Metallographic and Mechanical Studies of a Cast Heat-Resisting Alloy
A heat-resistant steel tube from an ammonia plant made of modified HP40 steel that failed after short-term service is studied for damage mechanism. The assessment of material degradation is carried out using optical microscopy, scanning electron microscopy in combination with energy dispersive spect...
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Інститут металофізики ім. Г.В. Курдюмова НАН України
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irk-123456789-1304002018-02-13T03:03:37Z Metallographic and Mechanical Studies of a Cast Heat-Resisting Alloy Aichaoui, M. Hadji, A. Физика прочности и пластичности A heat-resistant steel tube from an ammonia plant made of modified HP40 steel that failed after short-term service is studied for damage mechanism. The assessment of material degradation is carried out using optical microscopy, scanning electron microscopy in combination with energy dispersive spectroscopy analysis, x-ray diffraction analysis, and mechanical tests. Results show that precipitation of the chromium-rich carbides induces the coalescence of grain boundaries. Significant growth and poor distribution of secondary carbides are also noticed through the matrix, which lead to a reduction of material ductility even after a short-term service. The main cause of failure appears to be damaged catalyst. Such a problem can cause a rise in temperature leading to localized overheating in the lower part of the tube. Overheating is primarily responsible for significant degradation in microstructure, creep strength, and mechanical properties of the tube. Для установления механизма разрушения была изучена изготовленная из модифицированной жаропрочной стали НР40 труба с аммиачного завода, вышедшая из строя после кратковременного использования. Изучение деградации материала было проведено с помощью оптической и сканирующей электронной микроскопий в комбинации с энергодисперсионным спектроскопическим анализом, рентгенодифракционными исследованиями и механическими испытаниями. Установлено, что выделение насыщенных хромом карбидов вызывает коалесценцию границ зёрен. Также установлено существенное увеличение и разрежённое распределение вторичных карбидов в матрице, что приводит к снижению пластичности материала даже после кратковременного использования. Основной причиной выхода труб из строя является повреждённый катализатор. Эта проблема может вызвать повышение температуры, что приводит к локальному перегреву в нижней части трубы. Именно перегрев, в первую очередь, ответственен за существенные деградацию микроструктуры, ухудшение границы ползучести и механических свойств трубки. Для встановлення механізму руйнування було вивчено виготовлену з модифікованої жароміцної сталі НР40 трубу з аміячного заводу, що вийшла з ладу після короткотермінового використання. Вивчення деґрадації матеріялу було проведено за допомогою оптичної та сканівної електронної мікроскопій у комбінації з енергодисперсійною спектроскопічною аналізою, рентґенодифракційними дослідженнями та механічними випробуваннями. Встановлено, що виділення насичених Хромом карбідів викликає коалесценцію меж зерен. Також встановлено істотне зростання та розріджений розподіл у матриці вторинних карбідів, що приводить до зниження пластичности матеріялу навіть після короткотермінового використання. Основною причиною виходу труб з ладу є пошкоджений каталізатор. Ця проблема може спричинити підвищення температури, що призводить до локального перегріву в нижній частині труби. Саме перегрівання, перш за все, є відповідальним за значні деґрадацію мікроструктури, погіршення межі плазучости та механічних властивостей труб. 2017 Article Metallographic and Mechanical Studies of a Cast Heat-Resisting Alloy / M. Aichaoui, A. Hadji // Металлофизика и новейшие технологии. — 2017. — Т. 39, № 8. — С. 1119-1128. — Бібліогр.: 20 назв. — англ. 1024-1809 PACS: 62.20.Hg, 62.20.M-, 64.75.Op, 81.30.Mh, 81.40.Cd, 81.40.Lm, 81.40.Np DOI: doi.org/10.15407/mfint.39.08.1119 http://dspace.nbuv.gov.ua/handle/123456789/130400 en Металлофизика и новейшие технологии Інститут металофізики ім. Г.В. Курдюмова НАН України |
