Failure Analysis of Cracked Reducer Flange |
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Authors: | Khaled Habib |
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Affiliation: | (1) Materials Science Lab, Department of Advanced Systems, KISR, P.O. Box 24885, 13109 Safat, Kuwait |
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Abstract: | A cracked reducer flange was analyzed for the cause of the failure. The flange was carefully cut to obtain samples for metallographic,
X-ray, and scanning electron microscopy (SEM) Examinations. The examinations revealed that the introduction of chloride ions
in the operational service led to pitting corrosion in the inner surface of the flange. Chloride ion inclusions were probably
the result of chemical contaminations, i.e., cleaning chemicals’ contamination during shutdown of the operation. The introduction
of corrosion pits caused unexpected load stress intensification and cracking of the flange. Consequently, stress corrosion
cracking emanated from the pits under the influence of chloride attack and operational pressure. Then the cracks propagated
in a transgranular manner, in the radial direction of the flange, until the final failure occurred. |
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