ML19256E804
| ML19256E804 | |
| Person / Time | |
|---|---|
| Site: | Oconee  |
| Issue date: | 11/08/1979 |
| From: | DUKE POWER CO. |
| To: | |
| Shared Package | |
| ML15245A147 | List: |
| References | |
| PROC-791108, NUDOCS 7911150267 | |
| Download: ML19256E804 (111) | |
Text
{{#Wiki_filter:k STEAM GENERATOR INSPECTION PLAN OCONEE UNIT 1 NOVEMBER, 1979 REFUELING OUTAGE I. Eddy Current Testing "A" OTSG Plan Total of 10% of tubes will be inspected. A. Lane Region (all lane tubes plus two each side) B. Special interest tubes
- 1. previous OD/ID indication
- 2. previous dings / obstructions C. Balance of 10% - random selection concentrated in the periphery region.
D. Objectives: The objectives of the above examination plan are:
- 1. to monitor the growth of previously noted tube degradation
- 2. concentrate a relatively large random inspection in areas where degradation has been noted in or,'er to monitor any growth of the specific effect II. Eddy Current Testing "B" OTSG Plan Total of 60% of tubes will be inspected.
A. Lane Region B. Special interest tubes
- 1. previous OD/ID indications
- 2. prevlous ding / obstructions
- 3. tubes in areas selected for possible debris sample C. Inspection of sleeved tubes D. Profilometry 1333 211 E. Balance of 60%
- 1. 100% of the OTSG periphery from the support rods out
- 2. 3% random in center of bundle F. Objectives:
- 1. to monitor the growth of previously noted tube degradation
- 2. determine the behavior of sleeves previously installed in six (6) tubes
- 3. determine areas where " debris" is most probably located in order to support debris removal efforts.
- 4. determine via profilometry magnitude of various I.D. restrictions
- 5. the 14th tube support plate (TSP) type degration (i.e. erosion /
corrosion) has been located in the periphery of the bundle, that is from the support rods out. The "B" OTSG has been most affected. In order to determine completely the extent of the 14th TSP type degradation a 100% baseline inspection of the periphery area is required. In addition, 50% of this area was inspected in 1977. The new inspection will provide 3 q911150 M.b )
the best possible indication as to the overall growth of the effect. If the phenomenon is not growing, this inspection will locate all degraded tubes so that they can be monitored for future growth or removed from service, thereby minimizing the potential for future leaking tubes. III. 25 Khz Absolute Eddy Current (debris location) A. Scope - all tubes in "B" 0TSG B. Objective: The presence of " debris" in the Ocu...e 1 OTSG's has been noted previously. This debris is in the form of flakes of varying sizes lodged between the tub 3. The debris is primarily iron oxide. It has been postulateo = st the 14th tube support plate erosion / corrosion is related to che presence of the debris. An ECT technique has been developed which is capable of detecting debris in the OTSG. This data can be used to identify any correla-tions which exist. IV. Debris Removal A. Debris has been removed from the lower portion of the OTSG. However, it is known to be present in the upper portion, i.e. at 14th tube support plate but none has been removed. B. Objective: Remove debris from near the 14th tube support plate in order to determine completely the chemical make up of the debris. V. Visual Inspection: A. Task
Description:
Direct and fiberscopic visual examination of the upper portion, DNB region and lower portion of the OTSG. B. Objective: General examination of representative areas in the OTSG for comparative analysis. Samples will be taken from various areas for chemical characterization. VI. EPRI Steam Generator Owners Group Programs related to 14th Tube Support Plate Type defects A. Task
Description:
Evaluation of Steam Generator Tube 85-127 from OTSG 1B.
- 1. Objactive: A thorough examination of tube 85-127 from OTSG 1B to estaolish likely damage mechanisms. The results of this examination will be used to determine the scope of ada.itional investigative work (e.g. laboratory testing).
- 2. Status: The examination is complete and a draft report of the results is attached. The final report is in pr3paration. Future efforts res"'*ing from this examination are being defined at this time.
B. Task
Description:
Oconee Operating Experience review
- 1. Objective: "a review Oconee operating experience and procedures and determine any contributions to the 14th tube support plate erosion / corrosion phenomenon.
