ML032310060
| ML032310060 | |
| Person / Time | |
|---|---|
| Site: | Davis Besse  |
| Issue date: | 06/30/2003 |
| From: | Hour K, Hyres J BWXT, BWXT Services |
| To: | Framatome ANP, Office of Nuclear Reactor Regulation |
| References | |
| 2968 1140-025-02-24 | |
| Download: ML032310060 (129) | |
Text
BWXT SERVICES, INC. 1140-025-02-24 99 BWXT SERVICES, INC. 1140-025-02-24 99 Table 5.1: Sample identification listing for Piece A2A.
Sample Location Test Plan Met SEM A2A1 A2A section at -2250 No plan A2A2 A2A section at -1700-1900 Axial cracks at -1 80, see -1 Table 5-2 A2A3 A2A section at -1 350 No plan -- -
A2A4 A2A section at -2400-3500 No plan --
A2A5 A2A section at 900 Thin area of clad 1 at 900 (met), see Table 5.3 1-Axial crack at 10°; 4 (2 open A2A6 A2A section at -3500-700 circ. cracks at 200-450, see 4 cracks, 2 Table 5.4 through Table 5.10 mounts)
A2A section, contains Clad cracks; undercut regions, 4 (2 open exposed clad see Tables 5.11 and 5.12 6 cracks, 2 A2A8 A2A section, contains No plan -- -
cavity nose A2B Trimmed corner No plan
BWXT SERVICES, INC. 1140-025-02-24 100 1140-025-02-24 100 BWXT SERVICES, INC.
Figure 5.1: Sectioning of Piece A2A (lower portion of cavity) showing new sample identifications.
BWXT SERVICES, INC. 1140-025-02-24 101 Table 5.2: Sample identification listing for Piece A2A2.
Piece ID Location Test Plan Met SEM A2A2A Upper portion of nozzle #3 No plan =
bore A2A2131 Lower portion of nozzle #3 bore at -1 900 No plan A2A2B2 Lower portion of nozzle #3 No plan --
bore -1 800 A2A2B3 A2A2B3 in theaxial Contains J-groove at -1 800 cracksweld. togs axial through al1 A2A2B4 Lower portion or nozzle #3 No plan --
bore at -1700
- M3
- iCt l;;
.;1 * * ; i Figure 5.2: Sectioning of Piece A2A2, looking at the ID of the J-groove weld bore.
BWXT SERVICES, INC. 1140-025-02-24 102 Table 5.3: Sample identification listing for Piece A2A5.
Piece ID Location Test Plan Met SEM A2A5A RV head near 90° No plan -- --
A2A5B RV head clad near 900 No plan -- --
Thin ofMet region sample A2A5C Thin region of through 1 --
A2A5Cnear clad 900 thin region A2A5D J-groove weld and No plan -- --
clad near 900 f
F r ,\ 5 3:I i ce A 2 A5A r s.. io n The t s i;s ty Figure 5.3: Piece A2A5 before sectioning. The mounted surface is indicated.
BWXT SERVICES, INC. 1140-025-02-24 103 1140-025-02-24 103 BWXT SERVICES, INC.
4;:
5 5....s.
'V * '-X ., ',;
A2A5A ?
- ) I ' w; 5 S;
- nt d'!
1 I.
'i1 Figure 5.3 (cont.): Piece A2A5 after sectioning, looking down on the front face of previous photo. The mounted surface on sample A2A5C is indicated. This area contained the thinnest measured cladding (0.202").
BWXT SERVICES, INC. 1140-025-02-24 104 Table 5.4: Sample identification listing for Piece A2A6.
Piece ID Location Test Plan Met SEM A2A6A1 RV head near 900 No plan -- --
Lower portion of A2A6A2 Contains lower J-groove weld and clad from portion of axial (see below) 35009700 crack at -i 0 and 2 circ cracks (0°-45°)
A2A6B Upper portion of Contains upper (see below) J-groove weld from 350°-700 portion of axial 1 2 crack at - 1O' ____ _ _ _
K I
A2A6A2 , 2'
{
4$ -
AxJJ2J4 Figure 5.4: Piece A2A6 was first sectioned into Pieces A2A6A and A2A6B. Piece A2A6A was further sectioned into Pieces A2A6A1 and A2A6A2. Both cuts were made on the same plane, parallel to the paper. The first cut line is partially visible; Piece A2A6B is the upper portion of the weld. The second cut line between Pieces A2A6A1 and A2A6A2 is obscured by Piece A2A6A1.
BWXT SERVICES, INC. 1140-025-02-24 105 Table 5.5: Sample identification listing for Piece A2A6B.
Piece ID Location Test Plan Met SEM A2A6B1 Upper portion of J-groove No plan --
___________ weld at -3500 Lower surface A2A6132 Upper portion of J-groove mounted for11 weld axial crack at -10 met/SEM ce_
A2A6B3 Mid portion of J-groove weld Open crack 1 axial crack at -10° SEM sample A2A6B4 Upper portion of J-groove No plan weld from 300700
- A2A6133!',.
A2*A6B1; L v S .
- A 1 '-
%A2A61312A6B Figure 5.5: Piece A2A6B after sectioning. The bottom surface of A2A6B2 was mounted. The axial crack in A2A6B3 was opened up for SEM.
BWXT SERVICES, INC. 1140-025-02-24 106 Table 5.6: Sample identification listing for Piece A2A6A2.
Piece ID Location Test Plan Met SEM A2A6A2A Lower portion of J-groove No plan --
weld and clad at 70° A2A6A2B Lower portion of J-groove Contains circ crack 1 weld and clad at .450 near 450 A2A6A2C Lower portion of J-groove Open circ crack weld and clad at -30° sample for SEM 1 A2A6A2D Lower portion of J-groove Contains circ crack weld and clad at 200 near 200 Lowerporton o J-goove Contains axial A2A6A2E weld and clad at -1oo crack and circ 1 cracks at 100 A2A6AF Lower portion of J-groove No plan weld and clad at -00 A2A62A6AC Figure 5.6: Piece A2A6A2 after sectioning. Additional sections were made on A2A6A2B, -C, -D, and -E. Refer to the following four tables and figures.
BWXT SERVICES, INC. 1140-025-02-24 107 Table 5.7: Sample identification listing for Piece A2A6A2B.
Piece ID Location Test Plan Met SEM A2A6A2B1 Lower portion of J-grooveNopa---
weld at 450 (includes bore) No plan A2A6A2B2 Lower portion of J-groove Contains circ crack 1 --
weld and clad at 450 near 450 A2A6A2B3 Clad at -450 No plan -- --
SW -- 2 -
moUnteQI4 i . _x2 tp
< B o "' clrc crack in J-g'roove wl Figure 5.7: Piece A2A6A2B after sectioning (side view of Figure 5.6).
The top surface of A2A6A2B2 was mounted.
BWXT SERVICES, INC. 1140-025-02-24 108 BWXT SERVICES, INC. 1140-025-02-24 108 Table 5.8: Sample identification listing for Piece A2A6A2C.
Piece ID Location Test Plan Met SEM Lower portion of J-groove A2A6A2C1 weld and upper surface of No plan -- --
clad at 300 (includes bore)
A2A6A2C2 Lower portion of J-groove Circ crack near 30° -- 1 weld and clad at -300 bent open for SEM A2A6A2C3 Lower portion of J-groove No plan -- --
weld (ROS side)
INTO
~ ~C
~-C
. 3n
~~4 ~
Figure 5.8: Piece A2A6A2C after sectioning (side view of Figure 5.6). The circumferential cracks were bent open for SEM.
BWXT SERVICES, INC. 1140-025-02-24 109 Table 5.9: Sample identification listing for Piece A2A6A2D.
Piece ID Location Test Plan Met SEM A2A6A2D1 Lower portion of J-grooveNopa---
weld at -200 (includes bore) No plan A2A6A2D2 Lower portion of J-groove Contains circ crack 1 1 weld and clad at -200 at .200 D2 (Lower surface.
.:.mounted) circ.crack at
=.. ..- - . . :. -200 Figure 5.9: Section photo for Piece A2A6A2D (side view of Figure 5.6). The mounted surface of Piece A2A6A2D2 for optical and SEM examination is the lower surface (not visible) in the photo.
