Failure Analyses

Test Samples of Reinforced Concrete Are Often Too Small

A recent study from European university scientists suggests that samples of reinforced concrete need to be larger to ensure accuracy in corrosion detection.

U.K. Grant Targets Sensors for Corrosion Protection in Heating, Cooling Units

A collaborative project funded partly by the U.K. government is looking to develop cost-effective sensors capable of measuring the corrosion rates of metals used in water-based heating and cooling units.

Failure of Water Wall Tubes Caused by Hydrogen Embrittlement from Severe Underdeposit Corrosion

In a CORROSION 2017 paper, authors discussed two water wall tubes in a multistage flash distillation plant’s operating boiler that experienced failure after 14 years of service.

Texas Water Utility Partners with University on Corrosion Research

Water utility officials in Arlington, Texas, are working with University of Texas at Arlington researchers to inspect concrete manhole shafts and sewer pipes for corrosion, cracks, and other internal defects.

U.S. Airmen Target Noninvasive Methods to Spot Aircraft Defects

Airmen with the 19th Maintenance Squadron at the Little Rock Air Force Base in Arkansas are using nondestructive inspections to identify potential cracks in a variety of aircraft parts.

EPA Finds Moderate or Severe Corrosion in Most Underground Diesel Tanks

In a new report on corrosion inside underground storage tanks storing diesel fuel, the U.S. Environmental Protection Agency found moderate or severe corrosion could affect metal components inside both steel and fiberglass tank systems.

Results Posted for NACE International’s 2016 Annual Corrosion Career Survey

Average annual salaries in 2016 are reported for corrosion professionals in the United States, Canada, United Kingdom, and Europe. A slight gain was seen for the United States and United Kingdom, while a larger increase was recorded in Canada.

Corrosion Inspection by 3D Non-Contact Profilometry

Corrosion can either take place locally to form a pit or crack, or it can extend uniformly across a wide surface. Proper surface analysis of the corroded sample is vital for evaluating corrosion characteristics and mechanisms, so the best materials, protective coatings, and corrosion-control measures can be selected.

NACE International’s Annual Corrosion Career Survey Results for 2015

Corrosion professionals in North America and Europe have experienced another year of continued growth in career opportunities and salary levels, according to the 2015 Corrosion Career Survey conducted by Materials Performance magazine.

Wanted: Technical Articles for MP

To successfully communicate the wide variety of corrosion-related issues affecting corrosion professionals today, MP is actively encouraging corrosion control professionals worldwide to submit technical articles to share their corrosion-related experiences with over 36,000 NACE International members around the globe.

SCC Failure of a Super Duplex Separator Vessel in an Ammonium Nitrate Plant

This article presents findings of a failure investigation on a separator vessel in an ammonium nitrate (NH4NO3) plant. The super duplex stainless steel vessel leaked due to stress corrosion cracking initiated in the heat-affected zones of welds exposed to the NH4NO3 solution at ~180 °C.

Failure Analysis of Pyrolysis Furnace Transfer Line Tubes

Transfer line tubes of an ethane pyrolysis furnace, operating at 850 ±20 °C and 1.0 atm pressure, developed longitudinal cracks after less than one third of their expected service life. The tubes were constructed of Fe-based UNS N08810 alloy with a wall thickness of 10 mm. Metallurgical evaluation revealed that the mode of failure was high-temperature carburization attack leading to intergranular cracking. The cause of failure was overheating, likely to have occurred during decoking operations. Better control of furnace temperature was recommended to avoid overheating. Alternatively, a wrought alloy capable of developing highly protective aluminum oxide (Al2O3)-base scale such as Ni-based UNS N07214 could be used as a replacement.

Microbiologically Influenced Corrosion in a Copper Tube Chiller

The increased use of recycled water has led to the need for an effective water treatment program to prevent microbiologically influenced corrosion (MIC). This article describes an investigation of copper tubes in a chiller that failed from MIC because of a poor water treatment program.

Premium Connection Downhole Tubing Corrosion

This article discusses a field background search, macro- and micro-corrosion morphology analysis, and material testing of corroded premium connection downhole tubing. Tubing failure was caused by erosion-corrosion from highly disturbed liquid and high shear stress at the couplings.

Unusual Occurrence Causes Leak in High-Pressure Underground Gas Pipeline

A gas leak was detected on a 56-in (1.4-m) crosscountry gas pipeline from a small orifice on the bottom of an indentation. The pipeline had an epoxy primer and a hot polyethylene coating, and was only four years old. Metallurgical tests on the hole and theoretical calculations indicated that the pipeline had been penetrated by a bullet before being coated. This may be the first such case recorded, and would have been difficult to prove if an explosion had taken place.