133u3 212
9
- 2. Status: Work has only ecently begun in this arca. Completion is expected by Septembe 1980.
C. Task
Description:
Oconee 1 Debris Sample Analysis
- 1. Objective: To characterize completely the chemical nature of the debris removed from OTSG 1B. This will aid in establishing the role played by the debris in the erosion / corrosion defect mechanism,
- 2. Status: Work has begun on a small piece of debris removed during the 8/79 Oconee 1 outage. Debris removed as a result of the ongoing effort (1979 refueling) will also be examined under this program.
D. Task
Description:
Model OTSG Test Program (draft) Objective: As related to the 14th tube support plate de. ct mechanism, the objective of this program is verification of thermal hydraulic computer codes. These codes can then be used to calculate detailed conditions near the 14th tube support plate area which could result in the erosion / corrosion type defects. 1333 213
\ t t J l PA_t.- ,
"IVALUA!!CN OF S~IAM CINE?ATOF. 7"3E 35-127 P.0M OCONEI l-3" Task 5136-1 Final Report Freparec 3y Babcock and *411cc Oc pany Research and Oevelcpnen: Ti.ision F.O. Ecx 1:iG Lynchburg, Virginic 2'50f Submitted Tc Cary 'J. CeYoung Principal Investiga::rs M. A. ?.13 den
. A. 54..tr 1333 214
1.0 Introduction 2.0 Results 2.1.1 Sanple Docunentation 2.1.2 Macroscopic Examination 2.1.3 Radiography 2.1.4 Eddy Current Ivaluation 2.1.5 Scanning Electron Microscopy 2.1.6 Transmission Electron Microscopy 2.1.7 Electron Diffraction 2.2 Micro-chemical Analysis 2.2.1 Energy Dispersive X-Ray Analysis 2.2.2 Auger' Electron Spectroscopy 2.2.3 Electron Spectroscopy for Ccmpound Analysis 2.2.4 Secondary Ions Mass Spectroscopy 2.2.5 Electron Diffraction 2.3 Micro-Mechanical Analyses 2.3.1 Electron Channeling Analyses 2.3.2 X-Ray Line Broadening 2.3.3 Metallography 2.3.4 Microhardness 3.0 Discussion and Conclusions 3.1 Mechanical Effects 3.2 Chemical E!feees 3.3 Probable Mechanism 4.0 Rece=mendation 4.1 Debris Sampling 4.2 Laboratory Sinulation 4.3 Review by Consults 1333 215
LIST CF FIGURIS Figure 1 Schematic of tube 85-127. 2 Schematic showing orientation and location of damage at 14th support plate elevatian on tube 85-127. 3 Section1 s diagram of the 14th support place region of t the 85-127. 4 Black circu=ferential band of deposit. 5 Typical contact mark at 15th support place elevation on tube 85-127. 6 Major "v groove" damage feature above 14th support olate land contact on tube 85-127. 7 Finer detailed view of =ajor da= age area shown in figure 6. 8 " Candle flame" area from tube 40-108. 9 "3all-peen" feature coincident with 14th support ..?.2ce broach on tube 85-127. 10 *1all-peen" area from iube 83-117. 11 Small damage feature at top of 14th support place land contact mark on tube 85-127. 12 Macrograph of "v groove" showing areas of more detailed examination. 13 Stereo view of lower end of "v groove". 14 Upset =etal on lower left edge of "v groove". 15 Features at top end of "v groove" area. 16 Features at siddle of the "v groove" area. 1333 216
17 Features at bottom end of "v groove" area. 18 High magnification (5000X) of surf ace features frem
" ball-peen" damage on tube 83-117.
19 High magnification (5000X) of surface features frem
" candle flame" damage on tube 43-108.
