International Journal of

Materials Technology and Innovation

https://ijmti.journals.ekb.eg/ Volume 3, Issue 2 (2023), pages 30-36
Online ISSN 2682-4299

Failure Analysis of Welded Steam Boiler Flange

Abdel-Aleem Hamed1, *, Khodir Saad Ahmed1,2 and Newishy Mohamed Salah1
1 Welding and NDT Department, Advanced Materials Institute, Central Metallurgical Research and Development Institute (CMRDI),
Helwan, P.O. Box 87, Cairo 11421, Egypt.
2 The University of Bisha Faculty of Engineering, Mechanical Engineering Department, 255. Al Nakhil, Bisha 67714, Saudi Arabia

*Corresponding author: E-mail: [email protected]

Received 6 June 2023

Accepted 21 June 2023
Published 30 June 2023

Abstract
Steam boiler flange, made of steel ASTM A105 welded to spool pipe, experienced a failure near the welding area after six
years of service. The operator company has reported that a sudden increase in operating pressure and temperature exceeded the
normal operation conditions. As a result, the failed flange and welded spool pipe segments were received for further
investigation using root cause analysis to determine the reason for the failure. The failed parts were visually inspected (VT)
and tested for subsurface defects with a fluorescent wet magnetic particle test (MT). Chemical analysis, microstructure
observations, and hardness tests are conducted for the failed flange and pipe. It is noticed that there were no abnormalities or
indications of creep or overheating were found in the microstructure and hardness values. Upon examining the macro &
microstructure of the connecting weld joint, several welding defects, such as non-metallic inclusions, few porosities, and lack
of fusion between welded passes, were noticed. Scanning Electron Microscope (SEM) observations showed that fine striations
as beach marks on the fractured surface provided strong evidence of fatigue failure. The identified crack originated from
welding defects and progressed through the flange material due to fluctuating radial stresses due to the cyclic changes in
working pressure during service. To prevent similar failures, it is recommended to apply proper welding procedure
specifications (WPS) by qualified welders, conduct regular inspections and maintenance of the steam boiler, and keep working
conditions stable.

Keywords: boiler failure, flange, welding imperfections, fatigue mechanism, un-qualified welders.

1. Introduction
Carbon steel and low alloy steels are usually used for defects are among the most frequent reasons for the
fabricating pressure vessels and boilers due to their failure of boiler components. The occurrence of stress
excellent properties, such as strength and ability to concentration areas, such as notches, welding toes,
withstand corrosion and high temperatures. However, sharp corners, keyways, dents, gouges, laps, folds,
the final selection of materials for constructing pressure flakes, and tensile residual stresses from punched holes,
vessels and boilers depends on the specific heat treatment, and welding, among others, can trigger
requirements of the intended use and the design fatigue fractures [8-23].
specifications of the equipment [1-7]. Boiler William Liu et al. reported the failure case of creep-
components that come into contact with steam and hot fatigue interaction (CFI) on a superheater in a recovery-
water are exposed to severe operating conditions, fired boiler [19]. Two cracks were found at the weld
including high pressure, temperature, and harsh joint's heat-affected (HAZ) zone, both of which
environmental conditions. These conditions play the originated from the fire-side and propagated to the
primary role in boiler components damages such as steam side. The presence of beach marks on the failed
tension-compression, corrosion fatigue, creep damage, fractured surface suggested that CFI caused the failure
hydrogen embrittlement, and erosion, in addition to mechanism. The first crack was initiated and spread
short-term or long-term overheating and welding through the transgranular mode, whereas the second

IJMTI vol. 3, issue 2 (2023) 30-36 30 © 2023 EKB Publishing

EKB Publishing A.A. Hamed et al.
IJMTI vol. 3, issue2 (2023) 30-36 https://doi.org/ 10.21608/IJMTI.2023.204369.1083

crack was initiated via the intergranular mode and then agglomerated alpha alumina suspension. Then, they are
progressed through a blend of intergranular and rinsed and degreased with acetone. Finally, the
transgranular modes. This resulted in various stress specimens are etched for 40 seconds using a 3% Nital
levels caused by distinct modes of initiation. The solution.
primary factor leading to the fracture of CFI was the The hardness of the base metal (BM) of the flange
fluctuating stress, which was influenced by the hoop and pipe, weld metal (WM), and heat-affected zone
stress and axial stress. Hence, the fracture was (HAZ) was assessed through a hardness test. The test
attributed to the varying stress levels induced by was carried out following the ASTM standards E92,
different initiation modes. The presence of beach marks which pertains to the Vickers hardness test for metallic
on the failed fractured surface suggested that CFI materials, and E384, which pertains to the
caused the failure mechanism. microhardness test for metallic materials. A Scanning
After six years of service, the carbon steel flange Electron Microscope (SEM) with Energy Dispersive X-
connected to the 2-inch piping of a steam boiler ray Spectroscopy (EDS) analysis capability was used to
experienced failure when the operating pressure and investigate the fracture surface. Spot chemical analysis
temperature surged abruptly to 2400 psi and 350°C, using EDS was performed at several points in the
respectively, which exceeded the standard operating vicinity of the failed zone and in regions where unusual
conditions of 1400 psi and 308°C. These changes in the morphology in microstructure was observed. The
operating pressure and temperature resulted from some specific SEM model used was the Quanta FEG-250.
troubles in the turbine, which led several times to the
sudden closure of the main steam stop valve, and this 3. Results
led to an increase in the boiler pressure and 3.1 Visual examination
temperature. The failure occurred adjacent to the heat-
affected area of the weld joint that linked the 2-inch Figure 1 shows a general view of the flange and
pipe to the flange on the side. Consequently, an connected pipe that failed. The fracture surface was free
investigation was conducted to determine the from corrosion products and/or deposits. Figure 2
underlying cause of the failure. There are no data displays detailed views of the fracture initiation zone in
reported about the welding procedure specification the failed pipe. Figure 2 shows the initial fracture zone
(WPS), procedure qualification record (PQR), welder in the final filling weld layer region on the flange side,
qualification, and welding quality control during boiler specifically at the weld toe.
fabrication.

