电梯用高强度螺钉断裂分析

某电梯用高强度螺钉在安装2个月后出现批量断裂现象,利用直读光谱仪、氮氢氧联合测定仪、光学显微镜、扫描电子显微镜等对螺钉断裂原因进行了分析。结果表明:该批螺钉由于镀锌后除氢不及时导致其本身氢含量较高和螺钉冷拔后未进行车削导致其在镀锌前表面就已存在大量的微小缺陷,是导致该批螺钉安装后发生断裂的两个主要原因;这些微小缺陷充当了氢陷阱并造成应力集中,在螺钉所受的静拉应力作用下,氢在缺陷处不断富集,最终导致螺钉发生氢致延迟脆性断裂。     

Failure Analysis of Cap Screws in a Diesel Engine Front Gear Train

Two failures of the front gear train cap screws of a diesel engine in a marine vessel are investigated. Fractured cap screws were present in both failures. The cap screws’ strength was compared to standards. The thread engagement was also analyzed. In one failure, the cap screws used did not comply with the standard properties and in the other failure, improper thread engagement resulted in fast fracture after few load cycles.     

Damage associated with the interaction between hydrogen and microstructure in a high sulfur 17-4PH steel for studs

A great number of failure cases of precipitation hardenable 17-4PH steels have been described in the literature. Structural components working in harsh environments failed due excessive hardness. A maximum hardness of 33 HRC was specified for service in aggressive media. However, high impurity levels and chromium carbide precipitation may cause failure, even when the correct final heat treatment is applied and the hardness is below the maximum limit. This fact is investigated in this work, where a 17-4PH steel with 0.027%S was evaluated after hydrogen cathodic charging. Specimens with three different commercial heat treatments were evaluated. Specimens with treatments A (solution treated) and H900 (aged for the peak of hardness) showed inter and transgranular microcracks, pores and cracks associated with sulfide inclusions. Specimen with treatment H1150 (overaged), with low hardness, experienced intergranular attack and pores nucleation in the inclusions. The high sulfur steel was also more susceptible to pitting corrosion, which can also contribute to the hydrogen embrittlement process in high chloride solutions. It is recommended to limit the sulfur and other impurities contents to values lower than those specified by the usual standards.     

X52管线钢抗氢致开裂试验裂纹成因分析

针对某段时期出现的X52管线钢产品经抗阶梯型破裂试验后,试样有明显阶梯裂纹,产品检验不合格的问题,对不合格批次的试样进行化学成分、炼钢工艺以及显微组织等方面的分析,分析了该抗硫化氢腐蚀X52管线钢氢致开裂的原因。结果表明:开裂批次试样的钙硫含量比值偏低,导致出现夹杂物偏聚和中心偏析,且夹杂物呈线状分布,是造成该管线钢产品抗氢致开裂试验开裂的主要原因。最后对X52管线钢的生产控制要点提出了相应建议,以提高其抗硫化氢腐蚀的能力。     

10.9级高强度螺钉断裂分析

某单位生产的汽车门窗用10.9级20钢高强度螺钉在服役约一个月后相继出现多个断裂现象。利用光学显微镜、扫描电子显微镜、直读光谱仪、能谱分析仪和显微硬度计等对螺钉的断裂原因进行了分析。结果表明:该螺钉断裂的主要原因是其在使用之前就存在微裂纹,造成应力集中,在静载荷拉应力的作用下,材料中的氢原子向裂纹尖端移动、富集,使局部氢浓度较高,导致螺钉发生了氢致延迟脆性断裂;另螺钉表面硬度过高也增加了其对氢脆断裂的敏感性。     

Investigation of nonmetallic inclusions in continuously cast carbon steel by dissolution of the ferritic matrix

One of the main steel plant's problems has been the occurrence of inclusions throughout the process of steel making. In this sense, it is very important to detect nonmetallic inclusions in the steel, to determine their origin and to control the formation of such inclusions, in order to generate a final product of high quality. The aim of this work is to present a characterization method for nonmetallic inclusions which uses the expedient of dissolving the ferritic matrix in hydrochloric acid (HCl). Scanning electron microscopy connected to an energy-dispersive spectrometer (EDS) system is used to obtain the morphology, size and chemical composition of such inclusions. This analysis allows a better understanding about the nature of the inclusions, their incidence and distribution along the process of steel manufacturing, providing subsidies to formulate corrective actions that minimize the occurrence of nonmetallic inclusions.     