20 Small " ball-peen" area between land contacts on tube 35-127. 21 Damage surf ace near lower right side of ' ball-peen" area of figure. 22 Damage surface near lower center of " ball-peen" area of figure. 23 Stereo view of small " candle flame" area found en tube 85-127. 24 Lower lef t corner of small " candle flame" of figure. 25 Surface details of small " candle flame" of figure. 26 Small pit next to top of land contact nearese v-axis of tube 85-127. 27 Pits in contact area of land nearest v-axis of tube 85-127, 28 Stereoview of a pic from land contact area. 29 Features which resemble smearing of the surface on sputtered samples frem 8S-127, 43-108 and 83-117. 29a Tube 85-127 "v groove". 29b Tuba 47 108 " candle flame". 29c Tube 83-117 " ball-peen". 30 High magnification (8700X) transmission electron micrograph of "v groove". 31 High magnification (3700X) transmission stereo-cierograph of laboratory produced erosion. 32 Scanning electron micrograph of laboratorf produced erosica (500X). 33 Depth verses Atomic percene of elements found in surface films on tube 35-127. 1333 217
34 High magnification :ransmission electron micrograph (18,000X) showing Fe 03 4 particle obtained from "v groove on 85-127. 35 High magnification (18,000X) transmission electron micrograph showing A1 0 particles obtained from
" ball peen on 35-127.2 3 36 Areas of $5-127 from which channeling patterns were obca'.ned.
37 Areas of 43-108 from which channeling patterns were obtained. 38 Areas of 83-117 from which channeling patterns were obtained. 39 Diagram of 14th Support Place Region of tube 85-127 showing locations where x-ray line broadenian measurements were made. 40 Damage of similar geometry produced by 45" and mill and used for x-ray line broadening. 41 Micrograph of tube vall showing locations of higher nagnification metallography. 42 Micrographs from locations C, D & E of Figure 41. 42a Micrograph from Location C (2000X). 42b Micrograph from Location D (2000X). 42c Micrograph from location E (2000X). 43 Micrograph (2000X) at location A on Figure 41. 44 Views of undulating surface associated with two ' minor damage areas (Location 3 of Figure 41) adjacent to "v groove". 45 Micrograph showing microhardness test locations and results from "v groove" of tube 35-127. 1333 218
I-LIST OF IA3LES
- 1. Inside diameter measurements of tube 85-127.
- 2. Auger' Electron Spectroscopy (AES) data from tube 85-127.
- 3. Comparison of AES data for tube 85-127 with chenically cleaned surface of rods 43-108 and 83-117.
- 4. Comparison of AES data at the Oxygen equals Nickel point.
- 5. Comparison of Electron Spectroscopy for Compound Analysis (ESCA) data with AES data.
- 6. Electron binding energy Comparison for tube 85-127.
- 7. Sets of Interplanar spacings of particles found on tube surface.
- 8. Results of X-Ray Line Broadening Measurements of as-received tube 85-127.
- 9. X-Ray Line 3readening Results from si=ulated tube damage.
- 10. Table of Mechanical and Chemical effects.
E-1 EDI data F-1 AES profile data for tube 85-127 T-2 AES data from as-received surface and at 1500 A depth T-3 AES data from tube 85-127 F-4 AES from tubes 43-108 and 83-117 F-5 AES data from rods 83-117 and 43-108 G-1 ESCA data from tubes' 43-108 G-2 ESCA data from tubes 83-117 H-1 Secondary Ion Mass Spectroscopy Data (Sims) for tube 85-127 H-2 Ion Tield Corrected Sims Data I-1 Electron Channeling Patterns frta cube 85-127 I-2 Electron Channeling Patterns from tube 43-108 I-3 Electron Channeling Patteras fron tube 83-117 l l I
LIST OF APPENDICES A - Workscope for E?RI Contract 3 - Documentation of Tube 85-127 prior to remova. C - Results of Eddy Current Exam Data D - Che=dcal Cleaning Procedure E - Energy Dispersive I-Ray Analysis (EDI) F - Auger' Electron Spectroscopy Data (AES) C - Electron Spectroscopy for Con: pound Analysis (ESCA) H - Secondary Ion Mass Spectroscopy Data (SD'S). I - Electron Channeling Data 1333 220
ACX.'tC' UDCETS The assistance of Dr. J. A. Taylor of Physical Electronics Inc., Eden Prairie, Minnesota, in obtaining and interpreting ESCA and SIMS surf ace chemistry data and the assistance of Dr. David L. Davidsen of the Southwest Research Institute in obtaining and interpreting electron channeling data is gratefully acknculedged. 1333 221
~
- D *D 1'
^35 "' ":
