Metallurgical Investigation of Failed Locked Coil Track Ropes Used in a Mining Conveyor

A locked coil track rope (LCTR) is essentially composed of wires (round and rail-shaped) laid helically in different layers. These wire ropes are sometimes used in conveyors carrying empty and loaded buckets in mining areas. During service, such wire ropes may fail prematurely due to disintegration/failure of individual groups of wires. To understand the genesis of LCTR wire failures, a detailed metallurgical investigation of failed rope wires was made and included visual examination, optical microscopy, scanning electron microscopy (SEM), and electron probe microanalysis (EPMA). Two types of failed wires were investigated; one is from a 40 mm diameter locked coil track rope and the other from a 53 mm locked coil track rope. Optical microscopy of failed round wires in the 53 mm diameter rope clearly revealed fully decarburized layers at the surface and a few grain-boundary cracks. From the location of the failure, it was clear that apart from static tensile loads, the wire ropes had been subjected to bending and unbending loads near the saddle, as fully loaded or empty buckets traveled access the conveyor. The SEM studies confirmed that the fracture had been caused by initiation of fatigue cracks in the decarburized zone under conditions of repeated bending and unbending stresses superimposed on the static tensile load.     

Failure Investigation on Failed Blades Used in a Locomotive Turbocharger

A failure investigation has been conducted on the turboblades used in a locomotive turbocharger. These blades are made from as-cast K418 nickel-base (Ni-base) superalloy. Fracture occurred at the mid-airfoil and tip locations. In the mid-airfoil regions, a high density of intergranular cracks and dent marks are present. The microstructure at the mid-airfoil is typical of overheat damage, such as melting of the boundary or interdendritic region and degraded interdendritic carbides and remelting of eutectic phases (γ + γ′). The fracture surfaces of the failed blades have a dendritic appearance without evidence of fatigue features. It is suggested that these fractures were formed instantaneously. Overheat damage made the strength in interdendritic region decrease so that microcracking occurred preferentially in the interdendritic region. Under the action of bending stress and the spin centrifugal tensile stress, the microcracks propagated within the interdendritic region and converged so that the transverse fracture occurred at the mid-airfoil location where the maximum stress acted. The fragments from previously fractured blades hit neighboring blades, ultimately causing damage to all the turboblades.     

Damage Features of Bolts Connecting Main-Shaft with Turbo-Disk Used in a Locomotive Turbocharger

The connection between the turbo-disk and the main-shaft was found to be loose when performing a regular inspection on a locomotive turbocharger. When the bolts connecting main-shaft with the turbo-disk were disassembled, it was found that smeared threads and contact pressing deformation, etc., severe plastic deformation took place on the three connecting bolts. Metallurgical examinations indicate that the core microstructure is composed of the banded ferrite and pearlite along the axial other than the sorbite by the standard toughening process (quenching and tempering). Abnormal microstructure leads to low the hardness and strength so that various damages appeared on the flanks when twisting bolts with nuts (loosening or tightening). The plastic deformation took place on the bolts under the axial load due to low hardness, which resulted in loosening of the connection between the turbo-disk and the main-shaft. Not standardized fabrication process of the bolts is responsible for the failure of the bolts.     

RV减速器摆线轮模态分析与结构优化

目的根据摆线轮模态分析计算结果对摆线轮进行结构优化。方法通过Pro/E对RV减速器摆线轮进行三维造型,将完成的实体模型导入Ansys中,建立动力学仿真分析模型,进行有限元模态分析,得出摆线轮在自由边界与约束边界下的固有特性。将模态计算结果与整机模型固有频率进行比较,根据振型分析摆线轮最大刚体位移的位置,进行结构优化设计并验证。结果自由边界下的第7,8阶与约束边界下的第2,3阶固有频率均与整机相接近,容易引起整机共振的固有频率段为844.7?1163.7 Hz;摆线轮最大刚体位移的位置为贯穿孔外侧的摆线齿廓,自由和约束边界下的最大位移分别为44.349,59.484mm;结构优化后的最大位移分别为37.581,44.066 mm。结论摆线轮齿廓处为结构的薄弱环节,结构优化后的摆线轮模型在固有特性以及固有振型上都达到了有效改善效果。     