BWXT SERVICES, INC. 1140-025-02-24 110 Table 5.10: Sample identification listing for Piece A2A6A2E.
Piece ID Location Test Plan Met SEM A2A6A2E1 Lower portion of Lower surface J-groove weld at -100 mounted for met A2A6A2E2 Contains clad at -200 No plan -- --
A2A6A2E3 Contains clad at -O° No plan -- --
Lowerof J-gContains portion axial and A2A6A2E4 Lower portion of J-groove circ cracks at -1 weldside)(PNL (RS Sample) ____
4 moun~rted
.42 mounted surface axial cr'ackat clrc. crack at
.,--10 - 10° Figure 5.10: Section photo for Piece A2A6A2E (side view of Figure 5.6).
The mounted surface of Piece A2A6A2E1 is indicated. Piece A2A6A2E4 is reserved for PNL.
BWXT SERVICES, INC. 1140-025-02-24 ill 111 BWXT SERVICES, INC. 1140-025-02-24 Table 5.11: Sample identification listing for Piece A2A7.
Piece ID Location Test Plan Met SEM A2A7A RV head and clad near 3500 No plan A2A7B RV head and clad near 3400 No plan l A2A7C RV head near 3450 No plan --
A2A7D Undercut region near 3450 Met mount 1 A2A7E RV head and clad near nose No plan --
A2A7F Undercut region near nose Met mount 1 A2A7G RV head near nose No plan --
A2A7H Clad prior to nose No plan A2A71 RV head and clad near 50 ° No plan A2A7J RV head and clad near 400 No plan --
A2A7K Undercut region near 400 Met mount 1 A2A7L Center portion of clad cracks SEM open crack --
sample A2A7M Adjacent to center cracks Met mount (center 1 1 portion)
A2A7N Clad cracks toward 2700 Met mount (2700) 1 1 A2A70 Clad near 00 No plan -- --
A2A7P Center portion of clad cracks Reserved for PNL A2A7Q Clad near 40° No plan A2A7R Clad near 400 No plan --
A2A7S Clad cracks toward 900 Met mount 1 1 A2A7T Clad near 600 No plan --
A2A7U Clad near 100 No plan
BWXT SERVICES, INC. 1140-025-02-24 112
¶3 r7 ¢A r, Figure 5.11: Section photo for Piece A2A7. The mounted surfaces for the -D, -F, -K,
-M, -N, and -S samples are indicated by the white arrows. Further sectioning of Piece A2A7L is shown in Figure 5.12.
BWXT SERVICES, INC. 1140-025-02-24 113 BWXT SERVICES, INC. 1140-025-02-24 113 Table 5.12: Sample identification listing for Piece A2A7L.
Piece ID Location Test Plan Met SEM A2A7L1 A Center portion of clad cracks SEM open crack -- 1 sample A2A7L1 B Adjacent to center cracks No plan -- --
A2A7L2A Center portion of clad cracks SEM open crack -- 1 sample A2A71-21 Adjacent to center cracks No plan -- --
-Crack opened nd - ;
e'-xamined bySEM
-L1iB
,f - L-i ; -L '1A . 2B
- CRDIV Cv nozzle 34- nose I~~~~~~~7
- ;>-: . - . f<<Looking down a the corrosion exposed cladding surfac Figure 5.12: Section photo for Piece A2A7L. The main crack located near the center of A2A7L was opened in the laboratory, resulting in Pieces A2A7L1 and A2A7L2.
Additional sections, which created the -A and -B pieces, were made to facilitate the SEM examinations. The surfaces examined by SEM are indicated.
BWXT SERVICES, INC. 1140-025-02-24 114 1140-025-02-24 114 BWXT SERVICES, INC.
Table 5.13: Sample identifications for Piece Al.
Piece ID Location Test Plan Met SEM AlA Contains cavity nose No plan --
cavity side wall Met and (see SEM/EDS AlContains B toward 900 ~~~~~~samples5.14) Table 2 toward 90° AiB Al C Contains nozzle #3 bore and No plan --
small portion of cavity No plan Contains cavity side wall Met and SEM/EDS AiD D 2700 toward Al toward 2700 ~ samplesand L-5.15 Tables (see5.16) ___
2 ___
pr i , b *.
4-.4 4.,
'r7 I Figure 5.13: Sectioning of Piece Al into four pieces. Pieces Al B and Al D were further sectioned for metallography and SEM. Refer to Figure 5.14 through Figure 5.16.
BWXT SERVICES, INC. 1140-025-02-24 115 Table 5.14: Sample identifications for Piece Al B.
Piece ID Location Test Plan Met SEM Al Bi Upper portion of cavity side No plan --
wall near 90 Al B2 Upper portion of cavity side wall near 900 Transverse mount met 1 Al B3 Middle portion of cavity side SEM/EDS sample -
wall near 900 Al B4 Lower portion of cavity side Transverse met 1 wall near 90° mount A1 B5 RV head behind cavity side No plan wall__ _ _
Al B6 Lower portion of cavity side No plan --
wall near 90 Al B7 Cavity side wall No plan =
Al I AlP2.
A113511§ Al 1371"11. hidden',
Al 133, below
'Al B4'.
Al B6 N1111-0--i M
Figure 5.14: Section photo for Piece Al B, looking at the cavity side wall. The mounted surfaces of Piece Al B2 and Piece Al B4 is indicated.
BWXT SERVICES, INC. 1140-025-02-24 116 BWXT SERVICES, INC. 1140-025-02-24 116 Table 5.15: Sample identifications for Piece AlD.
Piece ID Location Test Plan Met SEM Al Dl Cavity side wall near 2700 No plan Al D2A Upper portion of cavity side No plan- -
wall near 2700 Al D2B Upper portion of cavity side Transverse met wall near 2700 mount location Al D2C Middle portion of cavity near 2700 SEM/EDS 1
Al D2D Lower portion of cavity side wall near 2700 Transverse met mount location Al D2E RV head behind cavity side Macroetch sample wall Al D2F Lower portion of cavity near No plan 2700__ _ _ _ _ _ _ _ __ _ _ _
Figure 5.15: Section photo for Piece Al D, looking at the cavity side wall. Refer to Figure 5.16 for the mounted surface locations.
BWXT SERVICES, INC. 1140-025-02-24 117 117~~~~~~~~~~~
BWXT SERVICES, INC.1140-025-02-24 Table 5.16: Sample identifications for Piece Al D2B and Piece Al D2D.
Piece ID Location Test Plan Met SEM Al D2Bl Upper portion of cavity side wall near 2700 Transverse met mount location 1
Al D2B32 Upper portion of cavity side No plan --
wall near 2700 Al D2Dl Lower portion of cavity side wall near 2700 Transverse met mount location 1
Al D2D2 Lower portion of cavity side No plan = =
wall near 2700
..... _._,. to ._, ........................ w . Anl_.. . . . P . W .
_ ........ . ,.. ........ ..A...... a, i .. ., .
Al D2i AlDMl2D2D Figure 5.16: Section photo for Pieces Al D2B and Al D20, looking at the cavity side wall. The mounted faces for Piece Al D2B1 and Piece Al D2D1 are indicated.
BWXT SERVICES, INC. 1140-025-02-24 118 BWXT SERVICES, INC. 1140-025-02-24 118 V"'
-:--- ,- - I - AIM .. . i ~.
Sample A2A7M Knoop Microhardness 350.0 y 300.0-250.0 -
w200.0-
, 150.0 O 100.0
> 50.0 0.0-0.000 0.050 0.100 0.150 0.200 0.250 0.300 Distance from Upper Clad Surface, inches Figure 6.1.1.1: 4X macro photograph of metallurgical mount A2A7M. Refer to Figure 5.11 for the sample orientation. Cladding thickness ranged from 0.227" to 0.277" (5.77 to 7.04 mm). Knoop microhardness values exhibited a hardness elevation near the exposed cladding surface.
BWXT SERVICES, INC. 1140-025-02-24 119 BWXT SERVICES, INC. 1140-025-02-24 119 Figure 6.1.1.2: Micrographs showing intergranular attack (IGA) and intergranular or interdendritic cracking on the exposed stainless steel cladding.
