Failure analysis of belt/roll tribological pair used for the production of eucalypt fiber panels

The premature failure of a large agglomeration machine used for the annual production of 360,000 m(3) of eucalypt fiber panels was investigated to identify the nucleation and growth mechanisms of cracking in PH stainless steel belts (126 m x 2.9 m x 3.0 mm). These belts are used to compress a cushion composed of eucalyptus fibers and glue, being the pressure transmitted from the pistons by the action of numerous case-hardening steel rolls. Examination of the belt working interfaces (belt/rolls and belt/eucalypt fibers) indicated that the main cracking was nucleated on the belt/roll interface and that there is a clear relationship between the crack nucleation and the presence of superficial irregularities, which were observed on the belt/roll working surface. Used rolls showed the presence of perimetric wear marks and 2 mu m silicon-rich encrusted particles (identified as silicon carbide). Lubricant residues contained the presence of helicoidal wires, which were originated by the release of the stainless steel cleaning brush bristles, and 15 mu m diameter metallic particles, which were generated by material detachment of the belt. The presence of foreign particles on the tribological interface contributed to an increase of the shear stresses at the surfaces and, consequently, the number of the contact fatigue crack nucleation sites in the belt/roll tribo-interface. The cracking was originated on the belt/roll interface of the stainless steel belt by a mixed rolling/slip contact fatigue mechanism, which promoted spalling and further nucleation and growth of conventional fatigue cracks. Finally, the system lubrication efficiency and the cleaning procedure should be optimised in order to increase the life expectancy of the belt. (c) 2006 Elsevier Ltd. All rights reserved.

Influence of Microstructures on Polarization Resistance and Hydrogen-Induced Cracking of a Micro-Alloyed Steel Submitted to Different Cooling Rates

The effect of different microstructures on the polarization resistance (Rp) and the hydrogen-induced cracking (HIC) of a micro-alloyed steel austenitized and submitted to different cooling rates was studied. Samples 19.1 x 6 x 2 mm, containing the whole thickness of the plate were extracted from a 20 mm plate and heat treated on a quenching dilatometer, were submitted to Rp and HIC corrosion tests. Both Rp and HIC tests followed as close as possible ASTM G59 and NACE standard TM0284-2003, in this case, modified only with regard to the size of the samples. Steel samples transformed from austenite by a slow cooling (cooling rate of 0.5 degrees C.s(-1)) showed higher susceptibility to hydrogen-induced cracking, with large cracks in the middle of the sample propagating along segregation bands, corresponding to the centerline of the plate thickness. For cooling rates of 10 degrees C.s(-1), only small cracks were found in the matrix and micro cracks nucleated at non-metallic inclusions. For higher cooling rates (40 degrees C.s(-1)) very few small cracks were detected, linked to non-metallic inclusions. This result suggests that structures formed by polygonal structures and segregation bands (were cutectoid microconstituents predominate) have higher susceptibility to HIC. Structures predominantly formed by acicular ferrite make it difficult to propagate the cracks among non-oriented and interlaced acicular ferrite crystals. Smaller segregation bands containing eutectoid products also help inhibit cracking and crack propagation; segregation bands can function as pipelines for hydrogen diffusion and offer a path of stress concentration for the propagation of cracks, frequently associated to non-metallic inclusions. Polarization resistance essays performed on the steel in theas received condition, prior to any heat treatment, showed larger differences between the regions of the plate, with a considerably lower Rp in the centerline. The austenitization heat treatments followed by cooling rates of 0.5 e 10 degrees C.s(-1) made more uniform the corrosion resistance along the thickness of the plate. The effects of heat treatments on the corrosion resistance are probably related to the microconstituent formed, allied to the chemical homogenization of the impurities concentrated on the centerline of the plate.

Corrosion Versus Mechanical Tests for Indirect Detection of Alpha Prime Phase in UNS S32520 Super Duplex Stainless Steel

Alpha prime formation leads to material embrittlement and deterioration of corrosion resistance. In the present study, the mechanical and corrosion behavior of super duplex stainless steel UNS S32520 aged at 475 degrees C from 0.5 h to 1,032 h was evaluated using microhardness measurements, Charpy impact tests, electrochemical impedance spectroscopy, and cyclic polarization curves. The sensibility of these tests to the effects of alpha prime phase was investigated. The microhardness test showed a gradual increase in hardness with aging time, whereas the impact tests revealed losses of about 80% in the energy absorption capacity for the material aged for 12 h in comparison with the solution-annealed samples. The most responsive analysis was the impact test, which indirectly revealed the presence of this deleterious phase in samples aged for 0.5 h. The electrochemical impedance spectroscopy and polarization tests were not highly sensitive to the alpha prime phase unless these are present in large amounts in the stainless steel.