Investigation of Failed Pin Carrier Plate for the Anti-Rotation Device in a Motor

Parts of the anti-rotation device expelled from a power plant motor were analyzed. The “anti-rotation” device prevents the pump from rotating backwards when there is pressure in the discharge line and the motor is off. Parts that were recovered include about 2/3 of the spring compression ring and an “ear” that apparently came from the missing segment of the spring compression ring. Results of this investigation revealed that a nearly simultaneous overloading occurred on both sides of the pin carrier plate as indicated by almost equal size fracture. At least two crack initiation sites were identified on both sides of the pin carrier plate. Under tensile loads, surface irregularities can lead to surface cracks resulting in the fracture of the plate. Areas rich in aluminum were identified (using energy dispersive spectroscopy) in the vicinity of surface irregularities. A number of suggestions on avoiding such failure are proposed.     

铝管蒸发器泄漏原因分析及质量改进

铝管蒸发器是冰箱制冷系统的重要部件,铝管腐蚀泄漏导致制冷系统不起作用。本文利用扫描电子显微镜、金相显微镜、化学成分分析和微区分析、溶出实验和应力腐蚀实验等方法研究了铝管腐蚀失效的原因和特征。铝管腐蚀方向主要是由外向内侧进行的,具有晶间腐蚀特征。微区能谱分析表明铝管腐蚀微区中铁杂质分布不均匀,且明显超标,这是铝管腐蚀的内因。防腐涂层涂刷不均匀和发泡材料的腐蚀性介质是引起腐蚀的外部条件。蒸发器生产现场的某些工装可引起铝管破损,加速腐蚀。在上述研究基础上,本文提出了质量改进措施,并取得了良好效果。     

钢管穿轧过程的三维热力耦合模拟

描述了使用有限元方法(FEM)模拟钢管在曼内斯曼式穿轧机上的穿孔过程,建立了三维有限元模型,并考虑了在金属成形过程中出现的热力学现象。模拟的结果动态地显示了在工件内部等效应变、等效应变率和温度的分布。基于这些参数,分析了钢管的穿孔过程,同时通过实验测试与有限元模拟的结果进行对比。结果表明,测试的结果与有限元模拟的结果比较吻合。     

组合式车桥减速器壳盖设计优化

目的 加强组合式车桥减速器壳盖刚性和密封性,对其进行设计优化。方法 针对减速器壳盖刚性问题,在常用车桥减速器壳盖结构的基础上,对减速器壳盖周边进行翻边处理,并通过建立有限元模型对减速器壳盖刚性进行了分析计算。针对减速器壳盖渗透问题,采用了CAE分析技术对减速器壳盖进行密封性分析。为满足减速器壳盖与减速器接触平面度要求,在减速器壳盖周边接触面设计凸起压痕。结果 最终优化后减速器壳盖最大应力为155.4 MPa,小于材料屈服强度,刚性满足强度设计要求。采用CAE分析技术对减速器壳盖进行密封性分析,得出使用12个螺栓时渗漏处工作间隙为0.03 mm为最好的解决方案。结论 翻边处理后的减速器壳盖刚度高于未处理的减速器壳盖。减速器壳盖接触面设计凸起压痕,用12个螺栓拧紧减速器壳盖很好地解决了密封性和拆解问题。     

Failure Analysis of Fire Tube Sleeve of Heater Treater

The fire tube sleeve of a Heater Treater that was installed in an Oil and Gas processing unit ruptured after a service life of around 15 years. The detailed failure analysis was undertaken on this failed Incoloy 800 (UNS N08800) fire tube sleeve to ascertain the causes and mechanism of failure. The various studies indicated that the exposure of the sleeve to excessive temperature resulted in internal oxidation corrosion and caused of the failure. Additionally, Incoloy 800 is susceptible to sensitization in the temperature range of 540–1095 °C which did occur and resulted in intercrystalline cracks causing grains to fall out of the metal leading to a thickness reduction. The main causes of failure were overheating and the resulting microstructural evolution and recommendations to prevent such failures in future are presented.     

