FAILURE ANALYSIS

THE FAILURE MAY BE DUE TO FOLLOWING REASONS THE FABRICATION SEQUENCE INHERENT METTALURGICAL PROBLEMS. IMPROPER SELECTION OF CONSUMABLES. IMPROPER APPLICATION OF PROCEDURE

LINIENCY IN DESIGN
LACK OF CLEAR CONCEPT

CASE STUDIES & FAILURE ANALYSIS WITH STICK WELDING(SMAW) PROCESS

ON DIFFERENT TYPES OF MATERIAL

FAILURE OF TEST COUPENS OF DISHED END PETAL TYPE HOT PRESSED/ COLD SPINNING

THE WPS/PQR ESTABLISHED USING E7018 ELETRODES FOR SA515Gr70 MATERIAL GAVE SATIASFACTORY RESULTS FOR PETAL D.E
THE SAME WPS FOUND TO VARIATION IN RESULT WHEN USED FOR COLD SPUN /HOT PRESSED D.E. WITH WELD JOINT.

ANALYSIS
THE HOT PRESSED ./COLD SPUN D.E.UNDERGOES NORMALISING OPERATION WHICH IS NOT ACCOUNTED IN WPS

WHEN USING E7018 ELECTRODES ,UTS DROPS BY 50-70 N/mm sq WITH NORMALISING OPERATION

FAILURE OF TEST COUPENS OF DISHED END(CONTD)

SOLUTION
IT IS RECOMMENDED TO USE E7018A1 WELDING CONSUMABLES.

PROPERTIES OF CONSUMABLES WITH TYPICAL H.T. CYCLES.

Sl.No

CONSUMALE TYPE

AS WELDED

SR

NORMALISED

1 2

E7018 E7018A1

530 540

525 535

480 530

FAILURE OF 5Cr-1/2 Mo SPIRAL HEAT EXCHANGER

PROBLEM: THE SPIRAL COIL WELD JOINTS WERE FOUND TO BE LEAKING AFTER SHORT SEVICE OF SIX MONTHS ANALYSIS: THE WELD JOINTS EXAMINED USING DP INDICATED SEVERE MICRO FISSURING ON ALL THE JOINTS. THE EXAMINATION OF WPS/PQR INDICATED ROOT RUN BY GTAW & BALANCE BY SMAW OF E 8018-B6 CONSUMABLES.

FAILURE OF 5Cr-1/2 Mo SPIRAL HEAT EXCHANGER(CONTD) ON EXAMINATION OF CONSUMABLE RECORDS ,BEING 2.5MM IN SIZE ,NO MECHANICAL TEST RESULS WERE CALLED FOR & HENCE NOT PROVIDED. REVIEW TAKING INTO CONSIDERATION TYPE OF BASE MATERIAL WHICH IS PRONE FOR INTERMEDIATE HARDANABLE MICRO STRUCTURE & MICRO FISSURING UNDER RESTRAIANT, IT WAS RECOMMENDED TO USE E8018-B6 DULY QUALIFIED WITH TEKKAN Y-GROOVE TEST TEKKEN Y-GROOVE ASSEMBLY

20mm

CROYOGENIC APPLICATION
TYPICAL REQUIREMENT 15 mil LE AT MINUS 196 Deg.C LOW CORBON(<0.04),NITROGEN(<0.05), FERRITE(2%) BASIC SLAG

SMAW 15 COATING TYPE FCAW LIME/FLUORIDE COATING

E308L 15/16 FOR CRYOGENIC APPLICATION(CONTD) PROBLEM

SELECTION OF PROPER CONSUMABLE FOR CRYOGENIC APPLICATION

ANALYSIS
THE CONVENTIONAL E308L-16 ELECTRODES GAVE ERRATIC RESULTS. EVENTHOUGH THE E308L-15 ELECTRODES FOUND TO GIVE GOOD RESULTS, RADIOGRAPHIC RESULTS WERE NOT CONSISTANT IT WAS POSSIBLE TO OBTAIN GOOD PERFORMANCE AS WELL AS CONSISTANT RESULT BY MODIFYING THE PRODUCT E308L-16 WITH CONTROLLED FERRITE(<2%)
RESULTS OF E308L-16 BATCH TEST BATCH CVN AT -196 C LE mil UTS mpa %E FN %

A
B C

32.3
40 35.3

17
19.2 19

536
543 564

45.4
49 47

2
1.5 1

THE RESULTS WITH MODIFIED PRODUCT FOUND SATISFACTORY

CORROSION APPLICATION

TYPICAL REQUIREMENTS 24 mpy PRAC.B/15MPY ASTM A 262 PRAC. C

BASIC SLAG,LOW FERRITE(NIL)