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Физика прочности и пластичности Физика прочности и пластичности |
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Физика прочности и пластичности Физика прочности и пластичности Aichaoui, M. Hadji, A. Metallographic and Mechanical Studies of a Cast Heat-Resisting Alloy Металлофизика и новейшие технологии |
description |
A heat-resistant steel tube from an ammonia plant made of modified HP40 steel that failed after short-term service is studied for damage mechanism. The assessment of material degradation is carried out using optical microscopy, scanning electron microscopy in combination with energy dispersive spectroscopy analysis, x-ray diffraction analysis, and mechanical tests. Results show that precipitation of the chromium-rich carbides induces the coalescence of grain boundaries. Significant growth and poor distribution of secondary carbides are also noticed through the matrix, which lead to a reduction of material ductility even after a short-term service. The main cause of failure appears to be damaged catalyst. Such a problem can cause a rise in temperature leading to localized overheating in the lower part of the tube. Overheating is primarily responsible for significant degradation in microstructure, creep strength, and mechanical properties of the tube. |
format |
Article |
author |
Aichaoui, M. Hadji, A. |
author_facet |
Aichaoui, M. Hadji, A. |
author_sort |
Aichaoui, M. |
title |
Metallographic and Mechanical Studies of a Cast Heat-Resisting Alloy |
title_short |
Metallographic and Mechanical Studies of a Cast Heat-Resisting Alloy |
title_full |
Metallographic and Mechanical Studies of a Cast Heat-Resisting Alloy |
title_fullStr |
Metallographic and Mechanical Studies of a Cast Heat-Resisting Alloy |
title_full_unstemmed |
Metallographic and Mechanical Studies of a Cast Heat-Resisting Alloy |
title_sort |
metallographic and mechanical studies of a cast heat-resisting alloy |
publisher |
Інститут металофізики ім. Г.В. Курдюмова НАН України |
publishDate |
2017 |
topic_facet |
Физика прочности и пластичности |
url |
http://dspace.nbuv.gov.ua/handle/123456789/130400 |
citation_txt |
Metallographic and Mechanical Studies of a Cast Heat-Resisting Alloy / M. Aichaoui, A. Hadji // Металлофизика и новейшие технологии. — 2017. — Т. 39, № 8. — С. 1119-1128. — Бібліогр.: 20 назв. — англ. |
series |
Металлофизика и новейшие технологии |
work_keys_str_mv |
AT aichaouim metallographicandmechanicalstudiesofacastheatresistingalloy AT hadjia metallographicandmechanicalstudiesofacastheatresistingalloy |
first_indexed |
2025-07-09T13:29:23Z |
last_indexed |
2025-07-09T13:29:23Z |
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1837176208161243136 |
fulltext |
PACS numbers: 62.20.Hg, 62.20.M-, 64.75.Op, 81.30.Mh, 81.40.Cd, 81.40.Lm, 81.40.Np
Metallographic and Mechanical Studies of a Cast
Heat-Resisting Alloy
M. Aichaoui and A. Hadji
Foundry Laboratory, Department of Metallurgy and Materials Engineering,
Badji Mokhtar University,
23000 Annaba, Algeria
A heat-resistant steel tube from an ammonia plant made of modified HP40
steel that failed after short-term service is studied for damage mechanism.
The assessment of material degradation is carried out using optical micros-
copy, scanning electron microscopy in combination with energy dispersive
spectroscopy analysis, x-ray diffraction analysis, and mechanical tests. Re-
sults show that precipitation of the chromium-rich carbides induces the coa-
lescence of grain boundaries. Significant growth and poor distribution of
secondary carbides are also noticed through the matrix, which lead to a re-
duction of material ductility even after a short-term service. The main cause
of failure appears to be damaged catalyst. Such a problem can cause a rise in
temperature leading to localized overheating in the lower part of the tube.
Overheating is primarily responsible for significant degradation in micro-
structure, creep strength, and mechanical properties of the tube.
Key words: heat-resistant steel, carbide, damage mechanism, overheating,
creep.