BWXT SERVICES, INC. 1140-025-02-24 120
- ' 1 " J %
I.I zs- -
- -. ,****** t*
- - ..* 'S 4
48X Figure 6.1.1.3: Micrographs showing the deepest crack observed in A2A7M.
Fine intergranular or interdendritic cracks emanating from the crack tip are visible. The crack tip is estimated to be approximately 0.057" (1.47 mm) below the surface. The cracks in the above two photos are the same, but are shown at slightly different planes due to re-polishing.
BWXT SERVICES, INC. 1140 025-02-24 121 BWXT SERVICES, INC. 1140-025-02-24 121 Figure 6.1.1.4: Typical clad microstructure in the mid-thickness of the cladding.
BWXT SERVICES, INC. 1140-025-02-24 122 1 UUA
- '.1 s.:' *.
0
- IiQ I N
{x. .A<1
-y JL 1.
/ K*J(.
- 9. *-
I p-*k Figure 6.1.1.5: Typical clad microstructure near RCS side surface of the cladding. No intergranular attack (IGA) was present.
BWXT SERVICES, INC. 1140-025-02-24 123 Line Scan 2 Line Scan I E s~~~~~- -OI SEM micrograph showing EDS locations.
111275-1 Elt Lire Corc Error M1 z A F 2-sig 3s Cr 0 Ka 0.000 wt% O.t11 0.000 1.2240 0.4581 1.0002 Al Ka 0.112 wt.% 0.013 0.077 1.0994 0.3700 1.0044 Si Ka 0.815 wt% o.032 0.073 1.1273 0.4745 1.0050 Cr Ka 16.361 wt% 0.150 0.068 0.9971 0.9900 1.2660 Mn Ka 1.377 wt.% 0.044 0.077 0.9790 0.9963 1.2377 Fe Ka 70.464 wt.% 0.383 0.113 0.9973 0.9648 1.0131 Iii Ka 8.870 wt.% 0.166 0.144 1.0124 0.8869 LOCO 10O.0K0 wt%
Fe 10 usor=O.025 keV 1049 cnt ID = U kal Vert=9316 Whdow 0.005 - 40.955= 488047 cnt EDS results for Area 1.
Figure 6.1.2.1: SEM micrograph showing the three deepest cracks in A2A7M. Crack tips are 0.042" to 0.069" (1.1 to 1.75 mm) below the surface. It is noted that these three crack tips are at approximately the same distance of 0.199" (5.06 mm) from the underside surface. EDS scans of areas 1, 2, and 3 and line scans 1 and 2 (not included) indicated a generally uniform chemical composition (including Cr content) across the cladding thickness.
BWXT SERVICES, INC. 1140-025-02-24 124 111275-2 Elt. Lre CcrK Error ML Z A 2-99g 3-sg 0 Ka 0.000 wt.% 0.000 1.2240 0.4579 1.0002 Al Ka 0.106 wt.% 0.013 0.078 1.0994 0.3698 1.C045 Si Ka 0.820 wt.% 0.032 0.074 1.1273 0.4743 1.OC49 Cr Ka 18.012 wt.% 0. 150 0.067 0.9971 0.9899 1.2695 Mrr Ka 1.415 wt.% 0.045 0.077 0.9790 0.9962 1.2916 Fe Ka 70.770 wt.% 0.387 0.111 0.9973 0.9654 1.0131 M Ka 8.877 wt.% 0.167 0.144 1.0124 0.8868 1.C00O 100.000 wt.%
I 4 , ~ ~AIICI W Mre Ni 5 10 Cusor=0.015 keV 1814 cnt ID=
Vert=9349 Window 0.005 - 40.955= 479918 cnt EDS results for Area 2.
111275-3 Fe Elt. Lre Conc Eiror MDL Z A F 2-ski 3IO 0 Ka 0.000 wt.- 0.OO 0.O0O 1.2240 0.4579 1.0002 Al Ka 0.098 wt.% 0.013 0.078 1.0993 0.3700 1.0045 Si Ka 0.855 wt,% 0.034 0.074 1.1273 0.4746 1.0049 Cr Ka 18.158 wt% 0.154 0.068 0.9971 0.9899 1.2675 W Ka 1.469 wt.% 0.047 0.077 0.9790 0.9962 1.2890 Fe Ka 70.543 wt.% 0.394 0.113 0.9973 0.9651 1.0131 N Ka 8.876 wt.% 0.171 0.147 1.0123 0.8869 1.0000
- 1 jA]~~ A~~~~I 15 S~~~~~ l ~~C
, , T 5
~~~~Mnr ,eCN F 10 Cvsor=0.015 keV 1848 cnt ID=
iert=6895 Whdow 0.005 - 40.955= 458883 cnt EDS results for Area 3.
Figure 6.1.2.1 (cont.): EDS results for Areas 2 and 3.
BWXT SERVICES, INC. 1 140-025-02-24 125 1140-025-02-24 125 BWXT SERVICES, INC.
Figure 6.1.2.2: SEM micrographs showing interdendritic crack path along the elongated ferrite pools.
BWXT SERVICES, INC. 1140-025-02-24 126 Figure 6.2.1.1: 4X macro photograph of metallurgical mount A2A7N.
Refer to Figure 5.11 for the sample orientation.
BWXT SERVICES, INC. 1140-025-02-24 127 BWXT SERVICES, INC. 1140-025-02-24 127 Figure 6.2.1.2: Micrograph of a crack observed on A2A7N. The crack tip is estimated to be approximately 0.036" (0.91 mm) below the surface.
BWXT SERVICES, INC. 1140-025-02-24 128 BWXT SERVICES, INC. 1140-025-02-24 128 375X Figure 6.2.1.3: Micrographs showing intergranular attack (IGA) and intergranular cracking on the exposed stainless steel cladding.
BWXT SERVICES, INC. 1140-025-02-24 129 a.,?< --. . 7: - ' S w.~~~ M. . - .- ./.He).::.v 375x Figure 6.2.1.4: Typical clad microstructure in the mid-thickness of the cladding.
BWXT SERVICES, INC. 1140-025-02-24 130 130
./.. -
pz
-, (3
.-.. ,,f: ..
-' .- 4.. (
Figure 6.2.1.5: Typical clad microstructure near RCS side surface of the cladding. No intergranular attack (IGA) was present.
BWXT SERVICES, INC. 1140-025-02-24 131 III 26-l Et ine conc Error MDL Z A F 2-sg 3-sig 0 Ka 0.0o wti% 0.000 0.000 1.2243 0.4584 1.0002 Al Ka 0.098 wt.% 0.015 0.090 1.0996 0.3696 1.0043 S Ka 0.720 wL% 0.037 0.08s 1.1275 0.4742 1.0050 Cr Ka 17.619 wt% 0.179 0.081 0.9974 0.9900 1.2756 Wn Ka 1.426 wt.% 0.054 0.091 0.9793 0.9963 1.2982 Fe Ka 71.671 wt% 0.472 0.133 0.9976 0.9662 1.0125 N Ka 8.466 wt% 0.198 0.170 1.0126 O.S861 1.0000 100.000 wt.%
S 10 mursor=0.02S keV 1024 cnt ID = U kal lert=6000 Whidow 0.005 -40.955= 323168 cnt EDS results for Area 1.
Figure 6.2.2.1: SEM micrograph showing the three deepest cracks in A2A7N. The maximum crack depth was approximately 0.056" (1.42 mm). EDS scans of areas 1, 2, and 3 and lines 1 and 2 (not included) indicated a generally uniform chemical composition (including Cr content) across the cladding thickness.
BWXT SERVICES, INC. 1140-025-02-24 132 11 7r,-7 Elt. Lire Conc Error IDL z A F 2-sig 3-sig
.Cr 0 Ka 0.000 wt.96 0,000 0.000 1.2242 0.4585 1.0002 Al Ka 0.094 wt.% 0.015 0.039 1.0996 0.3698 1.0044 Si Ka 0.746 wt.% 0.037 0.086 1.1275 0.4744 1.0050 Cr Ka 18.054 wt.% 0.183 0.078 0.9973 0.9900 1.2693 1,h Ka 1.547 wt.% 0.057 0.091 0.9792 0.9963 1.2906 Fe Ka 70.854 wt.% 0.471 0.133 0.9975 0.9654 1.0128 Nl Ka 8.706 wt.96 0.202 0.171 1.0126 0.8866 1.0000 i08.flD wt 96 Fe ri er m 5 10 ursor=0.025 keV 1116 cnt ID = U kal ert=6247 Whdow0.005 - 40.955= 318128 cnt EDS results for Area 2.