方管表面氢致鼓泡原因分析

方管表面热镀锌后出现不同程度的鼓泡现象.利用化学分析、金相检验和扫描电镜分析等手段对方管鼓泡原因进行了分析和研究.化学测试结果表明,镀锌后方管表层吸附了高浓度的氢.扫描电镜和能谱分析结果表明,泡界面几乎都是呈块状和层片状分布的硅酸盐类夹杂物.金相检验证实,基体板材中大量的硅酸盐类夹杂物沿轧制方向分布.此类夹杂物在热镀锌过程中为氢的吸附、聚集和鼓泡的形成提供了前提.夹杂物含量高和镀锌过程的氢吸附是鼓泡的重要原因.     

Experimental evaluation and modeling of sulfur content and anisotropy of sulfide inclusions on fatigue behavior of steels

This paper presents and discusses experimental results on the effect of sulfur content and sulfide inclusions on fatigue behavior of steels with different sulfur and hardness levels under different loading directions. Ductility and toughness of the transverse samples were found to reduce considerably by the increase in sulfur content, while the differences in the yield and ultimate tensile strengths were not significant. High sulfur resulted in significant adverse effect of inclusions on fatigue behavior of the transverse samples, particularly in the long life regime. The difference between the high and low sulfur materials was larger at the higher hardness level. Both sub-surface and surface failure modes were observed at long lives, where the sub-surface failures exhibited much longer life. The √area parameter was used to estimate the fatigue limit of the materials used, resulting in reasonable estimations in most cases. Roessle–Fatemi equation, which is used to predict the strain-life curve of steels based on hardness, was modified in order to incorporate the effects of sulfur under transverse loading. It is shown that this modified equation results in relatively good predictions of fatigue lives.     

The effect of baking time,fillet radius,and hardness on the lifecycles of pole fastening screws in an electric motor with hydrogen embrittlement

In order to protect bolts from corrosion, electroplating such as zinc plating is widely used. However, hydrogen can easily penetrate or diffuse into the vacancies and dislocations between the lattices of bolt steel during electroplating. As the diffused hydrogen defects inside the lattice are in gaseous form, small cracks can easily be produced due to high pressure from the hydrogen gas. In this research, in order to determine the root cause of the fracture in pole fastening screws resulting from hydrogen embrittlement in typical electric motors, additional factors that accelerate hydrogen embrittlement fracture were selectively applied, including a small fillet in the head–shank transition and excessive hardness, and parametric study was performed experimentally.     

N_Ⅳ型平列双扭弹簧延迟断裂分析

某N_Ⅳ型平列双扭弹簧约有0.7%在装配中和装配后发生延迟断裂,采用宏观分析、扫描电镜观察以及工艺分析等方法对扭簧延迟断裂的原因进行了分析。结果表明:扭簧失效是氢致延迟脆性断裂,基体夹杂物相处形成高危应力及电镀后去氢不彻底是导致其断裂的主要原因。     

Elastic wave fields in a half-plane with free-surface relief,tunnels and multiple buried inclusions

In this work, we study the elastic wave fields that develop in an isotropic half-plane which contains different types of heterogeneities such as free-surface relief, unlined and lined tunnels, as well as multiple buried inclusions. The half-plane is swept by traveling harmonic waves, namely pressure waves, vertically polarized shear waves and Rayleigh waves, as well as by waves emanating from an embedded source. The computational tool used is the direct boundary element method (BEM) with sub-structuring capabilities. Following development and numerical implementation of the BEM, two stages of work are performed, namely a detailed verification study followed by extensive parametric investigations. These last numerical simulations help determine the dependence of the elastic waves that develop along the surface of the half-plane, as well as of the dynamic stress concentration factors in the different types of buried inclusions, to the following key factors: geometry of the free-surface relief, geometry, depth of burial and separation distance of the inclusions, wavelength to inclusion diameter ratio and dynamic interaction phenomena between the multiple heterogeneities. In closing, the potential of the enhanced BEM formulation to treat dynamic soil-structure-interaction problems with the kind of complexity expected in realistic engineering applications is discussed.     