Для встановлення механізму руйнування було вивчено виготовлену з мо-
дифікованої жароміцної сталі НР40 трубу з аміячного заводу, що вийшла
з ладу після короткотермінового використання. Вивчення деґрадації ма-
теріялу було проведено за допомогою оптичної та сканівної електронної
мікроскопій у комбінації з енергодисперсійною спектроскопічною аналі-
зою, рентґенодифракційними дослідженнями та механічними випробу-
ваннями. Встановлено, що виділення насичених Хромом карбідів викли-
кає коалесценцію меж зерен. Також встановлено істотне зростання та ро-
Corresponding author: Meriem Aichaoui
E-mail: meriem.aichaoui@gmail.com
Please cite this article as: M. Aichaoui and A. Hadji, Metallographic and Mechanical
Studies of a Cast Heat-Resisting Alloy, Metallofiz. Noveishie Tekhnol., 39, No. 8: 1119–
1128 (2017), DOI: 10.15407/mfint.39.08.1119.
Ìåòàëëîôèç. íîâåéøèå òåõíîë. / Metallofiz. Noveishie Tekhnol.
2017, т. 39, № 8, сс. 1119–1128 / DOI: 10.15407/mfint.39.08.1119
Îттиски доступнû непосредственно от издателя
Ôотокопирование разрешено толüко
в соответствии с лицензией
2017 ÈÌÔ (Èнститут металлофизики
им. Ã. В. Êурдюмова НÀН Óкраинû)
Напечатано в Óкраине.
1119
1120 M. AICHAOUI and A. HADJI
зріджений розподіл у матриці вторинних карбідів, що приводитü до зни-
ження пластичности матеріялу навітü після короткотермінового викори-
стання. Îсновною причиною виходу труб з ладу є пошкоджений каталіза-
тор. Ця проблема може спричинити підвищення температури, що приз-
водитü до локалüного перегріву в нижній частині труби. Саме перегріван-
ня, перш за все, є відповідалüним за значні деґрадацію мікроструктури,
погіршення межі плазучости та механічних властивостей труб.
Ключові слова: жароміцна сталü, карбід, механізм пошкодження, пере-
грів, плазучістü.
Для установления механизма разрушения бûла изучена изготовленная из
модифицированной жаропрочной стали НР40 труба с аммиачного завода,
вûшедшая из строя после кратковременного исполüзования. Èзучение
деградации материала бûло проведено с помощüю оптической и сканиру-
ющей электронной микроскопий в комбинации с энергодисперсионнûм
спектроскопическим анализом, рентгенодифракционнûми исследовани-
ями и механическими испûтаниями. Óстановлено, что вûделение насû-
щеннûх хромом карбидов вûзûвает коалесценцию границ зёрен. Также
установлено существенное увеличение и разрежённое распределение вто-
ричнûх карбидов в матрице, что приводит к снижению пластичности ма-
териала даже после кратковременного исполüзования. Îсновной причи-
ной вûхода труб из строя является повреждённûй катализатор. Эта про-
блема может вûзватü повûшение температурû, что приводит к локалüно-
му перегреву в нижней части трубû. Èменно перегрев, в первую очередü,
ответственен за существеннûе деградацию микроструктурû, ухудшение
границû ползучести и механических свойств трубки.
Ключевые слова: жаропрочная сталü, карбид, механизм повреждения,
перегрев, ползучестü.