Effect of precracking method on K(Ic) results for medium-density polyethylene tested under cryogenic condition

The effect of different precracking methods on the results of linear elastic K(Ic) fracture toughness testing with medium-density polyethylene (MDPE) was investigated. Cryogenic conditions were imposed in order to obtain valid K(Ic) values from specimens of suitable size. Most conservative K(Ic) values were obtained by slow pressing a fresh razor blade at the notch root of the specimen. Due to the low deformation level imposed on the crack tip region, the slow pressing razor blade technique also produced less scatter in fracture toughness results. It has been shown that the slow stable crack growth preceding catastrophic brittle failure during K(Ic) tests in MOPE under cryogenic conditions should not be disregarded as it has relevant physical meaning and may affect the fracture toughness results. (C) 2010 Elsevier Ltd. All rights reserved.

Three-dimensional analysis of fracture, corrosion and wear surfaces

A brief look at the history of fractography has shown a recent trend in the quantification of topographic parameters through the use of three-dimensional reconstruction techniques, which associate SEM stereoscopy and stereophotogrammetry software, allowing the calculation of the elevation measurement at numerous points of the topography due to the parallax that takes place during the tilting of the sample along the microscope eucentric plane. Several investigators have used reconstruction techniques to correlate some fractographic parameters, such as fractal dimension and fractured to projected area ratio, to the mechanical properties of materials, such as fracture toughness and tensile strength. So far, the search for a clear relationship between the fracture topography and mechanical properties has provided ambiguous results. The present work applied a surface metrology software to reconstruct three-dimensionally fracture surfaces (transgranular cleavage, intergranular and dimple fracture), corrosion pits and tribo-surfaces in order to explore the potential of this stereophotogrammetry technique. The existence of a variation in the calculated topographic parameters with the conditions of SEM image acquisition reinforces the importance of both good image acquisition and accurate calibration methods in order to validate this 3D reconstruction technique in metrological terms. Preliminary results did not indicate the existence of a clear relationship between either the true to project area ratio and CVN absorbed energy or the fractal dimension and CVN absorbed energy. It is likely that each fracture mechanism presents a proper relationship between the fractographic parameters and mechanical properties. (C) 2009 Elsevier Ltd. All rights reserved.

Embrittlement of case hardened steel chain link

Various steel chain links presented cracking during their manufacturing process, which includes induction case hardening and electrogalvanizing steps. Fractographic examination of the exposed crack surfaces revealed intergranular cracking with some areas featuring a thin layer of iron oxide, indicating that the cracking took place after the electrogalvanizing step. The location of the cracks coincided with the position of the deepest case hardened layer, suggesting the occurrence of localized overheating during the induction case hardening step. Inductive heating finite element analysis (COSMOS Designstar Software) confirmed that during the case hardening the austenitising temperature reached in the crack region values of approximately 1050 degrees C. The results indicated that intergranular cracking was caused by hydrogen embrittlement. (C) 2009 Elsevier Ltd. All rights reserved.

Bending fatigue of stainless steel shear pins belonging to a hydroelectric plant

Coaracy Nunes was the first hydroelectric power plant in the Amazon region, being located in Araguari River, Amapa State, Brazil. The plant operates since 1976, presenting now a nominal capacity of 78 MW. The shear pins, which are installed in the turbine hydraulic arms to control the wicket gate and regulate the water flow into the turbine blades, suffered several breakdowns since 2004. These shear pins are made of an ASTM 410 stainless steel and were designed to break by a shear overload of 120 kN. Fractographic investigation of the pins, however, revealed two types of fracture topographies: a region of stable crack propagation area, with non-pronounced striation and secondary cracks; and a region of unstable propagation, featuring elongated dimples. These results indicated that the stable crack propagation occurred by fatigue (bidirectional bending), which was nucleated at machining marks under high nominal load. Finite element analysis was carried out using two loading conditions (pure shear and a combination of shear and bending) and the results indicated that the presence of a bending stress strongly increased the stress concentration factor (85% rise in the shear stress and 130% rise in the Von Mises stress). Misalignment during shear pins assembly associated with vibration might have promoted the premature failure of the shear by bending fatigue. (C) 2008 Elsevier Ltd. All rights reserved.