2. Experimental Procedure
A comprehensive analysis of the flawed piping and
flange was carried out, which comprised a detailed
visual inspection, non-destructive testing, and
destructive testing. Chemical analysis and ultrasonic
thickness measurement were conducted to assess the
extent of the damage. To determine the chemical
properties of the failed materials, an optical emission
spectrometer was employed [21-23].
The flange material base metal, weld metal, and
connecting pipe base metal were subjected to a
metallographic examination near and far from the failed Fig. 1 Fracture surface off the flange and connected
zone. The failed flange was sectioned utilizing a water- pipe (as received).
cooling cutting machine, and the resulting samples The reinforcement area (final filling weld pass)
were prepared for metallographic analysis. The samples seems slightly thicker than the remaining weld metal.
were examined for macro and microstructures using The detailed characteristics of the damaged part of the
metallographic techniques. The process of preparing flange are illustrated in Fig. 3, displaying the fracture
the specimens involves several steps. Firstly, they are initiation area, fatigue fracture (beach mark zone), and
mechanically ground down using 1200-grade emery final fracture surface. As shown in Fig. 3, the original
paper. Next, they are polished with 0.1µm fracture surfaces at low magnification and beach marks

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IJMTI vol. 3, issue2 (2023) 30-36 https://doi.org/ 10.21608/IJMTI.2023.204369.1083

were noticed, indicating that the fractures were caused pipe's internal surface using magnetic particle testing
by fatigue and had initiated and propagated through this (MT) did not reveal any signs of corrosion or pitting,
mechanism [27-31]. indicating the efficacy of the water treatment process.

Fig. 4 Mismatch fitting of Hi-Lo at the internal

Fig. 2 Enlarged view of fractured connected pipe surface of the weld connecting steel to flange
showing fracture initiation zone.
3.3. Chemical analysis
The chemical composition of the flange, weld metal,
and connected pipe is shown in Table 1 and confirmed
with the specifications given in Table 2 for ASTM
A105.

Fig. 3 Close-up views of the fractured section of the

flange depicting the fracture initiation zone, the fatigue
fracture or beach zone, and the final fracture surface.

The fatigue region of the fracture surface appeared

smooth, while the remaining area corresponding to the 3.4 Macrostructure investigations
final and rapid fracture exhibited the typical features of
Figure 5 shows the macrostructures of the weld
a brittle fracture, with minimal or no evidence of plastic
joint's as-polished and etched cross-section near where
deformation. No cracks were observed near the
the fatigue fracture originated (i.e., the final filling weld
ruptured areas, and there was no damage or loss of
layer). As shown, revealed several welding defects,
thickness (8mm) in the flange wall.
including porosity, slag inclusion, and lack of fusion at
the boundary line between the initial and final weld
3.2. Results of magnetic particle testing (MT)
passes. These findings provide evidence of the
Figure 4 shows the inner surface of the cross-section substandard quality of the weld joint. The
of the axially welded joint between the flange and the corresponding microstructures of the specimens can be
connected pipe. It revealed a non-acceptable High side shown in Figs 6 and 7.
while the other side is low (HI-LO) by almost (4mm)
on the inner surface of the weld joint. Such types of 3.5 Microstructure investigations
imperfection may disrupt the movement of fluids such
The microstructure of the flange material (ASTM
as water or steam, resulting in mechanical stress on the
A105 alloy) base metal (BM) reveals ferrite-lamellar
welded area. However, examining the flange and linked
pearlite, which can be seen in Figure 7a. No signs of

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IJMTI vol. 3, issue2 (2023) 30-36 https://doi.org/ 10.21608/IJMTI.2023.204369.1083

overheating were observed, such as creep indications or grain boundary ferrite. The initial layer, known as the
noticeable plastic deformation leading up to the root pass, has annealed ferrite-pearlite structures, as
fracture. The heat-affected zones (HAZ) have seen in Figure 7f. The grain size of the heat-affected
microstructures that include pearlite-upper bainite and zone (HAZ) is coarser near the fusion line and
tempered ferrite-pearlite, depicted in Figs. 7b and 7c, gradually becomes finer as it moves further away from
correspondingly. it.