(Received June 21, 2017)
1. INTRODUCTION
Reformer furnaces are widely used in the petroleum and chemical in-
dustries [1]. Steam-methane reformers typically contain vertical tubes,
which are expected to operate at about 900°C and 2 MPa. Tubes are
packed with catalyst through which the reaction gases pass. The tube
material is commonly centrifugally cast heat resistant steel. In addi-
tion to the high temperature and the internal pressure, the tube mate-
rial must also be able to withstand high temperature corrosion from
the chemical processes occurring within the tubes. The alloys common-
ly used are Cr–Ni stainless steels. Formerly, a preferred composition
was 25Cr, 20Ni and 0.4C, designated as HK-40 [2], but with increase in
operating temperature many reformers started using the alloy (Fe–
Ni–Cr–Nb) for their good exhibition of creep strength, mechanical
property and corrosion resistance at high temperatures. The micro-
METALLOGRAPHIC AND MECHANICAL STUDIES OF A HEAT-RESISTING ALLOY 1121
structure of these centrifugally cast microalloyed HP40-steel consists
of austenite dendrites delineated by a network of eutectic carbides [3,
4]. In order to have long-time strength at high temperature, the aus-
tenitic Cr–Ni matrix of these alloys is strengthened through a disper-
sion of hard deformation-resistant carbide particles. The high Cr con-
tent in this class of steels, lead to the precipitation of various types of
chromium carbides, for example, precipitation of Cr-rich carbide M7C3
and M23C6 is very common. The addition of stabilizing elements such as
Nb, Ti, and V usually results in MC type carbides [5, 6]. Under service
conditions, precipitates initially formed in as-cast microstructures
undergo morphological and chemical changes, which can be detri-
mental for the qualities listed above of the tube.
The reformer tubes were designed for 100000 h (11.4 years) of oper-
ation, but often some of the tubes in the furnace fail prematurely [7,
8]. Several reasons can affect the service life of the catalyst tubes. In
general, overheating seems to be the more common failure mode lead-
ing to premature creep [7, 9–11]. The purpose of this paper is to inves-
tigate the material degradation through the characterization of micro-
structure and mechanical properties of the microalloyed HP40Nb tube,
which failed after 1 year of service in an ammonia plant.
2. MATERIALS AND METHODS
In order to evaluate the microstructure of the tube after exposure to
service for about one year, metallographic specimens were cut from the
tube and polished according to standard polishing procedures. Then
sample surfaces were etched with an electrolytic solution of 10 g of ox-
alic acid in 100 ml of water (5 V, 10 s).
The chemical analysis of the sample was carried out using x-ray flu-
orescence spectroscopy (XRF). The microstructure of the specimens
was examined by using optical microscopy (OM), scanning electron mi-
croscopy (SEM) coupled with energy dispersive spectroscopy (EDS) and
x-ray diffraction (XRD).
The mechanical properties of the tube were evaluated by using ten-
sile testing and Charpy impact testing at room temperature (25°C). Mi-
crohardness testing was carried out, in order to identify the variation
of the mechanical characteristics of the wall through the modification
of the microstructure. The tests were performed along the tube thick-
ness from the inner to the outer surface. The hardness was measured
using a 200 g weight for 10 s.
The specified chemical composition (in % wt.) and the values ana-
lysed are presented in Table 1. The chemical composition of the re-
former tube material under investigation conforms to the chemical
composition specification for the grade. The properties of the cast al-
loy are linked to the chemical composition, since it has an important
1122 M. AICHAOUI and A. HADJI
influence on the formation of precipitates.
3. RESULTS AND DISCUSSION
3.1. Visual Examination
Figure 1 shows the damaged tube removed from the reformer furnace
causing a shutdown of the furnace. Service exposed tube revealed nor-
mal appearance on both the inner and outer surfaces. There is no trace
of cracks, carbon deposition or oxidation at a visual inspection. Even
though localized plastic deformation were seen in the lower part of the
tube. The content of the company report after failure shows that bro-
ken pieces of catalyst were seen. Such a damaged catalyst can cause a
TABLE 1. Chemical composition (in % wt.) of the reformer tube alloy.
Element C Si Mn Cr Ni Nb Ti
Specified 0.40–0.50 0.50–1.50 1.50
(max)
24–27 33–36 0.50–1.50 0.30
(max)
Analysed 0.40 0.40 1.05 23.80 35.02 0.60 0.08
Fig. 1. Photography of the failed tube.
METALLOGRAPHIC AND MECHANICAL STUDIES OF A HEAT-RESISTING ALLOY 1123
rise in pressure and temperature by way of blocking the passage of the
gas through the tube. Improper loading of the tubes with catalyst and
extra shutdowns’ cycles lead to the ineffectiveness of the catalyst.