9@P@O J d~ Y @JiL This project was undertaken to assess the relative roles of mechanical and chemical ef fects in the mechanism r$sponsible for the damage observed near the 14th support place elevation on tube 85-127 from econee Unit 1, steam generator 3. E7setronchanneling,2-raylinebroadening,hafess,and s-metallography were u 12ed to assess mechanical effects. Surface analysis techniques such as Auger' electron spectroscopy, electren spectroscopy for compound r.nalysis, secondary ion mass spectroscopy, energy dispersive x-ray analysis, and electron diffraction were used to assess chemical effects. Scanning '. and trantaission electron microscopy were also utili:ed for detailed charatteriza-tion of the damage surface. The analysis of mechanical effects provides conclusive evidence of mechanically induced damage. Surface chemistry analyses indicate the surface file on the damage area is thinner than on the surrounding tube. Also, the same chemical compounds are present on the damage surface that are present on the adjacent tube surface although not in the same proportions. No buildup of corrosion products is noted either en the damage surf ace or surrounding tube surface. The most probable damage mechanism is particle impingement by micron size particles. 1333 222
4
- 1. INTRODUCTICN The September 1978 in-service eddy current inspection of the steam generator tubes in Oconee 13 located several tubes with indications of metal loss in excess of 40% of the tube vall. Tuit 85-127* vas selected to be removed to confirm the damage and for comparison with tubes 43-108 and 31-117 which had been removed frem Oconee 13 previously because of eddy currenn indications of metal loss at the 14th support plate elevation.
~}
This tube was inspected on-site i= mediately after it was removed from the generator. Results of this preliminary examination indicated that damage en tais tube was very similar to that seen on tubes 43-108 and 83-117 Since the con clu. Shay damage mechanism had not beengdetermined by previous examinations and this tube was relatively free of artifsets from tube removal, a program was outlined to perform detailed macro and mi:ro scale analyses to conclusively determine the damage mechanism. This program was based on a series of micro-analyses to identify the role of mechanical and chemical facters which contribute to the observed damage at the 14th support plate elevation on tube 85-127. 'Jork was concluded on similar damage areas from Cconee 1-3 tubes 43-108 and 83-117 for comparison. This resulting program developed in collaboration with Duke Power Company _(Appendix ] was submitted to EPRI. EPRI accepted this proposal and funded this work under contract number S136-1. This document reports the ; rocedures used in this work, documents and discusses the results, and sets forth recocmendations based on conclusions drawn frem this work.
*In-service eddy current inspection of this tube in September 1977 and April 1978, shoved metal less in the range of 25 to 35: through wall.
1333 223
- 2. ESUI.TJ 2.1 Damage Characterization The first work on tube 85-127 was performed to characteri e the macroscopic nature of the observed damage at the lath support place elevation. This work includes photemacrography, eddy current inspection, orientatica mapping, x-ray radiography and scanning electron microscopy. The resulta of these examinations are reported in this section.
2.1.' Sample Documentation and Crientation Before tube 85-127 was removed from the steam generator, heritental and vertical scribe lines were placed on the inside su-face to provide a known reference for distance frem the upper surface of the tubesheet and to fix the circumferential orientation of the cybe,_sespectively ( Appendix 3) . Since the overhead clearance in the steam generator is restricted, the tube had to be cut , into pieces as it was removed. A permanent ink marking pen was used to mark each piece so that top and botten ends were known and so that circumferential orientation vac maintained frem piece to piece. The pieces were then placed in lay-flat plastic sleeves for protection as they were transported out of the steam generator. Once out of contai= ment, the pieces were taken to the Hot Machine Shop where they were given an on-site inspectiou to provide a timely correlation of observed damage with the eddy current indication. This netal namination indicated the major area of damage is 0.060" wide and began approximately 0.35" above the 14th support place and extended axially to about a'O.73" above the 14th support place. The damage region had the appearance of a "v" shaped groeve, which was shallow on the bottom end and deepest near the top end. The metal loss at this location was estimated by an optical technique to be 60t15 i' pertent of the tube wall. There was also seme minor damage at the top edgn of the region coincident with a support place breach and L= mediately above an adjacent support place contact mark. Af ter the on-site visual examination was cenpleted, the tube pieces were placed in their plastic sleeves and shipped to the 3abcock & 'Jilecx Ccmpany's 1333 224
D'9 @ * W' Vi
- D JfU a M. ; o
- i
. . :.. . .-:.. . . . .44,'_*
< -.-o
.. 27 7. / 6."