Sustainable hydrogen production system with sulfur–water–organic materials by hydrothermal reaction

Engineered process for hydrogen generation from hydrogen sulfide ions in aqueous solution using solar energy with photocatalysis has been established. In order to design a complete closed loop of hydrogen production system, reacted sulfide ions have to be reduced to photocatalysis-active hydrogen sulfide ion. We focused on hydrothermal reaction of sulfur for reducing the reacted sulfide ions. But the oxidized sulfur species are occurred inevitably by the reaction. Thus alternative reducers are required to sulfur hydrothermal reaction for a complete closed loop of hydrogen production system. We studied sulfur–water–organic materials interaction, and particularly on the effective utilization of waste elemental sulfur. In this study, hydrothermal experiments of sulfur, water urea, and/or alcohols were carried out under atmospheric constituent condition and hypoxic condition at 200 °C. Experimental results show that maintaining solution in weak alkaline condition is important and alcohol compounds had a great role for reduction of sulfur. Elemental sulfur was completely reduced to hydrogen sulfide by the hydrothermal reaction of sulfur with urea and propanol under hypoxic condition. Those results indicate that it is possible to create sustainable sulfur cycle for hydrogen production system using hydrothermal reaction with organic compounds.     

Failure analysis of vessel propeller bolts under fastening stress and cathode protection environment

This paper describes the failure analysis of propeller blade fastening bolts made from martensitic stainless steel 0Cr16Ni5Mo, which was ruptured under service of cathode protection for 5 years. The general crack pattern of the bolts, fractographic features, hydrogen content determination and slow tensile test results are all exhibiting the characteristics of hydrogen embrittlement. Accordingly, hydrogen diffusion driven by hydrogen concentration gradient and stress concentration was identified by experiment and finite element analysis (FEA). The morphology of the crack was intergranular of initiation from bolt cap root surface, and quasi-cleavage of propagation. The hydrogen distribution indicated that the hydrogen concentration in the bolt was in gradient distribution, and the region farther away from the sea water contains less hydrogen content. This revealed that hydrogen entered the bolt top surface through sea water under cathodic protection, and diffused from top to cap. The hydrogen content of the cap where crack initiated was 7.0 ppm, which was much higher than that in bolt shaft with normal content of 1.1 ppm. Results of low tensile test together with fractographic observation showed that the brittleness of the bolt was enhanced by the effect of hydrogen. Stress distribution calculated by FEA analysis indicated that the maximal stress of the bolt was about 1016 MPa, located at cap root surface which was consistent with crack initiation sites. The stress drove hydrogen to accumulate at root surface until cracking occurred. In a sum, the failure was attributed to the hydrogen diffusion, local high stress, and the martensitic microstructure susceptible to hydrogen embrittlement. Remedial measures such as avoiding over protection potential, that increase tempering temperature were suggested. Methods to optimize stress distribution of the bolt were also suggested based on FEA calculation.     

Einflüsse unterschiedlicher Reinheitsgrade auf die Dauerschwingfestigkeit des Federstahles 55 Cr 3

Influence of Different Degrees of Purity on the Fatigue Strength of Spring Steel 55 Cr 3 One of the most important factors for construction and development of high strength springs is the material selection. In this connection the opinion is often represented in bibliography that material defects are the main reason for fractures. Besides surface defects (surface decarburization or rolling defects) essentially nonmetallic inclusions are described as causes of fractures. Therefore high degrees of purity are demanded especially for severe strained springs, which only can be obtained by very expensive special melting processes. By testing specimens of spring steel 55 Cr 3 with different degrees of purity in the present work the quantitative influence of nonmetallic inclusions on the fatigue life was to be examined. About 400 repeated torsion tests with annealed as well as annealed and shotpeened specimens were carried out accompanied by investigations to determine inclusions causing fracture and their size.     