3.2. Metallographic Observations
Microstructural examinations taken transversely to the tube axis fo-
cused on three regions, namely inner surface, midsection and outer
surface. Figures 2, a, b show the optical microstructure performed on
the inner surface. It can be seen the interdendritic network of primary
carbides, coarsened and forming a continuous network. Secondary car-
bides precipitate at the intradendritic regions during service exposure.
Carbides particles are not uniformly distributed through the structure
this can strongly affect the mechanical properties of the alloy. Creep
voids in isolated form were seen in the inner wall. The creep voids are
formed by the generation of missing atoms produced during diffusion
of species under stress forming at last pores [12]. In the midsection of
the tube (Fig. 2, c), the ageing due to high temperature service induced
the formation of many isolated microvoids with a largest peanut shape
formed by the coalescence of two or more voids leading to the progress
of creep during service [13]. Figure 2, d shows the presence of string of
cavities along the grain boundary, which link with increasing strain to
Fig. 2. Optical micrographs of transverse section of service exposed samples:
inner wall (a, b), middle cross section (c, d), outer wall (e).
1124 M. AICHAOUI and A. HADJI
form microcracks. No creep voids were visible on the outer surface of
the tube (Fig. 2, e).
The combination of thermal stresses and internal pressure stresses
causes creep damage that typically develops at the inner surface of the
tube and just below the inner surface. This is the reason as to why creep
voids were absent from the outer surface. However, decarburization
layers followed by internal oxidation were observed both in the outer
and inner surfaces (Figs. 2, e and 3, a). In the preservice condition, for
the cast HP-microalloyed grade, microstructure is characterized by an
austenitic matrix and a network of primary carbides [14].
Service conditions, particularly the effect of temperature and aging
time, promote the dissolution of primary carbides and the development
of a fine array of secondary carbides precipitated from the highly su-
persaturated matrix. It has been reported that these carbides are of
two types: niobium carbide (NbC) and chromium-rich carbides (Cr7C3
or Cr23C6) [15–18]. Precipitates can be recognized by brightness con-
trast. The EDS microanalysis (Fig. 4, a) indicated that the white re-
gions (Fig. 3, b) are niobium carbides in the form of NbC as confirmed
by XRD (Fig. 5), while the dark phase at grain boundaries and also the
dark small particles inside the grains (Fig. 3, c) are chromium riche. As
revealed by the XRD results, these carbides are in the form of Cr7C3
Fig. 3. SEM BSE and SEI micrographs of service exposed simples: inner wall
(a), higher magnification of Fig. a (b), middle cross section with more blocky
precipitation (c, d), outer wall evidencing the G-phase (e).
METALLOGRAPHIC AND MECHANICAL STUDIES OF A HEAT-RESISTING ALLOY 1125
and Cr23C6. Primary chromium carbides Cr7C3 are thus partially trans-
formed into an intergranular and intragranular M23C6 precipitates,
which are more stable at high temperature. The strength of carbides
depends on their morphology, fine and uniform distribution through
the matrix lead to a best combination of properties.
Nevertheless, continuous form of carbides will not be able to block
dislocations motion and grain boundary sliding. In this case, plastic
deformation of the tube occurs easier, creep will especially manifest in
the lower part of the tube under the effect of its weight. Carbides in
Figs. 3, c, d are noticeably coalesced and blocky, which indicates over-
heating. Generally, precipitation and growth of carbides occurs for
Fig. 4. SEM-EDS results of the precipitate phases marked with arrows in
Figs. 3, a and b.
1126 M. AICHAOUI and A. HADJI
this kind of material exposed to high temperature.
However, this process needs a long time at normal service tempera-
ture. In the present study, it took only one year. This confirms that the
failure is mainly due to localized creep deformation under overheating
conditions. In Figure 3, light grey precipitates are observed and
marked with arrows both at inner (Fig. 3, a) and at outer wall (Fig. 3,
e). These precipitates are rich in Ni, Nb and Si as shown by the EDS
spectrum in Fig. 4, c. As quoted in literature [19, 20], Nb carbides are
not stable at temperatures between 700 and 1000°C, being transformed
into nickel niobium silicides, identified as the G-phase. According to
the results of the full area x-ray diffractions, there are four reflections
on the diffraction pattern, which correspond to the G-phase.