Failure of Tungsten Carbide Rolls from a Wire and Rod Mill

The paper presents the failure analysis of tungsten carbide rolls for the Wire and Rod Mill (WRM) and establishes the failure reasons and the corrective and preventive actions taken to improve roll performance. A sharp continuous increase in failure rate and decrease in average time between failure (ATBF) was observed during 2001 to 2004. The increase in premature failure of these rolls (16 rolls in 2003 and 38 rolls in 2004) raised the cost of operations. Due to unscheduled stoppage of the mill after roll failures, the unplanned mill delays also increased, causing production losses. The analysis revealed significant increase in premature failure of rolls in the finishing stands 19, 22, 23, and 24 and prefinishing stand 14. The primary causes of such failures were faulty roll cooling and roll mounting and accumulation of cobbles. Implementation of modified cooling headers, a calibrated gage to monitor hydraulic pressure during roll mounting, and eddy current inspection resulted in decreasing the trend in roll failure and increasing the trend in ATBF.     

R134a通过短管流动的试验研究

短管机构在汽车空调、家用空调和热泵系统中得到越来越广泛的应用。目前，关于提供通过短管机构ＣＦＣ替代物性能研究方面的数据很少。本文给出了ＣＦＣ替代物Ｒ１３４ａ通过短管机构的流动特性试验研究。在很宽的操作条件下，通过试验研究了Ｒ１３４ａ流过短管机构的性能参数变化。长径比在７￣２０范围内，冷凝温度为３５℃￣５４℃时，过冷度可达１３．９℃，短管入口干度可达１０％左右。对进入短管的两相流和过冷液体性能进行了     

高压液氨装置用大型锻件的焊接修复

介绍了大型锻件的焊接修复工艺的制订以及焊后热处理,通过两年的运行表明,该焊接工艺可靠安全。     

彩色显像管用销钉封接白线研究

EDAX分析表明，封接白线是销钉封接时玻璃沿销钉氧化膜的爬坡，是否产生封接白线受销钉氧化膜表层尖晶石的成份控制，R＞0．65时，产生封接白线。避免湿氮参与氧化膜形成过程使R＝0．4，则可消除这一封接缺陷。     

R134a臣卧式螺旋管内流动沸腾换热特性实验研究

对R134a在水平直管和螺旋管内的沸腾换热特性进行了实验研究.在三个不同的蒸发温度(5℃、10℃和20℃),工质R134a的质量流量范围为100～400kg/(m~2·s)和干度范围为0.1～0.8的条件下,实验得到了R134a在水平直管和螺旋管内的沸腾换热系数随其质量流量和干度的变化关系,将水平直管和螺旋管内的沸腾换热特性数据进行了比较,结果显示,在实验条件下,卧式螺旋管的传热系数比直管的平均增加13.7%.     

新型椭圆形套管-管翅式蒸发式冷凝器研究

本文设计了一种新型椭圆形套管-管翅式蒸发式冷凝器,该冷凝器采用套管结构,制冷剂在圆型内管与椭圆形外管之间的环形区域流动,同时与内管中的冷却水、外管外的喷淋水及冷却空气进行热量交换。以北京阜通地铁站为实测地点,对位于该站的圆管-管翅式蒸发式冷凝器运行数据进行现场实测,以实测数据为基础对椭圆形套管-管翅式蒸发式冷凝器进行传热理论和机理分析,并通过Fluent数值模拟,将模拟结果与圆管-管翅式蒸发式冷凝器的实际运行数据进行对比。研究结果表明:当空气入口温度为27℃、空气流速为3～4 m/s时,椭圆形套管-管翅式换热器管外压降与圆管-管翅式换热器相比降低11. 18%～14. 65%;当喷淋水温度为27. 5～33. 5℃时,椭圆形套管-管翅式换热器出口制冷剂温度比圆管-管翅式换热器模拟值低2. 66～10. 21℃;当入口制冷剂温度大于44℃时,椭圆形套管-管翅式换热器出口制冷剂温度比圆管-管翅式换热器实测值低1. 9～4. 3℃,其总传热系数比圆管-管翅式换热器提高47. 42%。     

