oxidation resistance by forming a Cr2O3 protective oxide lm. However, if the service tempera-
ture exceeds 1000 C, the stabilized Cr2O3 lm becomes unstable and transforms into volatile CrO3, thereby
456 G. Dini et al. / Engineering Failure Analysis 15 (2008) 445457

losing its protective eect. Therefore, to prevent abnormal oxidation, the current radiant tube material should
be used in a temperature range which does not exceed 1000 C [12].
If the operating temperature exceeds the recommended temperature range, the total length of the radiant
tube increases and the creep rate (induced by weight) accelerates. In this study, after the tube length increased,
bowing (bending) occurred in the radiant tube. The user reported that all of the failed tubes were similarly
bowed when they failed. When the tube bows signicantly out of plane, it is directly exposed to the burner
ame. In normal operating conditions, the temperature distribution is equal in all positions. However, due
to the tube bowing, one side of tube wall is closer to the burner ame than the other side. The closer side
of the tube will therefore operate at a higher temperature and be more likely to overheat and fail. Higher tem-
peratures will also cause the tube to bend further. By increasing the temperature and the length of the tube
subjected to bending, the areas which operated at higher temperatures increased. In fact, bending in tube
led to hot-spot formations. The temperature in hot-spots is much higher than in other areas and locally yields
abnormal oxidation. Thermal growth of radiant tube may occur when the tube is subjected to localized short-
term overheating, long-term high temperature (creep), or localized thinning of tube through corrosion or ero-
sion. Therefore, the localized increasing of tube may occur, named eyebrow raising mechanism. When hot
ame ow sideswipes an eyebrow, rst high damage (corrosion and erosion) occurs and then thinning and
tearing may take place. Hence, it may be predicted that creep and local oxidation are the main causes of tube
thinning.
From the results presented in the earlier sections, it appears that tubes at elevations of about 6590 cm
failed due to long and high-temperature exposure. However, the other sections of the same tube did not fail
even though they had undergone the same period of service life. Therefore, it is understood that there was
some uniqueness in the failure of the tube in this section. The rise in metal temperature led to creep, wall thin-
ning, severe oxidation, coarsening of carbides and ruptures. In other parts of the tubes, the prevalence of the
carbides was not obvious. Generally, precipitation and growth of carbides do occur for this kind of material
when exposed to a high temperature. However, at normal service temperatures, this process requires a long
time. In the present case, it took only about two years. Thus, the present case of failure was due to
overheating.

5.1. Cause of failure

Most of the evidence indicated that the cause of failure was exposure to an excessively high temperature.
Exposure to an excessively high temperature could have two detrimental eects. First, the creep rate acceler-
ates, thereby leading to the formation of grain boundary voids as observed in Fig. 3. Furthermore, creep
deformation leads to cracking of the protective oxide scale, thereby causing an accelerated oxidation attack.
Another contributing cause to the cracking is the reduction of ductility of the material in this section
because of overheating. Overheating can lead to signicant degradation in high-temperature strength and duc-
tility during service. On the other hand, with high-temperature exposure, secondary carbides precipitate in the
austenitic matrix of heat-resistant material, reducing elongation and ductility [13].

5.2. Prevention approaches

Although INCONEL alloy 601 appears to have a good performance at continuous-annealing furnace con-
ditions [14], before considering alloy replacement, it was highly recommended to rst consider better control-
ling the furnace temperature to avoid overheating. Notably, the tubes overheating at the elevation of about
6590 cm is not conned to only one furnace, but occurs in many furnaces.

6. Conclusions

By conducting a failure analysis on the damaged radiant tubes used in a continuous-annealing furnace
employed in a hot-dip galvanizing line, the following conclusions are derived.
The radiant tube with the same chemical composition as a typical INCONEL alloy 601 could be used with-
out problems if it is operated at a temperature lower than 1000 C in order that a protective Cr2O3 oxidation
 G. Dini et al. / Engineering Failure Analysis 15 (2008) 445457 457

lm forms. However, if the operating temperature were to exceed 10001100 C, the stabilized Cr2O3 would
transform into volatile CrO3 and an abnormal or rapid oxidation would occur. The failed tube in the current
study must have been used at or above the recommended temperature range and, as a result, locally thinned
areas were formed by excessive oxidation. This oxide scale was usually cracked because the heat expansion
coecient of the oxide was dierent from that of the tube metal to which the scale was attached. Through
the opening of the oxide crack, fresh tube metal located beneath the oxide crack tip was subjected to repeated
oxidation, which resulted in the initiation of small cracks in the tube metal. Tube failure nally occurred as
these small cracks propagated to the outer surface of the tube.
Modeling results indicate that increasing the burner temperature can play a considerable role in causing a
particular tube failure mode. The simulation results showed that the failed region in radiant tubes is suscep-
tible to high-temperature creep. Tube failure occurred as a result of bending in the tube length, which may be
responsible for hot-spot formations and high-temperature oxidation. Moreover, a simulation displaying that
modication in radiant tube installation is necessary, utilization of supports in specic locations can extend
creep life.
Additionally, signicant growth of carbide precipitates was observed in the failed zones. Overheating dur-
ing service is primarily responsible for the signicant degradation in mechanical properties and microstructure
in the failed portion of the tubes. To avoid such overheating, precautions should be taken to improve the
burning condition of the bottom burners and decrease the peak tube metal temperature. It is necessary to
check the tube temperature periodically in critical positions; one should ensure that the temperature is lower
than the design temperature.

Acknowledgement

The authors acknowledge the support of the Research and Development Center of MSCo for providing
samples.

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