3.3. Mechanical Strength Properties
Tensile and Charpy impact tests of the service-exposed tube were per-
formed. Test results are shown in Table 2. Mechanical strength and
ductility of the service exposed tube are decreased compared with the
as cast tube. The fracture surface of the Charpy impact samples was
analysed in order to identify the mode of fracture (Fig. 6).
Fig. 5. XRD pattern of precipitate.
TABLE 2. Mechanical properties of HP40-microalloyed.
Tensile strength,
MPa
Yield strength,
MPa
Elongation,
%
Toughness,
J⋅m−3
As cast 515 295 12 –
Aged 445.15 330 7.41 6.5
METALLOGRAPHIC AND MECHANICAL STUDIES OF A HEAT-RESISTING ALLOY 1127
The image of the fractured surface reveals a mixed mode of frac-
ture. Most of the surface is of the fragile type with a shiny fracture
surface. Changes in the microstructure such as coalescence of carbides
and presence of voids reduce the energy absorbed during fracture. Lit-
tle plastic deformation is observed due to the formation of some dim-
ples. Since matrix, metal around precipitates has good ductility.
The measured results of the microhardness profile are shown in Fig.
7. It can be seen that the evolution of microhardness values is hetero-
geneously following the heterogeneity of the microstructure (carbides
hard and less hard matrix).
A slight reduction in the microhardness in the external face com-
pared to the internal is found. This is due to the size difference of the
grains between the two surfaces caused by the cooling rate during so-
lidification process.
Fig. 6. Fractured surface.
Fig. 7. Vickers microhardness profile measured across the wall thickness.
1128 M. AICHAOUI and A. HADJI
4. CONCLUSION
The main cause of failure appears to be damaged catalyst. Such a prob-
lem could cause a rise in temperature leading to localized overheating
in the lower part of the tube. This overheating lead to significant deg-
radation in microstructure, creep strength and mechanical properties
limiting the serviceability of the tube. Precautions should be taken
while charging the catalyst to avoid such problems and to ensure the
safe operation of the tubes.
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/ENU (Use these settings to create Adobe PDF documents best suited for high-quality prepress printing. Created PDF documents can be opened with Acrobat and Adobe Reader 5.0 and later.)
>>
/Namespace [
(Adobe)
(Common)
(1.0)
]
/OtherNamespaces [
<<
/AsReaderSpreads false
/CropImagesToFrames true
/ErrorControl /WarnAndContinue
/FlattenerIgnoreSpreadOverrides false
/IncludeGuidesGrids false
/IncludeNonPrinting false
/IncludeSlug false
/Namespace [
(Adobe)
(InDesign)
(4.0)
]
/OmitPlacedBitmaps false
/OmitPlacedEPS false
/OmitPlacedPDF false
/SimulateOverprint /Legacy
>>
<<
/AddBleedMarks false
/AddColorBars false
/AddCropMarks false
/AddPageInfo false
/AddRegMarks false
/ConvertColors /ConvertToCMYK
/DestinationProfileName ()
/DestinationProfileSelector /DocumentCMYK
/Downsample16BitImages true
/FlattenerPreset <<
/PresetSelector /MediumResolution
>>
/FormElements false
/GenerateStructure false
/IncludeBookmarks false
/IncludeHyperlinks false
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/IncludeLayers false
/IncludeProfiles false
/MultimediaHandling /UseObjectSettings
/Namespace [
(Adobe)
(CreativeSuite)
(2.0)
]
/PDFXOutputIntentProfileSelector /DocumentCMYK
/PreserveEditing true
/UntaggedCMYKHandling /LeaveUntagged
/UntaggedRGBHandling /UseDocumentProfile
/UseDocumentBleed false
>>
]
>> setdistillerparams
<<
/HWResolution [2400 2400]
/PageSize [612.000 792.000]
>> setpagedevice
|