水平管外R404A降膜蒸发传热的实验研究

搭建了降膜蒸发实验台,研究了水平单管外的降膜蒸发传热特性。测试管为外径19mm、有效实验长度为2500mm的光滑管和强化管。实验采用R404A作为管外降膜蒸发工质,与管内热水进行换热。布液采用喷嘴喷淋的方式,通过21个喷口当量直径为2mm的喷嘴完成。分别在变饱和温度(0、5、10、15℃)、变热流密度(从8到30kW/m2)和变喷淋量(从0.07到0.11kg/(m·s)时进行实验,研究了降膜蒸发换热性能相应的变化情况,得到R404A的管外降膜蒸发换热的一些规律,这对降膜蒸发器的设计及应用具有一定的参考作用。     

翅片管换热器过冷管设计对系统性能影响研究

试验对比研究在翅片管换热器底部设置1根U形管过冷、2根并联U形管过冷、2根串联U形管过冷的过冷效果,测试数据表明用2根U形管串联进行过冷的效果最好。当把2根铜管串联用于过冷时,对R22制冷剂在B工况测试条件下,与没有过冷相比,过冷度增加了1．1℃,能效比高出0．33W／W,提高了8．25％;对R410A制冷剂在B工况测试条件下,与没有过冷相比,过冷度增加了2．0℃,能效比高出0．10W／W,提高了2．69％。     

Failure Analysis of Two Stainless Steel Based Components Used in an Oil Refinery

The petroleum industry has changed significantly over the past decades. For example, in Brazil, oil extraction under very deep sea water is growing very quickly. As a consequence, materials and components used for such applications must have properties required to withstand adverse conditions and ensure satisfactory performance and reliability in service. Nonetheless, components that normally fulfill these standard requirements can fail under severe service conditions such as high pressure and temperatures and high concentrations of H₂S and CO₂. Among the factors that can cause the premature failure in metallic components are the use of inadequate materials, the presence of defects that appeared during the production, and errors of project, assembly, or maintenance. Failure analysis allows the identification of causes and thus contributes to improvements in the operation and performance of similar equipment. In this work, light optical microscopy and scanning electron microscopy (SEM) were used to analyze the microstructure and fracture surface of two centrifugal pump shafts that failed during use in a Brazilian petroleum refinery. The results showed that one shaft, made of duplex stainless steel, failed by fatigue fracture, and the other, made of 316 austenitic stainless steel, experienced a similar fracture, which was promoted by the presence of nonmetallic inclusion particles.     

运动平台上跟踪系统主镜筒动态特性分析

本文根据运动平台上某跟踪系统主镜筒的设计方案,在ansys平台下建立系统有限元分析模型,求得了主镜筒的前十阶固有频率和结构的强弱分布,确定了结构分析的重点为主、次镜的相对位置变化.定义了描述主、次镜相对位置变化的参量及其计算方法,并在冲击载荷作用下计算分析了主、次镜相对位置的瞬态响应,总结了主镜筒的响应规律.分析结果为...     

KF-23型空调器用等焓加湿翅片管式冷凝器性能的实验研究

本文针对KF-23型空调器用等焓加湿翅片管式冷凝器的性能进行了实验研究。以热水作为被冷却介质,对冷凝器进行了对比实验研究,在不同环境温度下测量了原冷凝器换热量和淋水量为0.053kg/s下填料厚度分别为50mm、65mm、80mm和100mm时冷凝器的换热量。研究结果表明:等焓加湿可提高翅片管式冷凝器的冷却效果,且随着环境温度的增大,换热量增幅也增大;等焓加湿冷凝器的风量随填料厚度的增加而减小;淋水密度的大小决定了填料的湿润程度,在淋水量为0.053kg/s时,100mm厚填料的表面刚好完全湿润。