111265-3 e E LMre ccn Eror 'X Z A F Cr 2-sig 3-sg 0 Ka 0.000 wt.A 0.000 0.000 1.2240 0.4579 1.0002 Al Ka 0.146 wt.% 0.018 0.090 1.0993 0.3700 1.0044 Si Ka 0.816 wt.% 0.039 0.086 1.1273 0.4744 1.0049 Cr Ka 18.20S wt.% 0.184 0.080 0.9971 0.9900 1.2668 in Ka 1.497 wt.% 0.056 0.093 0.9790 0.9962 1.2881 Fe Ka 70.448 wL% 0.471 0.132 0.9973 0.96S1 1.0131 N Ka 8.889 wt.% 0.205 0.169 1.0123 0.8869 1.000 100.000 wt.%
Fe b gh~~~~i ~Al: I * [ ' ,N 5 ~~~~~~~~~~~~10 Crsor=0.OS keV 68 nt ID = U kal Vert=6213 Whdow 0.005 - 40.955= 316922 cnt EDS results for Area 3.
Figure 6.2.2.1 (cont.): EDS results for Areas 2 and 3.
BWXT SERVICES, INC. 1140-025-02-24 133 BWXT SERVICES, INC. 1140-025-02-24 133 Figure 6.2.2.2: Higher magnification SEM micrographs of crack tip, showing the interdendritic crack path along the elongated ferrite pools.
BWXT SERVICES, INC. 1140-025-02-24 134 BWXT SERVICES, INC. 1140-025-02-24 134 Sample A2A7S Knoop Microhardness 300.0
!~ 250.0-uY 200.0
,, 150.0 co c 100.0 0
E 50.0-0.0*
0.000 0.050 0.100 0.150 0.200 0.250 0.300 Distance from Upper Clad Surface, Inches Figure 6.3.1.1: 4X macro photograph of metallurgical mount A2A7S. Refer to Figure 5.11 for the sample orientation. Knoop microhardness values exhibited lower hardness readings toward the exposed clad side (left side of graph), which was in contrast to A2A7M.
BWXT SERVICES, INC. 1140-025-02-24 135 rr t-
<,i
- Joti~a *\ / * ?
9 ~~~~'O
(. (~ *--
j.
-<7X 1;~~~Z < e.
t_---- - fs ;--\wI/, j}, P _
ikx-f'9 (S E1*'xsA Figure 6.3.1.5: Typical clad microstructure near RCS side surface of the cladding. No intergranular attack (IGA) was present.
BWXT SERVICES, INC. 1140-025-02-24 139 111286-1 Elt. Lxe Con Enr~ MDL. Z A F 2-n9 3smg Al Ka 0.098 t.% 0.013 O.084 1.0994 0.3699 1.0045 S Ka 0.807 .% 0.034 0.079 1.1273 0.4744 1.0050 Cr Ke ,8.407 A..% 0.162 0.072 .997 0.900 1.2640 Mn Ka 1.542 . .% 0.050 0.082 0.9790 0.9963 1.28348 Fe Ka 70.005 'A.% 0.420 0.120 o.973 0.9647 1.0135 M Ka 9.140 .8.% 0.181 0.148 1.0224 0.8872 1.oco Fe
. Ni Al ( ,,
5 10 Ctusor=0.075 keV 1482 cnt ID = U ka Vert=8190 Whdow 0.005 - 40.955= 422988 cnt EDS results for Area 1.
Figure 6.3.2.1: SEM micrograph of the three deepest cracks in A2A7S. The maximum crack depth was approximately 0.056" (1.42 mm). These three crack tips are approximately the same distance from the underside surface. EDS scans of areas 1, 2, and 3 and lines 1 and 2 (not included) indicated a generally uniform chemical composition (including Cr content) across the cladding thickness.
BWXT SERVICES, INC. 1140-025-02-24 140 1112B6-2 Elt. Ike cnc tError MDL z A 2-Og 350i 1.04 Al Ka 0.137 wt.% 0.016 0.003 1.0994 0.3702 S Ka 0.825 wt.% O.34 0.079 1.1273 0.4746 1.0049 Cr Ka 18.235 wt.% 0.161 0.071 0.9971 0.9900 1.2671 Mi Ka 1.461 wt.% 0.049 0.082 0.9790 0.9963 1 2886 Fe Ka 70.626 wt.% 0.412 0.120 0.9973 0.9650 1 0129 N Ka 8.717 wt.% 0.177 0.151 1.0123 0.8867 LO0000 DOwt.%
I Fe z~
vn i
- d fi
. n~l1 ro s l 1lr l 14, r -- :N4 N
5 10 Cursor=0.035 keV 525 ct ID = U kal Vet-4000 Wrdow 0.005 - 40.955= 424596 t EDS results for Area 2.
111286-3 El. Le Cc ,,- 10DL z A F 2,i 3.,
Al Oa 0.069 .4% O.Otl 0.003 1.D3 0.3702 2.(647
- 5. Ka 0.913 :.% 0.036 0.073 1.1272 0.4749 D.0849 Cr 18e.48 MA.% 0.162 0.070 0.9970 0.9900 1.2645
"' K. 2.398 .4.% 0.047 0.081 0.9789 0.9963 1.2809 Fe a 70.277 .4% 0.410 0.1Z0 0.9972 0.9646 2.0131 M K. 8.885 .% 0.178 0.148 2.0123 0.8870 L.OO 100.000 wt.%
l~~~~~~~~~~~~~~~~~~~~~~~~P ti N 5 10 D-sor=0.025 keV 1131 cnt ID = U kL ert=8194 Wndow 0.005 - 40.955= 426515 cnt EDS results for Area 3.
Figure 6.3.2.1 (cont.): EDS results for Areas 2 and 3. Note that the Cr peak was set at full screen height for Area 2.
BWXT SERVICES, INC. 1140-025-02-24 141 BWXT SERVICES, INC. 1140-025-02-24 141 Figure 6.3.2.2: Higher magnification SEM micrographs of crack tip, showing the interdendritic crack path along the elongated ferrite pools.
BWXT SERVICES, INC. 1140-025-02-24 142 BWXT SERVICES, INC. 1140-025-02-24 142 Figure 6.3.2.3: Secondary electron SEM images of crack tip, showing the interdendritic crack path along the elongated ferrite pools.
BWXT SERVICES, INC. 1140-025-02-24 143 BWXT SERVICES, INC. 1140-025-02-24 143 Figure 6.4.1.1: Low magnification SEM mosaic showing the opened main crack (sample A2A7-L1 A). Refer to Figures 5.11 and 5.12 for the sample location. The exposed cladding surface is oriented downward in the SEM micrographs.
BWXT SERVICES, INC. 1140-025-02-24 144 BWXT SERVICES, INC. 1140-025-02-24 144 Figure 6.4.1.2: Near mosaic area "A". Heavy deposits are present toward the exposed side of the cladding (darker contrast in BSE micrograph).
Fracture morphology is interdendritic in nature.
BWXT SERVICES, INC. 1140-025-02-24 145 BWXT SERVICES, INC. 1140-025-02-24 145 Figure 6.4.1.3: Near mosaic area "B". Cracking is intergranular/interdendritic.
BWXT SERVICES, INC. 1140-025-02-24 146 BWXT SERVICES, INC. 1140-025-02-24 146 Figure 6.4.1.4: Near mosaic area "C". Fracture mode is intergranular or interdendritic for in-service cracking and ductile tearing for lab opened-up fracture.
BWXT SERVICES, INC. 1140-025-02 24 147 147 BWXT SERVICES, INC. 1140-025-02-24 Figure 6.4.1.5: Near mosaic area "D". Fracture mode is intergranular or interdendritic for in-service cracking and ductile tearing for lab opened-up fracture (upper right).
