JFAPBC (2005) 2:21-24 © ASM International

DOI: 10.1361/15477020522988 1547-7029 / $19.00

High-Temperature Failure of a
Cast Soot Blower Lance Tube Nozzle
T.N. Ackerson
(Submitted January 28, 2005; in revised form February 2, 2005)
A cast stainless steel lance tube nozzle failed prematurely in a brittle manner after one to two years
of service. Metallographic examination of the nozzle revealed a Widmanstätten structure, likely
resulting from the precipitation of sigma phase. The presence of this structure suggests that the
component was exposed to temperatures beyond the specified operating range.

Keywords: brittle fracture, CK-20 stainless steel, high-tempersture failure, sigma phase

Introduction and The nozzle was sectioned to expose the multiple

Background Information
Due to the accumulation of soot over time, soot
blowers were developed to perform in situ cleaning
of boiler tubes. Proper cleaning is necessary to
maintain the efficiency and longevity of the boiler.
In the case of a retractable soot blower, a lance tube
is inserted into the operating boiler. The lance tube
nozzle sprays a jet of steam through a venturi at
the ash-covered boiler tubes. A constant flow of
steam through the nozzle is important to keep the
component cooled below its maximum specified
operating temperature of 900 °F (482.2 °C). Once
the cleaning cycle is completed, the lance tube
nozzle is retracted to a cooler location of the boiler
prior to stopping the flow of steam.
fracture surfaces associated with the cracks. Figure
3 shows the fracture morphology, which exhibited
an unusual square and delaminated appearance.
This observed fracture morphology was generally
brittle in appearance. The significant degree of
oxidation to the fracture surfaces precluded a useful
microfractographic study via scanning electron
microscopy.
Metallographic and
Heat Treatment Evaluation
Metallographic specimens were prepared from
the fractured nozzle tip and the non-cracked venturi
region using a multi-specimen automated grinding

Visual Examination
The failed CK-20 austenitic stainless steel lance
tube nozzle (Fig. 1) had been in service approx-
imately one to two years when cracking was ob-
served along its tip, as shown in Fig. 2.

Fig. 1 Lance tube nozzle in the as-received condition, showing

the venturi (arrow) Fig. 2 Failed tip of the lance tube nozzle, as received

T.N. Ackerson, Materials & Metallurgy Group, Southern Research Automotive Division, Southern Research Institute, 757 Tom
Martin Drive, Birmingham, AL 35211. Contact e-mail: ackerson@sri.org.

Journal of Failure Analysis and Prevention Volume 5(2) April 2005 21

 High-Temperature Failure of a Cast Soot Blower Lance Tube Nozzle (continued)

and polishing system. Once polished, the specimens suspected to be a polishing artifact. However, this
were electrolytically etched with a 10% chromic condition was reproducible after several polish/etch
acid solution to reveal the microstructure.
The specimen prepared from the fractured nozzle
tip is shown at relatively low magnification in Fig.
4. The general microstructure consisted of austenite
(light) with ferrite islands (dark). Two parallel
primary cracks were observed, which contained
additional secondary cracks. The crack tips con-
tained an oxide layer with oxide pegs (Fig. 5). This
oxidation pattern is indicative of high-temperature
exposure in conjunction with thermal fatigue or
corrosion fatigue.[1] Higher magnification examina-
tion of the sample revealed a crosshatched con-
dition. This feature appeared to be oriented parallel
to many of the observed cracks. The crosshatched Fig. 5 Oxide needles emanating from a nozzle crack, indicative
condition, shown in Fig. 6 and 7, was originally of high-temperature exposure and thermal fatigue.
Originally 200×

Fig. 3 Fractured tip of the nozzle after initial sectioning. Fig. 6 Another region of the failed nozzle tip. Originally 100×
Originally 20×

Fig. 7 Higher magnification view of the area shown in Fig. 6,

Fig. 4 Metallographic cross section through the failed nozzle originally 500×. Note the crosshatched structure, which
tip, showing two cracks. Originally 25× was first suspected to be a polishing artifact.

22 Volume 5(2) April 2005 Journal of Failure Analysis and Prevention