Cracking of 2.25Cr-1.0Mo steel tube/stationary tube-sheet weldment of a heat-exchanger

The premature failure of a horizontal heat-exchanger, which occurred after service exposure at 580 degrees C for 50,000 h, revealed the occurrence of extensive through-thickness cracking in approximately 40% of the tube/stationary tube-sheet welds. Additionally, the internal surface of the welded joint featured intensive secondary intergranular cracking (up to 250 mu m deep), preferential formation of a 150 mu m thick layer of (Fe, Cr)(3)O-4 and internal intergranular oxidation (40 mu m deep). The welded region also showed intense carbon pick-up and, as consequence, severe precipitation of intergranular M7C3 and M23C6 carbides. The fracture surface was composed of two distinct regions: a ""planar"" region of 250 mu m, formed due to the stable crack growth along by the intergranular oxidation; and a slant region with radial marks, formed by the fast crack growth along the network of intergranular carbides. The association of intergranular oxidation pre-cracks with microstructural embrittlement promoted the premature failure, which took place by an overload mechanism, probably due to the jamming of the floating tube-sheet during the maintenance halt (cooling operation). (C) 2007 Elsevier Ltd. All rights reserved.

An engineering methodology to assess effects of weld strength mismatch on cleavage fracture toughness using the Weibull stress approach

This work describes the development of an engineering approach based upon a toughness scaling methodology incorporating the effects of weld strength mismatch on crack-tip driving forces. The approach adopts a nondimensional Weibull stress, (sigma) over bar (w), as a the near-tip driving force to correlate cleavage fracture across cracked weld configurations with different mismatch conditions even though the loading parameter (measured by J) may vary widely due to mismatch and constraint variations. Application of the procedure to predict the failure strain for an overmatch girth weld made of an API X80 pipeline steel demonstrates the effectiveness of the micromechanics approach. Overall, the results lend strong support to use a Weibull stress based procedure in defect assessments of structural welds.

Effects of weld strength mismatch on J and CTOD estimation procedure for SE(B) specimens

This work examines the effect of weld strength mismatch on fracture toughness measurements defined by J and CTOD fracture parameters using single edge notch bend (SE(B)) specimens. A central objective of the present study is to enlarge on previous developments of J and CTOD estimation procedures for welded bend specimens based upon plastic eta factors (eta) and plastic rotational factors (r (p) ). Very detailed non-linear finite element analyses for plane-strain models of standard SE(B) fracture specimens with a notch located at the center of square groove welds and in the heat affected zone provide the evolution of load with increased crack mouth opening displacement required for the estimation procedure. One key result emerging from the analyses is that levels of weld strength mismatch within the range +/- 20% mismatch do not affect significantly J and CTOD estimation expressions applicable to homogeneous materials, particularly for deeply cracked fracture specimens with relatively large weld grooves. The present study provides additional understanding on the effect of weld strength mismatch on J and CTOD toughness measurements while, at the same time, adding a fairly extensive body of results to determine parameters J and CTOD for different materials using bend specimens with varying geometries and mismatch levels.

Numerical study of tensile tests conducted on systems with elastic-plastic films deposited onto elastic-plastic substrates

In this work, a series of two-dimensional plane-strain finite element analyses was conducted to further understand the stress distribution during tensile tests on coated systems. Besides the film and the substrate, the finite element model also considered a number of cracks perpendicular to the film/substrate interface. Different from analyses commonly found in the literature, the mechanical behavior of both film and substrate was considered elastic-perfectly plastic in part of the analyses. Together with the film yield stress and the number of film cracks, other variables that were considered were crack tip geometry, the distance between two consecutive cracks and the presence of an interlayer. The analysis was based on the normal stresses parallel to the loading axis (sigma(xx)), which are responsible for cohesive failures that are observed in the film during this type of test. Results indicated that some configurations studied in this work have significantly reduced the value of sigma(xx) at the film/substrate interface and close to the pre-defined crack tips. Furthermore, in all the cases studied the values of sigma(xx) were systematically larger at the film/substrate interface than at the film surface. (C) 2010 Elsevier B.V. All rights reserved.