BWXT SERVICES, INC. 1140-025-02-24 148 BWXT SERVICES, INC. 1140-025-02-24 148 Figure 6.4.1.6: Near mosaic area "E". Cracking is intergranular/interdendritic.
BWXT SERVICES, INC. 1140-025-02-24 149 BWXT SERVICES, INC. 1140-025-02-24 149
-=0.035 keY 403 cnt ID = U kal 11692 Whdow 0.005 -40.955= 373168 cnt EDS results for area Figure 6.4.1.7: SEM micrograph and EDS results for deposited region near area "E".
The corrosion deposits contained carbon, oxygen, along with iron, aluminum, silicon, and chromium. Possible trace levels of nickel and chlorine were also detected in this area.
BWXT SERVICES, INC. 1140-025-02-24 150 111231-1 0 Specimen: Davis Besse Head A2-A7-L-1-A EDS of point 1, Image 111231.
Uncoated, 10 kV.
Elements: C, 0, Si, Cr, Fe, NI Possible Trace: Al, S/Mo, Ca
~KI Cr
- ixusor=0.035 keV 488 cnt ID = U kal Vert=4673 Window 0.005 - 40.955= 194401 cnt EDS results for point 1above.
Figure 6.4.1.8: Higher magnification SE micrograph and EDS results for a grain boundary deposit near area "E". This area contained primarily carbon, oxygen, silicon, chromium, iron, and nickel. Lesser amounts of aluminum, sulfur, and calcium were also detected.
BWXT SERVICES, INC. 1140-025-02-24 151 Sample A2A5C Knoop Microhardness (Exposed Clad) 350.0 300.0 i 250.0 200.0 C
150.0 0 100.0 V 50.0 0.0 l 1
0.0 00 0.050 0.100 0.150 0.200 0.250 Distance from upper (exposed) clad surface, Inches Sample A2A5C Knoop Microhardness (Low Alloy Steel and Stainless Clad) 350.0 300.0 f, 250.0 c 200.0 -
2 150.0 -
.M 100.0 0 Low Alloy Steel Stainless Clad 5 0.0 0.000 0.100 0.200 0.300 0.400 Distance from upper surface of mount, Inches Figure 6.5.1.1: 4X macro photograph of metallographic mount A2A5C, along with Knoop microhardness data. Refer to Figure 5.13 for the sample orientation. The two Knoop microhardness traverse lines are visible in the macro photo. The significant microhardness variations occur in the heat affected zone of the low alloy steel and the cladding adjacent to the fusion line.
BWXT SERVICES, INC. 1140-025-02-24 152 BWXT SERVICES, INC. 1140-025-02-24 152 4X Figure 6.5.1.2: Low magnification photograph of mounted sample A2A5C after chemical etching to reveal the cladding microstructure. It did not appear that a weld deposition change occurred in this region.
BWXT SERVICES, INC. 1140-025-02-24 153 BWXT SERVICES, INC. 1140-025-02-24 153 E chAt.. "e
- At'! '., fr ......- i %: ". .
Etched 48X Figure 6.5.1.3: Micrograph showing the undercutting due to boric acid corrosion in the RV head low alloy steel at the interface between low alloy steel (above the notch) and stainless steel cladding (below the notch).
Etch e ' 37 Etched 375X Figure 6.5.1.4: Micrograph showing the interface between low alloy steel (above) and stainless steel cladding (below). The austenitic grains in the first interface layer on the stainless steel cladding side are equiaxed and growing preferentially from the ferrite grains (low alloy steel). The subsequent grain growth in the cladding is columnar.
BWXT SERVICES, INC. 1140-025-02-24 154 BWXT SERVICES, INC. 1140-025-02-24 154 Etched 375X Figure 6.5.1.5: Micrographs of the cladding surface exposed due to boric acid corrosion of the RV head low alloy steel. Intergranular attack (IGA) of stainless steel cladding to a depth of the first or second layers of grains is clearly visible. The IGA is probably due to oxygenated and highly concentrated boric acid. There was no evidence of plastic deformation observed in the cladding in this area.
BWXT SERVICES, INC. 1140-025-02-24 155 BWXT SERVICES, INC. 1140-025-02-24 155 375X Figure 6.5.1.6: Micrographs showing typical stainless steel cladding microstructure.
The dendritic solidification structure is delineated by small pools (or islands) of ferrite in an austenitic matrix.
BWXT SERVICES, INC. 1140-025-02-24 156 BWXT SERVICES, INC. 1140-025-02-24 156
.-. y*
rs-, .
- Sample A2A2B3 Knoop Microhardness 350.0 Ie 300.0 Ot 250.0 - *-. A c 200.0
° 150.0 S 100.0
- 50.0 0.0 0.000 0.100 0.200 0.300 0.400 0.500 Distance from bore ID surface, inches Figure 7.1.1.1: Macro photograph and Knoop microhardness results for metallographic sample A2A2B3 (see Figure 5.2 for the sample orientation). The lower concave surface is the I.D. of the nozzle 3 bore from the nozzle removal process. The crack tips of the two cracks are estimated to be approximately 0.24" and 0.20" below the surface, respectively. The indentations from the microhardness traverse are visible. The elevated microhardness level near the surface is due to the surface cold work layer from the boring of nozzle 3 removal process (see Figures 5.2 and 7.1.1.5).
BWXT SERVICES, INC. 1140-025-02-24 157 BWXT SERVICES, INC. 1140-025-02-24 157
- a~ If6 ~~~~~~~
Figure 7.1.1.2: Micrographs showing the crack at -180° in sample A2A2B3.
Top as-polished, bottom etched. Both micrographs 24X.
Etched 375X Figure 7.1.1.3: Typical microstructure of sample A2A2B3. The grain size and dendritic structure within each grain are consistent with typical Alloy 182 weld.
BWXT SERVICES, INC. 1140-025-02-24 158 BWXT SERVICES, INC. 1140-025-02-24 158 10OX 375X Figure 7.1.1.4: Higher magnification micrographs of the crack tips. Cracking is intergranular or interdendritic.
BWXT SERVICES, INC. 1140-025-02-24 159 V , ..4*
- 1*
A; - *-.
I / ..-. %-
- I-. -
/
I
.4 ' 1Z .J.., lv
, {X%&<X _ Rae Zi~~~~~~~I, X~~~~~~~~~~~~~~~~~~~~ X 375X Figure 7.1.1.5: Higher magnification micrographs of the cracking at -1800 near the bored surface. The bored surface shows evidence of surface cold work. The surface cold work is due to the nozzle removal from the RV head and is not related to the J-groove weld fabrication process.
BWXT SERVICES, INC. 1 140-025-02-24 160 BWXT SERVICES, INC. 1140-025-02-24 160 10O 2.aB low,;
I' Nozzle 3 Bore .D.
10b, 0 10° 4X Figure 7.2.1.1: Macro photograph of metallographic mount sample A2A6B2 (see Figures 5.4 and 5.5 for the sample orientation). The axial cracking at 10° is through the J-groove weld, in contrast to the cracking near 1800, which was partially through the weld. A slightly higher magnification micrograph is also provided.
.BWXT SERVICES, INC. 1140-025-02-24 161 BWXT SERVICES, INC. 1140-025-02-24 161 I UUA Figure 7.2.1.2: Higher magnification micrographs of the J-groove weld cracking.
Cracking is intergranular or interdendritic, similar to the cracking at 180° in Figure 7.1.1.4.
BWXT SERVICES, INC. 1140-025-02-24 162 BWXT SERVICES, INC. 1140-025-02-24 162 375X Figure 7.2.1.3: Typical microstructure of sample A2A6B2, which was similar to Figure 7.1.1.3 (at -180°).
BWXT SERVICES, INC. 1140-025-02-24 163 BWXT SERVICES, INC. 1140-025-02-24 163 11 1171-1 Fe Specimen: Davis Besse A2A6B2 EDS of area 1, Image 111373.
Carbon Coated, 20 kV.
Elements: C, 0, Cr, Mn, Fe, Ni, Zr*
Trace: Al, Si, Ti Possible trace Ca overlapped by Sn.
,< Zr * - No K-Alpha lines (expected->low conc.)
