DAVID N FRENCH

METALLURGISTS
Failure and Material Evaluation

Corporate Office 
David N. French Metallurgists
2681 Coral Ridge Rd. Brooks, KY 40109
502 955-9847
Fax: 502 957-5441
Email: sales@davidnfrench.com
www.davidnfrench.com

(502) 955-9847
www.davidnfrench.com
 DNFM Quarterly Newsletter
INTRODUCTION
View From the Penthouse
Past Issue Topics
David N. French Metallurgists
Boiler Lay Up
David N. French Metallurgists is a metallurgical consulting firm providing failure analysis,
condition assessment studies, metallurgical consultation, and educational seminars relat- 1st Quarter 2007
ing to metallurgical failure in boilers. Our primary mission is to solve metallurgically re-
lated failures with the highest standard of engineering methodology, innovative ideas, Creep Fatigue
and ethical practice. David N. French Metallurgists is at the leading edge of metallurgical
technology with state-of-the-art laboratory services, equipment, publications, and educa- 4th Quarter 2006
tion.
Oil Ash Corrosion
DNFM specializes in boiler tube failure analysis, weld failure analysis, and life and mate-
3rd Quarter 2006
rial condition assessments. Our engineering staff is qualified and able to determine the
failure mechanism and perform a second-to-none evaluation of conformance to industry
specifications. Laboratory evaluation, engineering analysis, engineering support, solu- Waterside Deposits
tions to manufacturing problems, enhancing boiler quality and performance, and an im-
proved level of reliability are just some of the quality services David N. French Metallur- 2nd Quarter 2006
gists deliver.
Reducing Condition Corrision
The metallurgical staff at David N. French Metallurgists has 60+ years of wide-ranging 1st Quarter 2006
industrial metallurgy processing, welding, metallurgical engineering, quality assurance,
and manufacturing/ root-cause failure-analysis experience. Carbon steels, stainless
steels, nickel based, and other alloys used in ASME boilers and pressure vessels are our
Reducing Condition Corrosion
specialty. 4th Quarter 2005

Our primary objective is to provide independent, unbiased, expert opinions regarding

materials, fitness for continued service, and failures. Utilizing the latest in analytical
equipment and techniques, David N. French Metallurgists can determine the root cause
of failure for any given sample.

David N. French
Technical Director
Oxygen pitting and stress assisted corrosion   Severe corrosion can occur underneath depos‐
at an attachment  its in a roof tube, especially during lay up  