HIGH NICKEL&/OR HIGH MANGANESE

E316LF WITH NIL FERRITE

PROBLEM THE E316LF ELETRODES QUALIFIED FOR JOB GAVE MICRO FISSURING IN ACTUAL FABRICATION PARTICULARLY ON RESTRAIANT JOINTS. ANALYSIS: THE QUALIFIED CONSUMABLE ,EVENTHOUGH GAVE SATISFACTORY RESULTS IN L-SEAMS,FOUND TO GIVE MICRO FISSURING IN C-SEAM& NOZZLE JOINTS. THE CRATER GRINDING THOUGH CONTROLLED THE PROBLEM, IT WAS NOT DESIRED SOLUTION SOLUTION: BASED ON OBSERVATION & STUDIES ,IT WAS DECIDED DEVELOP THE E316LF CONSUMABLE CAPABLE ON WITHSTADING HEAVY RESTRAINANT. TO EVALUATE THE CONSUMABLE ,THE THOMAS-SCHFFLER TEST WAS TAKEN AS BASIS

E316LF WITH NIL FERRITE

TEST RESULTS OF CORROSION ON MOD.E316LF BATCH NO

TEST DURATION

CORR.RATE mpy

REMARKS

NO OF CRACKS

FERRITE NO.

A B C

48X5 48X5 48X5

14 10.5 5.5

FAIL REVIEW ACCPT.

5 1 -

NIL NIL NIL

THOMAS SCHFLLER TEST ASSEMBLY

WELDING OF DISSIMILAR STEELS

WELDING OF DISSIMILAR METALS PROBLEM:

FOR WELDING OF CS &LAS TO SS THE COMMON CONSUMABLES SELECTED LIKE E309/309L/309Mo GAVE PROBLEMS WITH REGARD TO DUCTILITY

ANALYSIS
THE COMMONLY AVILABLE CONSUMABLES IN ABOVE GRADES COMMONLY HAD FERRITE 8-16% THESE CONSUMABLES EVEN THOUGH SUITABLE FOR THIN SECTIONS,GAVE VERY LOW %E WHEN USED ON THICKER JOINTS/SR APPLICATION THE REASON FOR ABOVE WAS DUE TO FORMATION OF INTERMEDIATE BAINITE(SIGMA) PHASE

SOLUTION
USE MODIFIED CONSUMABLES WITH CONTROLLED FERRITE OF 6-9% & QUALIFY THE SAME WITH SR AT 680deg C FOR 1HOUR WHEN WELDING JOINTS THICKER THAN 20mm ,BUTTER THE CS/LAS WITH E309&WELD WITH SUITABLE SSCONSUMABLES.

EFFECT OF POST WELD HEAT TREATMENT ON E309 TYPE CONSUMABLES

% AGE ELONG. WITH REF TO ORIGINAL%E

4 8 16
POST WELD HT TEMP POST WELD HT FOR 10 HOURS

C 600 C

D 700 C

B 500 C

A 550 C

TYPICAL MECHANICAL PROPERTIES OF WELDING CONSUABLES STEEL WELDING USED FOR DISSIMILAR
Sl. No Type
T e c h n I c a l C o n d i t I o n

Mech. Prop (ASME Specified As Welded PWHT As Welded

Mech. Prop (Actual) PWHT

UTS N/mm2
550 550 550 550

% E
30 30 30 30

UTS N/mm2
-

% E
-

UTS N/mm2
550-650 550-650 550-650 550-650

% E
30 30 30 30

Ferrite

UTS N/mm2
650- 750 550- 650 550- 6O0 580- 680

% E
10 30 30 25

Ferri te
4 6

1 2 3 4

E309/E309MO E310 ENiCrFe3 E309/E309MO (Modified)

16 8

Undiluted E309 deposit E309 BUTTERING

40 20 10

SS18/8 TYPE WELD METAL

CS TO SS WELDING WITH E309 TYPECONSUMABLES

CS TO SS WIELDING WITH CS SIDE BUTTERING

PROBLEMS RELATED

TO CLAD STEEL WELDING

MISMATCH OF 1.2MM-CONVENTIONAL EDGE PREPARATION

Barrier layer location

1-2MM

NOZZLE TO SHELL WELD

Contamination of high alloy steel With CS/LAS
5mm

STRIP BACK & HIGH ALLOY WELD

SEQUENCE OF WELDING
FIRST SIDE
BASE METAL WELDING BG &SECOND SIDE BASE MEATL WELDING FIRST LAYER

BARRIER LAYER

COMMON TYPES OF EDGE PREPARATIONS

3mm

5mm

3mm

REPAIR WELDING
CS/LAS WELDING TO BE RESTRITED 1MM BELOW ORIGINAL BARRIER LAYER LEVEL OF BARRIER LAYER 5mm DEPTH

REPAIR FROM CS/LAS SIDE

T-Thickness a-Clad thickness b-High alloy steel dep. Depth

BALANCE CS/LAS} WELD METAL }

t- (d+b)

c-Balance CS/LAS weld metal d-Gouging depth

15 CDV 6 IN AERO SPACE INDUSTRY

15CDV6

Due to its excellent mechanical properties, the material 1.7734 / 15CDV6 meets the requirements of international quality- and safety standards. High yield strength and excellent weldability. Weldable without subsequent heat-treatment, in both conditions High resistance of the weld, without subsequent heattreatment (Rm > 980 N/mm2).