Zr much better peak fit than P. I i
i i
j i
I i i ml z
Ni
.iz - I I .
- ~
IR
~~~~. ll i .- . ..:ipl,i'. i2
.. I.Is r. .' , .
Fn
- - ICr - 'I". -
I I . --r -
-;-r Ji 5 10 Cursor=0.045keV 202cnt ID=Ukal Vert=4000 Whndow 0.005 - 40.955= 255021 cnt EDS results for area 1 above.
Figure 7.2.2.1: BSE micrograph showing portion of crack filled with corrosion products. The EDS results indicated high concentrations of carbon, oxygen, iron, and nickel.
BWXT SERVICES, INC. 1140-025-02-24 164
(~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Cr Specimen: Davis Besse A2A6B2 EDS of small area 1, image 111381.
Carbon Coated, 20 V Elements: C, 0, Al, Si, TI, Cr, Mn, Fe, N, Nb, Sn Possible Trace Ca, overlapped In Sn.
Cr
=0.025 keV 1267 nt ID =U kl ert4000 Window 0.005 - 40.955= 431661 nt EDS results for area 1 above.
Figure 7.2.2.2: BSE micrograph showing corrosion products near crack tip. The EDS results collected from the area 1 indicated high concentrations of carbon, oxygen, niobium, titanium, chromium, manganese, iron, and nickel.
BWXT SERVICES, INC. 1140-025-02-24 165 165 BWXT SERVICES, INC. 1140-025-02-24
,-,I..... , .I V
MA Figure 7.2.3.1: Macro photograph of metallographic mount A2A6A2E1 (see Figure 5.6 and 5.10 for the sample orientation). Cracking was partially through the J-groove weld in the sample plane.
BWXT SERVICES, INC. 1140-025-02-24 166 1140-025-02-24 166 BWXT SERVICES, INC.
Figure 7.2.3.2: Micrograph showing axial cracks in the lower portion of the J-groove weld at -100. The crack maximum depth is approximately 0.45" beneath the bore .D.
surface.
BWXT SERVICES, INC. 1140-025-02-24 167 BWXT SERVICES, INC. 1140-025-02-24 167 Figure 7.2.3.3: Cracks located near the bored surface. Surface cold work layer is due to the boring (nozzle removal) process.
BWXT SERVICES, INC. 1140-025-02-24 168 S. . 'C
/
w -.
yri. . *
- .'- -. -t -
fr's
,&t.-r,?4 .
t:' r £ Zr t '. .;i . -
V.
,> ; l
^y:~', *..
, '.. ~tj* --- .
Etched 375X Figure 7.2.3.4: Interdendritic or intergranular cracking in the J-groove weld away from the bore 1.0. surface.
BWXT SERVICES, INC. 1140-025-02-24 169 169 BWXT SERVICES, INC. 11 40-025-02-24 Etched 77X Figure 7.2.3.5: Crack tips toward the J-groove weld O.D.
BWXT SERVICES, INC. 1140-025-02-24 170 BWXT SERVICES! INC. 1140-025-02-24 170 F - -.
-. "2Z Figure 7.2.3.6: Crack detail from Figure 7.2.3.5.
BWXT SERVICES, INC. 1140-025-02-24 171 171 BWXT SERVICES, INC. 1140-025-02-24 of -weld 4X Figure 7.2.4.1: Macro photograph of sample A2A6B3 with the middle portion of the axial cracking at -10° opened-up for SEM. Refer to Figures 5.4 and 5.5 for the sample location.
BWXT SERVICES, INC. 1 140-025-02-24 172 BWXT SERVICES, INC. 1140-025-02-24 172 Ductile tearing Interdendritic Fracture surface is corner from crack cracking heavily oxidized opening up in lab
\ CRDM nozzle 3 bore I.D. surface Figure 7.2.4.2: Low magnification SEM mosaic of the fracture surface after opening-up the axial crack. BSE 6.7X Figure 7.2.4.3: Higher magnification of the left section in Figure 7.2.4.2.
Cracking is interdendritic exposing a well-defined columnar solidification structure.
BWXT SERVICES, INC. 1 140-025-02-24 173 BWXT SERVICES, INC. 1140-025-02-24 173 Figure 7.2.4.4: Higher magnification of the middle section in Figure 7.2.4.2. The fracture surface is heavily oxidized; the fracture mode is indeterminate.
Figure 7.2.4.5: Higher magnification of the right section in Figure 7.2.4.2.
Cracking to the left side of ductile tearing (lab fracture) is interdendritic.
BWXT SERVICES, INC. 1140-025-02-24 174 BWXT SERVICES, INC. 1140-025-02-24 174 BSE 6.7X 111326 MA-1 0
Specimen: Davis Besse A2A6A2C2 EDS of area 1, Image 111326_MA.
Uncoated, 10 kV 4i Elements: C, 0, S, Cr, Mn, Fe, NI, ZrI Zr - Confirmed using 30 kV. P - peak overlaps Zr and may, or may not, be present also.
,c
- i II i I I
j I Zr I
ii
.{
6 Cr M.-'f i
.j - n M ~ ... , ML M
5 10 ursor=0.035 keV 551 ant ID = U kal Vert=4000 Window 0.005 - 40.955= 366735 nt EDS results for area 1.
Figure 7.2.4.6: BSE micrograph mosaic of the open crack surface (same area as Figure 7.2.4.2) along with EDS results for three areas of the fracture surface. The dark area in the BSE image indicates the fracture surface was covered by a thick oxide layer. The light area (right side) indicates a fresh fracture surface due to crack opening-up (i.e., less oxide on surface). For area 1, the primary elements included carbon, oxygen, silicon, chromium, manganese, iron, nickel, and zirconium.
BWXT SERVICES, INC. 1140-025-02-24 175 111326 MA-2 Specimen: Davis Besse A2A6A2C2 EDS of area 2, Image 111326_MA.
Uncoated, 10 kV.
Elements: C, 0, Al, Si, Ti, Cr, Mn*, Fe, Ni, Zr, Sn Mn - ikely. Overlapped by Cr/Fe. Aplitude relative to Cr K-Beta suggests its presence.
IY Ni I;
. . . .. - . . I
- - -- --- r> - I l r11
. - -'. . iI 5
Cr pn i r
-F ~
Ri I
-10 Cursor=0.045 keV 705 cnt ID = U kal Vert=20000 Whdow 0.005 - 40.955= 1141267 cnt EDS results for area 2.
rl Figure 7.2.4.6 (cont.): For area 2, the primary elements included carbon, oxygen, silicon, chromium, manganese, iron, nickel, and zirconium. Similar results were obtained for area 3, except area 3 also contained niobium and calcium.
BWXT SERVICES, INC. 1140-025-02-24 176 Figure 7.3.1.1: Macro photograph of metallographic sample A2A6A2B2. The mounted surface is through the J-groove weld at -450. Refer to Figures 5.6 and 5.7 for the sample orientation.
BWXT SERVICES, INC. 1140-025-02-24 177 BWXT SERVICES, INC. 1140-025-02-24 177 Figure 7.3.1.2: Slightly higher magnification photograph of metallographic mount A2A6A2B2.
BWXT SERVICES, INC. 1140-025-02-24 178 178 BWXT SERVICES, INC. 1140-025-02-24 Figure 7.3.1.3: Intergranular or interdendritic cracking initiating at the cladding surface and extending into the J-groove weld. Note that the micrographs shown are mirror image of the photo in Figure 7.3.1.2.
Intergranular attack (IGA) is also evident on the exposed surface of J-groove weld and cladding (surface exposed to oxygenated boric acid). This cracking is likely initiated by IGA.
BWXT SERVICES, INC. 1140-025-02-24 179 BWXT SERVICES, INC. 1140-025-02-24 179 I I
\'
)
-? -- , "-;.
Etched 375X Figure 7.3.1.4: Higher magnification micrograph showing intergranular or interdendritic cracking initiating at the cladding surface and extending into the J-groove weld.
BWXT SERVICES, INC. 1140-025-02-24 180 BWXT SERVICES, INC. 1140-025-02-24 180
/
Figure 7.3.1.5: Low magnification micrographs showing shallow circumferential cracking in the J-groove weld.