A convergent approach for the generation of dendrimers containing the [Ru3O(CH3COO)(6)] electroactive core

We report on a convergent approach for the generation of dendrimers containing the [Ru3O(aC)(6)] electroactive core, of great interest as multielectron transfer catalysts. The proposed strategy is based on the generation of the trimeric complex [(Ru3O(ac)(6)(4-pic)(2)(pz))2-mu(2)-Ru3O(ac)(6)(CH3OH)](3+) (ac = acetate, 4-pic = 4-methylpyridine, pz = pyrazine). In this complex, the labile CH3OH ligand can be displaced by the bridging pyrazine ligand of [Ru3O(ac)(6)(pz)3](0), leading to the self-assembly of the [{[Ru3O(ac)(6)(4-pic)(2)(pz)](2)-mu(2)-Ru3O(ac)(6)(pz)}(3)- mu(3)-Ru3O(ac)(6)](n+) dendrimer containing 30 ruthenium atoms. ((C) Wiley-VCH Verlag GmbH & Co. KGaA, 69451 Weinheim, Germany, 2008).

Bifurcation in growth patterns for arrays of parallel Griffith, edge and sliding cracks

This paper presents the recent finding by Muhlhaus et al [1] that bifurcation of crack growth patterns exists for arrays of two-dimensional cracks. This bifurcation is a result of the nonlinear effect due to crack interaction, which is, in the present analysis, approximated by the dipole asymptotic or pseudo-traction method. The nonlinear parameter for the problem is the crack length/ spacing ratio lambda = a/h. For parallel and edge crack arrays under far field tension, uniform crack growth patterns (all cracks having same size) yield to nonuniform crack growth patterns (i.e. bifurcation) if lambda is larger than a critical value lambda(cr) (note that such bifurcation is not found for collinear crack arrays). For parallel and edge crack arrays respectively, the value of lambda(cr) decreases monotonically from (2/9)(1/2) and (2/15.096)(1/2) for arrays of 2 cracks, to (2/3)(1/2)/pi and (2/5.032)(1/2)/pi for infinite arrays of cracks. The critical parameter lambda(cr) is calculated numerically for arrays of up to 100 cracks, whilst discrete Fourier transform is used to obtain the exact solution of lambda(cr) for infinite crack arrays. For geomaterials, bifurcation can also occurs when array of sliding cracks are under compression.

ESEM observations of SCC initiation for 4340 high strength steel in distilled water

The stress corrosion cracking (SCC) initiation process for 4340 high strength steel in distilled water at room temperature was studied using a new kind of instrument: an environmental scanning electron microscope (ESEM). It was found that the applied stress accelerated oxide film formation which has an important influence on the subsequent SCC initiation. SCC was observed to initiate in the following circumstances: (1) cracking of a thick oxide film leading to SCC initiation along metal grain boundaries, (2) the initiation of pits initiating SCC in the metal and (3) SCC initiating from the edge of the specimen. All these three SCC initiation circumstances are consistent with the following model which couples SCC initiation with cracking of a surface protective oxide. There is a dynamic interaction between oxide formation, the applied stress, oxide cracking, pitting and the initiation of SCC. An aspect of the dynamic interaction is cracks forming in a protective surface oxide because of the applied stress, exposing to the water bare metal at the oxide crack tip, and oxidation of the bare metal causing crack healing. Oxide crack healing would be competing with the initiation of intergranular SCC if an oxide crack meets the metal surface at a grain boundary. If the intergranular SCC penetration is sufficiently fast along the metal grain boundary, then the crack yaws open preventing healing of the oxide crack. If intergranular SCC penetration is not sufficiently fast, then the oxidation process could produce sufficient oxide to fill both the stress corrosion crack and the oxide crack; in this case there would be initiation of SCC but only limited propagation of SCC. Stress-induced cracks in very thin oxide can induce pits which initiate SCC, and under some conditions such stress induced cracks in a thin oxide can directly initiate SCC.

Linearly-increasing-stress testing of carbon steel in 4 N NaNO3 and in Bayer liquor

This paper reports the application of linearly increasing stress testing (LIST) to the study of stress corrosion cracking (SCC) of carbon steel in 4 N NaNO3 and in Bayer liquor. LIST is similar to the constant extension-rate testing (CERT) methodology with the essential difference that the LIST is load controlled whereas the CERT is displacement controlled. The main conclusion is that LIST is suitable for the study of the SCC of carbon steels in 4 N NaNO3 and in Bayer liquor. The low crack velocity in Bayer liquor and a measured maximum stress close to that of the reference specimen in air both indicate that a low applied stress rate is required to study SCC in this system. (C) 1998 Chapman & Hall.