Influence of metallurgical factors on the performance of IS:7887 Gr. 3 billets for fastener applications

The quality advantages of continuous casting (concast) have enabled the production of a wide range of billets for various end applications, including IS:7887 Gr. 3 billets for the fastener industry. This paper discusses the influence of the internal quality of these concast billets on the processing of a wide range of products for the fastener industry. Internal soundness, inclusion volume fraction, and cleanliness were found to have a strong influence on the cracking susceptibility of self-tapping screws and nuts. A high incidence of hairline cracks on nut surfaces was found to be due to a combination of a high volume fraction of inclusions (0.54%) and the presence of complex manganese (Mn) (aluminate-silicate)-type inclusions.     

High temperature removal of hydrogen sulfide using an N-150 sorbent

In this study, an N-150 sorbent was used as a high temperature desulfurization sorbent for the removal of hydrogen sulfide from coal gas in a fixed bed reactor. The results indicate that the N-150 sorbent could be used for H(2)S removal in the tested temperature ranges. Regeneration test also reveals that utilization of the N-150 sorbent maintains up to 85% compared to the fresh sorbent. No significant degeneration occurs on the N-150 sorbent. In addition, various concentrations of H(2)S, H(2) and CO were also considered in the performance test of the N-150 sorbent. Except for H(2)S, H(2) and CO act the important roles in the high temperature desulfurization. By increasing the H(2) concentration, the sulfur capacity of the sorbent decreases and an adverse result is observed in the case of increasing CO concentration. This can be explained via water-shift reaction. On the basis of the instrument analysis, X-ray powder diffraction determination and SEM images with EDS spectrum characterization, residual sulfur is found in the regenerated N-150 sorbent and this sulfur species is sulfate which resulted by incomplete regeneration. The sulfate formation and sintering effect are major reasons to cause activity loss in the sulfidation/regeneration cycles.     

储氢材料与噻吩反应中的影响因素分析

采用氢气反应球磨法制备Mg/C复合材料,利用储氢材料受热释放出的氢和噻吩进行加氢反应,分析了加氢反应中的相互影响因素。结果表明,噻吩加氢反应对氢分压影响小,储氢材料的放氢量低于其同温下连续放氢量;升高温度及适当延长反应时间,反应产物中的固相硫含量增多,但反应时间过长,固相硫含量基本稳定不变;适当的材料粒径对固硫有益,但粒径过细不利于固相硫的产生。     

大型调质输入轴开裂分析

某大型调质输入轴放置约9个月后开裂,采用宏观分析、化学成分分析、低倍检验、断口分析、金相检验以及力学性能测试等手段对输入轴开裂原因进行了分析。结果表明:该输入轴为在组织应力及氢析出所造成内应力共同作用下的氢致延迟开裂;输入轴原材料氢含量高、偏析严重、非金属夹杂物含量高以及锻造不充分,引起零件内部发生了氢气积聚,形成了较大的内应力,这是导致输入轴发生氢致延迟开裂的主要原因。     

Finite Element Analysis of Hydrogen Transport in Steel Pressure Vessel at High Temperature

Hydrogen embrittlement is commonly considered as an important failure mechanism for some typical steel pressure vessels and pipes made of such as Cr–Mo and 4130X steels at high-pressure hydrogen environment. In previous work, we investigated the hydrogen transport mechanisms of Crmo steel pressure vessels at room temperature. Furthermore, high temperature environment may affect the hydrogen transport mechanisms and hydrogen-induced crack behaviors in these structures to a large extent. In this paper, we study the hydrogen transport mechanisms in 2.25Cr–1Mo steel pressure vessel at high temperature under the support of National Key Fundamental Research and Development Project of China (2015.1-2019.12). The main work is to explore the effects of temperature, hydrogen concentration, and structural sizes on the transient hydrogen diffusion and distribution behaviors in Crmo steel pressure vessels using finite element analysis. Numerical results show that elevated high temperature accelerates the hydrogen embrittlement sensitivity, especially at structural discontinuities.