BWXT SERVICES, INC. 1140-025-02-24 181 BWXT SERVICES, INC. 1140-025-02-24 181 Figure 7.3.1.6: Micrograph showing the shallow circumferential cracks in the J-groove weld. The cracking is intergranular or interdendritic, with a maximum depth of approximately 0.019" below the surface. The two wider crack regions just below the surface may have been dendrites or grains encircled by cracks that subsequently dropped out during sample preparation.
BWXT SERVICES, INC. 1140-025-02-24 182 1140-025-02-24 182 BWXT SERVICES, INC.
Figure 7.3.1.7: Micrographs showing crack tips of the circumferential cracking in the J-groove weld.
BWXT SERVICES, INC. 1140-025-02-24 183 BWXT SERVICES, INC. 1140-025-02-24 183 Etched 375X Figure 7.3.1.8: Typical J-groove weld microstructure.
BWXT SERVICES, INC. 1140-025-02-24 184 BWXTSERVICES, INC.
1140-025-02-24 184~~~~~~~~~~~~~~~~~~~~~~~~
J 1
4 4X Figure 7.3.2.1: Macro photograph of metallographic mount A2A6A2D2. The mounted surface is through the J-groove weld at -30°. Refer to Figures 5.6 and 5.9 for the sample location.
BWXT SERVICES, INC. 1140-025-02-24 185 1140-025-02-24 185 BWXT SERVICES, INC.
Etcned 1sA Figure 7.3.2.2: Micrograph showing the circumferential intergranular/interdendritic cracks in the J-groove weld. The maximum cracking depth is approximately 0.018" below the surface. The cavity just below the surface may be due to dendrites or grains encircled by the cracks that dropped out during sample grinding and polishing.
BWXT SERVICES, INC. 1140-025-02-24 186 186 BWXT SERVICES, INC. 1140-025-02-24 vie.;
%.Etched1 '" 1 Etched 1looX Figure 7.3.2.3: Micrographs showing the intergranular or interdendritic cracking between the J-groove weld and cladding interface. The micrographs shown here are mirror of the photo in Figure 7.3.2.1. Intergranular attack (IGA) is also evident on the exposed surface of J-groove weld and cladding (surface exposed to oxygenated boric acid). This cracking was likely initiated by IGA.
BWXT SERVICES, INC. 1140-025-02-24 187
...
- Y
- ' A' I Etched 1OOX
- - *a 4~~~~~~~~~~~~~~~~~~~~~~5
.4~~~~~~~~~~~~7
- .1 . ,
Etched 375X Figure 7.3.2.4: Intergranular attack (IGA) on the Jgroove weld surface exposed to oxygenated boric acid.
BWXT SERVICES, INC. 1140-025-02-24 188 BWXT SERVICES, INC. 1140-025-02-24 188 Figure 7.3.3.1: Low magnification BSE micrograph of sample A2A6A2D2 showing the cracking in the exposed cladding surface and the axial cracking in the J-groove weld surface exposed to RCS. The EDS spectrum collected from area 1 is presented in Figure 7.3.3.2.
BWXT SERVICES, INC. 1140-025-02-24 189 111493-1 Ni Specimen: Davis Besse A2A6A2D2 EDS of area 1, Image 111493 ( MA)
Carbon Coated, 20 kV.
Elements: See Quantitation Carbon not included (coated).
El. to. Cn. E- . MIt Z A F C K. aim .i% 0000 SAM 1.23130.1431 10FM Al . 0.03 .. % 0411 04O 1914 OX73 3.0032 90 K. OW7 #,4.1 0031 *J7S 1.0111 0.414 33032 i K, 05t2 M.% 02S 0460 .5133 0.1S1 1.161t C, .C, ,4t4 A,% 0.10 kS1.14 Q E5 0.31 3.) 7Z08 XX4E 0732 I.10 R 1( 0213 , .l. . 0 40M 043 0.1070 1.:310 F. F. 120 ,% 0.154 04% 0."16 50 0.1730 Vat5444324 ho 0.1 0.43 0.15 1440 0070 .nt withtom 1.14 a l.01.
All01 0.101 0.el C
5 ~~~~~~~~~~~~~10 Csor=0.06S keV 20 cnt ID =U ka Vert=5464 Windcow .005 - 40.955= 440070 cnt Figure 7.3.3.2: The EDS spectrum for area 1 in Figure 7.3.3.1. The semi-quantitative results from this area, which was located within the J-groove weld, were consistent with Alloy 182 weld metal.
BWXT SERVICES, INC. 1140-025-02-24 190 BWXT SERVICES, INC. 1140-025-02-24 190 S -. 39* S S OS I BSE 10OX Figure 7.3.3.3: Low magnification BSE micrograph showing the cracking that initiated from the exposed cladding surface (left side of figure). The maximum crack depth is approximately 0.055" below the cladding surface.
BWXT SERVICES, INC. 1140-025-02-24 191 BWXT SERVICES, INC. 1140-025-02-24 191 Figure 7.3.3.4: SE micrographs of the circumferential cracking in the J-groove weld. The maximum circumferential cracking depth is approximately 0.032" below the surface. Cracking was interdendritic in nature.
r!PA/yvT D'WVA I cnwrPIC4 INNr' 11 4-025-02-24 192 Figure 7.3.4.1: Macro photograph of the opened-up circumferential cracking in the J-groove weld at -300. The underside surface of the J-groove weld (in contact with RCS) is shown. Refer to Figures 5.6 and 5.8 for the sample location. The rectangular sample (A2A6A2C2) is secured to the round SEM stub with black carbon tape.
BWXT SERVICES, INC. 1140-025-02-24 193 1140-025-02-24 193 BWXT SERVICES, INC.
Figure 7.3.4.2: SE micrographs showing the shallow circumferential cracking in the J-groove weld. Cracking was interdendritic.
BWXT SERVICES, INC. 1140-025-02-24 194 "4
- Ii 4,
V.
5 Figure 8.1.1.1: Macro photograph of sample Al B2. Refer to Figures 5.13 and 5.14 for the sample location. The white box shows area enlarged in Figure 8.1.1.2.
BWXT SERVICES, INC. 1140-025-02-24 195 Figure 8.1.1.2: Low magnification micrograph showing horizontal striations aligned with the major axis of the RV head low alloy steel plate (SA-533, Gr. B (mod), Cl. 1). The striations are due to the segregation of carbides, which promote a slightly faster local corrosion rate along the striations. Note that this micrograph is a mirror image of Figure 8.1.1.1.
BWXT SERVICES, INC. 1140-025-02-24 196 BWXT SERVICES, INC. 1140-025-02-24 196 Figure 8.1.1.3: Higher magnification micrograph, which indicates a slightly faster local corrosion rate along the striations.
Figure 8.1.1.4: Micrograph showing the typical tempered martensitic microstructure of SA-533, Gr. B (mod), Cl. 1 low alloy steel plate.
BWXT SERVICES, INC. 1140-025-02-24 197
- ~~~~~~~~~~~~~~~~~~~~~~~~~~~.
4X Figure 8.1.2.1: Macro photograph of metallurgical mount Al B4. Refer to Figures 5.13 and 5.14 for the sample location. The white box indicates the area shown at higher magnification in Figure 8.1.2.2.
BWXT SERVICES, INC. 1140-025-02-24 198 BWXT SERVICES, INC. 1140-025-02-24 198 iz' 4 4, Z I
Etched 18X Figure 8.1.2.2: Higher magnification micrograph showing the horizontal striations aligned with the major axis of the RV head low alloy steel plate (SA-533, Gr. B (mod), Cl. 1). However, unlike Figure 8.1.1.3, the striations do not appear to promote a faster corrosion rate locally.
BWXT SERVICES, INC. 1 140-025-02-24 199 BWXT SERVICES, INC. 1140-025-02-24 199 Figure 8.1.2.3: At higher magnification, the local corrosion rate along the striations is increased only very slightly.
Etched 375X Figure 8.1.2.4: Micrograph showing the typical tempered martensitic microstructure of SA-533, Gr. B (mod), Cl. 1 low alloy steel plate.