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PUBLICATIONS
Metallurgical Failures in Fossil Fired Boilers
Hailed instantly as the definitive field reference, the book provides a comprehensive
catalog of the types of metallurgical failures common to boilers. Using actual case histo-
ries of boiler shutdowns, the book documentes the full range of causes of boiler tube
failure - providing a blueprint for cutting maintenance costs and upgrading the efficiency
and reliability of any power plant operation.
Reflecting the heightened focus throughout the industry on boiler tube failure analysis,
the expanded Second Edition sheds light on the latest innovative insights and solutions
highlighting the field. features information on fluid dynamics, heat transfer, stress cal-
culations, and essential requirements of boiler design is included. For added relevance,
this edition includes important information on making material-condition and end-of-life
assessments for plant equipment being used beyond its original design expectations.
Also included is up-to-date information on the higher temperature ranges now experi-
enced by boilers. An expanded listing of boiler equipment as well as new case studies
examining an even wider, more current range of problems makes this book more useful
than ever.
The fundamentals of elementary metallurgy are clearly presented, enabling even non-
metallurgists to fully grasp the analyses of the examples given.
SOFTWARE
Each failure has a full description of external and internal appearances. Common loca-
tions, causes, and preventive maintenance actions are included; detailed photos of the
failure, technical information, and metallurgical insight are also included.
Key Features
■ Browse the most common known failures
■ Search specific failure content to assist in determining the root cause
■ Print failure reports with photographs
■ Copy and paste technical information into real time documents
■ Customization option allow the user to add new and unusual failures
■ Built in “Boiler Dictionary” for in-depth searches
User Interface Search Engine
Dr. David N French
Dr. David N. French is Technical Director for David N. French Metallurgists. Dr.
French received his ScD in Metallurgy from Massachusetts Institute of Technology
in 1962. He brings 45 years of metallurgical engineering experience, including 10
years as a Quality Assurance Leader for a major boiler manufacturer (Riley Stoker
Corp.) and a pressure parts manufacturer (Leighton Industries Inc.). He’s managed
corporate quality assurance functions, materials selection for alloys not governed
by the ASME Boiler and Pressure Vessel Code, metallurgical control of welding
fabrication, heat treatment, and the metallurgical laboratory for failure analysis of
boiler components. His book Metallurgical Failures in Fossil Fired Boilers has been a
vital reference to the industry for years. In 1984, Dr. French founded David N.
French Metallurgists, providing failure analysis, material condition assessment,
metallurgical consultation and seminars on metallurgical failures in boilers. He is an
expert in fuel ash corrosion, welding, high temperature oxidation, creep and
stress-rupture failure, and is knowledgeable in boiler operations, boiler design,
materials selection, casting and foundry techniques. Dr. French has presented
many papers and conducted numerous seminars, most recently those offered by
David N. French Metallurgists and United Dynamics Corporation.
Dr. David C Crowe
Dr. David Crowe is a Senior Metallurgical Engineer with over 21 years of industrial
experience. He holds a Bachelors Degree in Mechanical Engineering and a PhD in
Metallurgical Engineering. His specialties include failure analysis, equipment in-
spection and evaluation, material selection, and corrosion testing and monitoring.
Dr. Crowe’s early career focused on corrosion research in the Pulp and Paper In-
dustry, and he is familiar with the full range of processes and equipment there,
including recovery boilers, pressure vessels, tanks and paper machines. Crowe has
worked to improve safety and reliability of equipment through inspection, condition
assessment and design of repairs. Other efforts have included the establishment of
corporate inspection and repair standards and training staff in their use. He has
directed hundreds of metallurgical analyses to determine the root cause of failures,
utilizing microstructural examination, electron microscopy, mechanical testing and
other test methods. Crowe has been an Assistant Professor, has given numerous
seminars and presentations, and has published a number of papers on corrosion
and materials.
DNFM Educational Seminars
We offer educational seminars catering to the needs of those who function in all
capacities within the industry providing continuous education and training.
Joint Approach for Boiler Tube Failure Prevention
An insightful seminar with “in-the-field” experience and laboratory analysis of boiler
tube failures; identifying and prevention the occurrence. Topics include cycling the
boiler, operational upsets and resulting damage, quench cracking from water lances/
cannons and strategies for approaching these problems. The effects of fuel changes,
burner retrofits, i.e. fireside corrosion; causes, methods of prevention and acceptable
repairs. The importance of a good water chemistry program, acid phosphate
corrosion, caustic corrosion/gouging, copper deposition and hydrogen damage, along
with pitting, scale and water side contaminants; including causes, preventions, and
acceptable repairs. Common boiler materials, fabrication, installation defects,
graphitization, low temperature creep, and boiler lay-up procedures are also included.
 FAILURE ANALYSIS FAILURE ANALYSIS CAPABILITIES
The DNFM Laboratory is equipped with a wide variety of metallurgical and photo-
graphic instruments used to conduct failure-analysis investigations. Failure analysis Testing Procedures and Capabilities
is conducted by an experienced staff of engineers trained in such disciplines as: DNFM offers a wide variety of analysis and testing procedures to meet the require-
▪ Microstructural Characterization of Metals ments of our clientele.
▪ Microstructural Characterization of Deposits
▪ Fractography SERVICES MECHANICAL TESTING
▪ Corrosion Processes
▪ Welding Metallurgy Life Assessment Rockwell Hardness
▪ Mechanical Testing Condition Assessment Room Temperature Tensile
▪ Non-Destructive and Destructive Testing Procedures
▪ Chemical Analysis Failure Analysis Elevated Temperature Tensile
Metallography Stress Rupture
Failure analysis investigations conducted in the laboratory typically consist of the
following actions: Deposit Loading Charpy Impact
As Pictured: A series
of micros used for ▪ Determine the failure mechanism or main cause of damage for any given sample Corrosion Testing Bend Testing
metallurgical analy-
sis
and provide recommendations to correct or avoid recurrences Fracture Evaluations Fatigue Testing
▪ Identify service-related environmental factors which contribute to material Creep and Stress Rupture Evaluation CHEMICAL ANALYSIS
degradation or failure
Larson Miller Parameter Evaluation Carbon Steels
▪ Characterize materials and assess their compliance with specifications as well as Microhardness Alloy Steels
condition after service
Identification of Material Defects Stainless Steels
▪ Resolve material- related issues pertaining to fabrication defects and impurities
Failure Mode Identification Nickel Alloys
Sample Services Conformance to Industry Specifications pH Measurement
All services offered through DNFM are processed to meet the needs of our clientele:
Sensitization Testing (Austenitic SS only) Ion Chromatography
• Standard– Generally 14 Days Turn-around Time Scanning Electron Microscopy (SEM) ID Scale or Ash Analysis
Ring Sections Energy-Dispersive X-Ray (EDX)
• Rush– Generally 48 Hours Turn-around Time
Material Certification NDE
Oxide Thickness
Client ‘Value-Added’ Services
Liquid-Penetrant
▪ As a value added service, DNFM will periodically make recommendations to Magnetic-Particle
perform additional metallurgical testing procedures and material life assessment
studies based off component, operational, and material failure data Ultrasonics
Replications
▪ Client reports are kept on file indefinitely

▪ All reports may be accessed at www.davidnfrench.com using a provided user name

and password for each client.

▪ All failure information may be submitted to DNFM via an easy-to-use online form