CHEMICAL &MECHANICAL PROPERTIES OF 15CDV6

CHEMICAL

C
MIN MAX 0.12 0.18

Cr
1.25 1.5

Mo
0.8 1.0

V
0.2 0.3

Material Number

Tensile Strength

Yield Strength

N/mm2 (MPa)
1.7734.4 / 15CDV6 1.7734.5 / 15CDV6 700 980 1180

N/mm2 (MPa)
550 NORMALISED 790 TEMPERED

15 CDV6 FABRICATION EXPERIANCE

FIRM ASKED MANUFACTURE BOOSTER MOTOR FOR ROCKET LAUNCHING.

ASKED ABOUT FABRICATION CODE,TOLD US TO FOLLOW GOOD ENGINEERING PRACTICE.

NO APPLICATION DETAILS PROVIDED DUE TO HIGH SECURITY CLASSIFICATION

MANUFACTURED THE VESSEL FOLLOWING ASME GUIDELINES.

VESSEL FAILED TO MEET BURST TEST VALUES SPECIFIED. TESTING FROM VESSEL WELDMENT CONFIRMED COMPLIANCE WITH DESIGN DATA. AFTER DISCUSSIONS PARTY AGREED TO GIVE ONE RUSSIAN VESSEL FOR TESTING AT OUR END.

15 CDV6 FABRICATION EXPERIENCE(CONTD)

BURST TEST MET THE SPECIFIED PRESSURE. THE WELDMENT WHEN SUBJECTED TO TEST,THE BEND FAILURE NOTICED AT 25-30 DEG. DISCUSSION WITH PARTY CONFIRMED DESIGN CAN BE MODIFIED TO MEET RUSSIAN VESSEL. THE SR WAS ELIMINATED &TEMPERING INTRODUCED TO MEET THE CUSTOMER SPECIFICATION. AS BOOSTER MOTOR IS FUEL CARRYING VESSEL & WILL BE DISCARDED AFTER FUNCATIONAL UTILITY,IT IS REQUIRED TO DISINTEGRATE DURING REENTRY TO ATMOSPHERE.HENCE THE NONDUCTILE NATURE OF VESSEL IS ADVANTAGEOUS IN THIS REGARD.

15 CDV6 FABRICATION EXPERIANCE

THE OTHER EXPERIENCE IS AS FOLLOWS THE SAME FIRM PLACED ORDER FOR AIR BOTTLES WITH 15CDV 6 MATERIAL AS WE HAD ALREADY ESTABLISHED FABRICATION PROCEDURE ,WE WERE ASKED TO FOLLOW THE SAME. THE BOTTLES WERE MADE READY & WAITING FOR FINAL INSPECTION.

BECAUSE OF EARLIER EXPERIENCE , STILL THERE WAS APPREHENTION ABOUT APPLICATION.

ON OUR PERSISTANT REQUEST ,FINALLY THE INSPECTION PERSON CONFIRMED THAT THESE AIR BOTTLES ARE USED TO STORE AIR & WHENEVER THERE IS FALL IN LINE PRESSURE,THESE BOTTLES SUPPLY AIR TO MAINTAIN UNIFORM PRESSURE. THE AIR BOTTLES RECEIVE REQUIRED AIR TO COMPENSATE THE LOSS FROM ON LINE COMPRESSOR

15 CDV6 FABRICATION EXPERIENCE(CONTD)

OUR DESIGN WITH LIMITED BEND DUCLITY WAS NOT OK FOR THIS APPLICATION AS LOWER & OPTIMUM MAINTAINANCE OF PRESURE WILL CAUSE FATIGUE LOAD. FOR SUCH APPLICATION VERY GOOD ELONGATION & IMPACT PROPERTIES ARE MUST

THE MATTER WAS TAKEN TO HIGHEST LEVEL & JOB WAS RE-HEAT TREATED TO SUIT THE APPLICATION WITH RE-ESTABLISHED WPS/PQR.
THE BASIC PROBLEM WAS THE FIRM(DEFENCE) WAS WORRIED ABOUT SHARING BASIC D ESIGN PARAMETERS WHICH COULD HAVE RESULTED IN CATASTROPHIC FAILURES.TIMELY ACTION HAS AVERTED THE SAME.