BWXT SERVICES, INC. 1140-025-02-24 200 BWXT SERVICES, INC. 1140-025-02-24 200 Figure 8.1.3.1: Low magnification SE micrographs of cavity wall surface near 900. The surface contains generally round depressions measuring -0.039" or less in diameter.
BWXT SERVICES, INC. 1 140-025-02-24 201 BWXT SERVICES, INC. 1140-025-02-24 201 Figure 8.1.3.2: Higher magnification micrographs of the cavity side wall near 900.
BWXT SERVICES, INC. 1140-025-02-24 202 BWXT SERVICES, INC. 1140-025-02-24 202 Figure 8.1.3.3: SE micrographs showing corrosion products on cavity side wall near 900.
BWXT SERVICES, INC. 1140-025-02-24 203 SERVICES, BWXT 1140-025-02-24 INC. 203 a:= -:7 - --- -- 7' 11 ,
A11D2E (face-e A1 D2E (fac perpendicular parallel t to cavity cavi 96 !.-
sidewall) sidew Figure 8.2.1.1: Low magnification photographs showing macro etch results.
Arrows indicate corrosion grooves associated with corresponding micro-structural banding. Macro etch was performed on two surfaces of sample Al D2E ground with 400 grit paper. Etchant: 10% nital.
BWXT SERVICES, INC. 1140-025-02-24 204 I. I'. -" .
I i , .. -
- I II I 2 , I fI I I
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.4 Figure 8.2.2.1: Macro photograph of metallurgical mount Al D2B1. Refer to Figures 5.13, 5.15, and 5.16 for the sample location. The white box indicates the area shown at higher magnification in Figure 8.2.2.2.
BWXT SERVICES, INC. 1140-025-02-24 205 BWXTSERVICES,INC.
1140-025-02-24 205 Etched 1tA Figure 8.2.2.2: Slightly higher magnification micrograph showing the horizontal striations aligned with the major axis of the RV head low alloy steel plate (SA-533, Gr.
B (mod), Cl. 1). Striations appear to be caused by a very slightly faster local corrosion rate. Note that this micrograph is a mirror image of Figure 8.2.2.1.
BWXT SERVICES, INC. 1140-025-02-24 206 BWXT SERVICES, INC. 1140-025-02-24 206 Figure 8.2.2.3: Higher magnification detail of Figure 8.2.2.2, which suggests a slightly faster local corrosion rate along the striations.
Figure 8.2.2.4: Micrograph showing the typical tempered martensitic microstructure of SA-533, Gr. B (mod), Cl. 1 low alloy steel plate.
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I77, I, I Figure 8.2.3.1: Macro photograph of metallurgical mount Al D2D1. Refer to Figures 5.13, 5.15, and 5.16 for the sample location. The white box indicates the area shown at higher magnification in Figure 8.2.3.2.
BWXT SERVICES, INC. 1140-025-02-24 208 BWXT SERVICES, INC. 1140-025-02-24 208 Figure 8.2.3.2: Higher magnification detail of Figure 8.2.3.1 showing the horizontal striations aligned with the major axis of the RV head low alloy steel plate (SA-533, Gr.
B (mod), Cl. 1). Striations appear to be caused by a very slightly faster local corrosion rate.
BWXT SERVICES, INC. 1140-025-02-24 209 BWXT SERVICES, INC. 1140-025-02-24 209 Figure 8.2.3.3: Higher magnification detail of Figure 8.2.3.2, which suggests a slightly faster local corrosion rate along the striations.
Figure 8.2.3.4: Micrograph showing typical tempered martensitic microstructure of SA-533, Gr. B (mod), Cl. 1 low alloy steel plate.
BWXT SERVICES, INC. 1140-025-02-24 210 BWXT SERVICES, INC. 1140-025-02-24 210 Figure 8.2.4.1: SE (top) and BSE (bottom) micrographs of the cavity wall surface near 270°. The surface contained rounded depressions measuring 0.020" in diameter or less. Orientation of micrographs: lower portion of cavity to the right and upper portion to the right. Nozzle #3 is closer to lower edge of micrograph.
BWXT SERVICES, INC. 1140-025-02-24 211 BWXT SERVICES, INC. 1140-025-02-24 211 Figure 8.2.4.2: SE micrographs of cavity side wall near 2700. These micrographs suggest that larger (1 mm dia.) shallower depressions are caused by acid boiling and smaller (-0.3 mm dia.) deeper depressions are caused by inclusions.
BWXT SERVICES, INC. 1140-025-02-24 212 BWXT SERVICES, INC. 1140-025-02-24 212 Figure 8.2.4.3: Higher magnification SE micrograph showing corrosion products on cavity side wall near 2700.
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Figure 8.3.1.1: Macro photograph of metallographic mount A2A7D. Refer to Figures 5.1 and 5.11 for the sample location.
BWXT SERVICES, INC. 1140-025-02-24 214 BWXT SERVICES, INC. 1140-025-02-24 214 Figure 8.3.1.2: Micrograph showing the edge of the exposed cladding in the undercut region. Note: the micrograph is a mirror image of the macrograph in Figure 8.3.1.1.
Etched 48X Figure 8.3.1.3: Micrograph showing intergranular attack (IGA) and intergranular or interdendritic cracking in the cladding. The maximum depth of the crack tip is approximately 0.047" below the exposed cladding surface.
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Etched 375X Figure 8.3.1.4: Micrographs showing intergranular attack (IGA) and intergranular or interdendritic cracking on the exposed cladding surface.
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Etched 375X Figure 8.3.1.5: Micrographs showing the interface between the low alloy steel (above the fusion line) and the stainless steel cladding (below the fusion line).
BWXT SERVICES, INC. 1140-025-02-24 217 BWXT SERVICES, INC. 1140-025-02-24 217
~~Etched 375X Figure 8.3.1.6: Micrographs showing typical stainless steel cladding microstructure.
The interdendritic solidification structure is delineated by small pools (or islands) of ferrite in an austenitic matrix.
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r 4X Figure 8.3.2.1: Macro photograph of metallographic mount A2A7F.
Refer to Figures 5.1 and 5.11 for the sample location.
BWXT SERVICES, INC. 1140-025-02-24 219 BWXT SERVICES, INC. 1140-025-02-24 219 Figure 8.3.2.2: Micrograph showing the exposed cladding surface. A slight undercut is evident in the low alloy steel. Note: the micrograph is a mirror image of the macrograph in Figure 8.3.2.1.
BWXT SERVICES, INC. 1140-025-02-24 220 BWXT SERVICES, INC. 1140-025-02-24 220 Etc: r Etched 375X Figure 8.3.2.3: Micrographs showing intergranular attack (IGA) and intergranular or interdendritic cracking. The maximum depth of the crack tip is approximately 0.024" below the exposed cladding surface.
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Etched 375X Figure 8.3.2.4: Micrographs showing the interface between the low alloy steel (above the fusion line) and the stainless steel cladding (below the fusion line).
BWXT SERVICES, INC. 1140-025-02-24 222 BWXT SERVICES, INC. 1140-025-02-24 222 Figure 8.3.2.5: Micrographs showing the typical stainless steel cladding microstructure. The interdendritic solidification structure is delineated by small pools (or islands) of ferrite in an austenitic matrix.
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4X Figure 8.3.3.1: Macro photograph of metallographic mount A2A7K.
Refer to Figures 5.1 and 5.11 for the sample location.
BWXT SERVICES, INC. 1140-025-02-24 224 BWXT SERVICES, INC. 1140-025-02-24 224 Figure 8.3.3.2: Micrograph showing the edge of the exposed cladding in the undercut region. Note: the micrograph is a mirror image of the macrograph in Figure 8.3.3.1.
Figure 8.3.3.3: Micrograph showing minor intergranular attack (IGA) in the exposed cladding surface.
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Etched 375X Figure 8.3.3.4: Micrographs showing the interface between the low alloy steel (above the fusion line) and the stainless steel cladding (below the fusion line).
BWXT SERVICES, INC. 1140-025-02-24 BWXT SERVICES, INC. 226 1140-025-02-24 226 Figure 8.3.3.5: Micrographs showing the typical stainless steel cladding microstructure. The interdendritic solidification structure is delineated by small pools (or islands) of ferrite in an austenitic matrix.
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