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Lecture 3 - Damage Mechanisms

This document discusses various damage mechanisms and failure modes for materials, including mechanical failures from overload, wear, and fatigue. It also discusses corrosion mechanisms, effects of high temperatures, and welding defects such as solidification cracking, lamellar tearing, and cold/hydrogen cracking. The full document provides detailed descriptions and diagrams to explain these different failure analysis topics.

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امين
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168 views19 pages

Lecture 3 - Damage Mechanisms

This document discusses various damage mechanisms and failure modes for materials, including mechanical failures from overload, wear, and fatigue. It also discusses corrosion mechanisms, effects of high temperatures, and welding defects such as solidification cracking, lamellar tearing, and cold/hydrogen cracking. The full document provides detailed descriptions and diagrams to explain these different failure analysis topics.

Uploaded by

امين
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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YOUR LOGO

Damage Mechanisms
and Failure Modes

Quest Integrity
October 2015

1
Damage mechanisms YOUR LOGO

Mechanical Corrosion
• Overload • Rusting – Uniform corrosion
– Brittle fracture • Galvanic
– Ductile tearing • Pitting
– Deformation, Buckling
• Crevice corrosion
• Wear
• Intergranular corrosion
– Sliding, Fretting, Abrasion
• Flow assisted corrosion
• Fatigue
• Stress corrosion cracking
– Low cycle
– High cycle fatigue
• Microbial corrosion
– Thermo-mechanical fatigue • Hydrogen damage
• Erosion • Liquid metal embrittlement

Temperature
• Creep rupture/deformation
• Microstructural degradation
– Temper embrittlement
– Over-ageing
• Oxidation/high temperature corrosion processes, sulphidation, carburisation
• Incipient melting

2
Tensile test YOUR LOGO

• Ductile failure involves deformation - onset is at the yield point


• Yield strength
• Measure of strength is Ultimate tensile strength
• Measure of ductility is Elongation

3
Brittle and ductile failures YOUR LOGO

Brittle Failure Ductile Failure

No deformation Always deformation


4
Failure Assessment Diagram (FAD) YOUR LOGO

BRITTLE
FRACTUR
E
FR
AC
TU
TOUGHNESS RATIO

RE
+P
LA
ST
IC
DE
FO
RM
AT
IO
N
SAFE

RUPTURE/
PLASTIC COLLAPSE

LOAD RATIO

5
Brittle cleavage and ductile dimples YOUR LOGO

Brittle Cleavage Ductile Dimples

6
Brittle fracture YOUR LOGO

7
Fatigue YOUR LOGO

• Subjection of a metal to fluctuating loads

• The most common cause of engineering failures

• Small fatigue cracks mostly start at surfaces usually from pre-existing


defects

• Fatigue cracks grow perpendicular to tensile axis a step at a time by plastic


deformation tearing

• Can sometimes leave a characteristic marking-shell, ripple, on the fracture


surfaces called beach-marks

• Crack propagation ending in final fracture

8
Initiation of fatigue crack YOUR LOGO

• At free surface
• Alternating stresses
slip bands

• Two types of surface deformation


- extrusion
- intrusion
• Stage I crack propagation

9
Schematic of typical fatigue YOUR LOGO
fracture surface

Sketch shows three origins

Stage 1 at (O); thousands of


microscopic, closely spaced
fatigue striations

Stage 2 at (S); a few beach-


marks, or arrest lines, at (B); and
two ratchet marks (R) where
fatigue cracks growing from the
origins join up as the cracks
become deeper

10
Unidirectional bending fatigue high nominal
YOUR LOGO
stress, minor notch effect around periphery
Initiation of fatigue cracking

Final fracture

11
Creep - What Is It? YOUR LOGO

• The mechanical strength of metals decreases with increasing


temperature. Mechanical properties become more time dependent

• Metals when held under constant load at creep temperature will


experience an extension in length in the direction of applied stress

• ‘Creep’ is the term we use when a metal slowly moves or deforms


permanently under the influence of stresses

• Usually as a result of long term exposure to levels of stress that are below the
yield strength of the material

• Creep becomes significant when materials are at a temperatures over 0.5Tm


and is more severe in materials that are subjected to heat for long periods of
time

• Creep always increases with temperature

12
Creep failure and failure criterion YOUR LOGO

13
Creep cracking YOUR LOGO

14
Welder having a bad day YOUR LOGO

Defects found in a
steam pipe in Australia

15
Solidification cracking YOUR LOGO

• Occurs during cooling


• Weld centre line or between
columnar grains
• Susceptibility depends on
– Coarseness of microstructure
– Amount and species of segregation
– Joint geometry
• Causes
– High heat input
– Segregation
– High residual/restraint stresses
Reference: Introduction to Physical Metallurgy of Welding,
Easterling, 1983

16
Lamellar tearing YOUR LOGO

• Low through thickness /short


traverse ductility of parent material
due to segregation of sulphides

• Susceptibility depends on
– Parent ductility
– Elongated stringers
– High residual stresses in short
traverse direction
– High plate thickness

Reference: Introduction to Physical Metallurgy of Welding,


Easterling, 1983

17
Cold/hydrogen cracking YOUR LOGO

• Often delayed cracking

• Trans or intergranular

• Initiated at notches or
microstructure inhomogeneities

• Susceptibility depends on
– Hydrogen

– High residual stress

– Susceptible microstructure

Reference: Introduction to Physical Metallurgy of Welding,


Easterling, 1983

18
HAC in HT shift damage found in outlet YOUR LOGO
nozzle – 70% through wall

19

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