Fig. 6 Microstructures of the cross-section of the weld

metal showing several internal defects.

Fig. 5 Macrostructure of the welding cross-section Fig. 7 Microstructures of different areas of weld joint
reveals internal flows at the boundary line between showing: (a). flange (BM), (b), (c) HAZ of the weld
inter-passes. (as-polish and etched) joint, (d) BM of welded pipe, (e) final pass (cap pass),
and (f) root pass of the weld.
The microstructure of the base metal of the connected
pipe shows an acicular ferrite-pearlite structure, as 3.6 Scanning electron Microscopy (SEM)
shown in Figure 7d. Figure 7e shows the microstructure investigation
of the final layer's weld metal (WM), which contains
acicular ferrite, side plate ferrite, and grain boundary The fracture surface was investigated using a
ferrite. The initial layer, known as the root pass, has Scanning Electron Microscope (SEM) showed the
annealed ferrite-pearlite structures, as seen in Figure 7f. presence of striation marks, which indicated that the
The grain size of the heat-affected zone (HAZ) is fractures had resulted from fatigue and had progressed
coarser near the fusion line and gradually becomes finer over time, as depicted in Fig. 8. An Energy Dispersive
as it moves further away from it. Spectroscopy (EDS) analysis equipped with the SEM is
The microstructure of the base metal of the used to examine the original fatigue fracture surface, as
connected pipe shows an acicular ferrite-pearlite shown in Fig. 9. The analysis results indicated that
structure, as shown in Figure 7d. Figure 7e shows the harmful elements, such as Cl, S, Ca, K & Na, were
microstructure of the final layer's weld metal (WM), absent.
which contains acicular ferrite, side plate ferrite, and

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IJMTI vol. 3, issue2 (2023) 30-36 https://doi.org/ 10.21608/IJMTI.2023.204369.1083

4. Discussions

The material was found to conform to the ASTM

A105 specification, with typical microstructure and
hardness values and no abnormalities or indications of
creep, thus ruling out the possibility of overheating.
Additionally, no cracks were observed near the fracture
area, eliminating the possibility of the flange material
being defective or overstressed. The fracture surface of
the flange appears to have occurred due to fatigue
cracks initiated near or at the toe of the weld, a high-
stress concentration area, caused by welding defects.
Fig. 8 Scanning electron microscope (SEM) images of Examination of the macro and microstructures of the
the original crack initiation zone showing fatigue weld joint (Figs. 5, 6) revealed several welding defects
striations. at the fusion of the boundary between the root pass and
final filling passes of the weld layer, as shown in Fig.
2. The crack began at the weld's toe and proceeded
through the flange material, caused by the fluctuating
radial stresses resulting from the fluctuating working
pressure during service, with increasing and decreasing
values.
The EDS analysis conducted on the fracture surface
showed the existence of carbon, silicon, manganese,
oxygen, and iron. Examination under a Scanning
Electron Microscope (SEM) revealed the presence of
fine striations in the beach mark areas of the broken
flange, indicating a fatigue failure. The ultimate tensile
strength of the flange material was suddenly surpassed
when the operating pressure rose sharply, causing the
final fracture, which had lower hardness values than the
connected pipe material (as seen in Table 3).
Fig. 9 Results EDS analysis of SEM and at the original Fatigue fractures are known to occur when a steel
fracture surface. flange undergoes cyclic variations in stress, which lead
to the development of fractures below its yield strength.
3.7 Hardness measurements The critical factors that lead to fatigue fractures include
high tensile stress, significant stress variations, and
Table 3 shows the Vickers hardness measurements,
numerous stress cycles [9, 10]. As shown in Figs. 4 and
which were taken along the cross-section transverse to
5, weld quality such as Hi-LO, irregular bead, and un-
the welding direction under a load of 9.8N for a loading uniform heat inputs distributions inside the weld grove
time of 15 seconds. The hardness values for the flange during welding sequences passes lead to stress
(BM), flange (HAZ), (WM) of the cap pass of the last concentration areas that can trigger fatigue fractures.
weld layer, (WM) first layers, connected pipes (BM), Visible beach marks can indicate the location of
and connected pipe HAZ were 180, 210, 220, 195, 205, fracture initiation. These marks form when oxidation at
and 220Hv, respectively. These measurements confirm the crack tip propagates under alternating stress and is
that the weld joint was free from any creep effects, occasionally interrupted, such as when working
indicating its soundness. pressure varies during service. Visible beach marks
also occur during non-steady-state loading or rapid
changes in loading, such as when a boiler is turned on
Table 3 Hardness of different steel pipes. and shut down.
In flange materials such as steel A105 with ductile
properties, crack propagation occurs through the
coalescence of microvoids, resulting in a crack path
direction perpendicular to the applied tensile axis. The
correlation between the striations spacing and applied
tensile load has been well investigated, where each

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IJMTI vol. 3, issue2 (2023) 30-36 https://doi.org/ 10.21608/IJMTI.2023.204369.1083

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