- g. ** ?.; .
.-u. .**mk= ..
N*. ..s
.* .L
~
^ ' ~ ' " -
' , ;. . ..,. . ~ ' ., 23,'97.16"f.' '. ..
PIECE I ' ~ ~ '
~*
U.T.S.--- -
.".3-
. . , ).::.:. . .. ..' -
'e . 28 3/16" + " *
. .. . . . . .... . . , . . - ;... . -c.......
3.'" . PIECE 2 . 4- : .
. . . . . . :c .
aw. , .
.n
,.f,. . ,. -
.....e
..... 27 3/4 . .. . . _
. w~ .e_....~ ,.: c:- v v. ...q. :.. y .:. -
. q.- -
II 3/4, -
~5'!Wa .h PIECE 3 8f TO TOP OF 15th S.P..
t - PIECE 3C J . .- c=!== - PIECE 3A -
,c . _ l
., ... 4 :., .e . . .;'-........... . . .
~
- . 14 5/16" !! 11/16"- ' '.. . .#:.'i __...
..v......... e: # ' - Il': :'
- l. .y.. : . . .-- .
m- . . ..
- ., . -- %. ,,.2..w.%
. - -- ~
- q. y ..%.G -2.E.3>~,.' l' [~3/,4. ,
. :.:. .s ",b.m' s.; ..du...
2515/16";:
~ ,
t _;?- ., _ .;'. .. .;.~- 19n. ~ 2 ,-
. . . ' -r' 9~4 8 4. . ...TO TOP OF 14th S.P. -
I. 2 ;
- M. . !, PIECE 4C N
. - 5:4;.J PIECE 4 A ' -~-- #i" t-9 .' - e-
. . =.- .+. < e . v-;*...r;w xen'; a ,.-s :g-:.2 .. . n. : / . r.- p' p . -:
-- _ . ._. :..: +-5 3/8 . : :-
~~J ~ 18 3/16" ' :
4Y
- m. 'C E4 "C:yq:W. 3 ythe.FIW.M-Df : f; - '
4 .
..e~ s.ye g '.n%'*y*$ M.
3/.8 ,, S- ~@1i%.dh.'y'.'3 su.g e.ppy ;z..;.. . . _ a . ..e ;-?e- - . e -
=
~.
G'3 h.*s:....s .-if..T 4 ., w..-.:.:.
..~
. :', M:' . . . . . . ..
~--;1. ::..u. . .
;w-
? JL.';h c = .~ - . j.. <
' $~ .:.'.. s- ._. hMEeCvfs*fi.-:. .55=4.g
".'WW.??znp* e - - - ..~ ' . f.7
. . w' .
.: . -fis.- *- .- ? '
- . .. e.. : g.,. ,... . 27 7_ /16," *~ :
.,z...~....;..
.;--.~.. .<
PIECE 5
. .y. . ..v:-
.. .s. .. .. . , .
3
....s.. ~. ..- .-.- = . . - . . . . . ..-,
.g- . :. -
s r y , figure 1. Schematic of tube 35-127
,... _ . . . _ :~ ., - q z.~. . - . . , . '
;. . c. . ,
. , . ~ . . . . . . . . w. ....9.,.
e. 1333 225 .
s FLOW o ,
,"X" . TOP OF UPPER X-AXIS W-TUBE SHEET- .- * - -
- 2. Y._ , ,
[ '
'85-127;.
.. n , N L , '
a e '.:.; . . 39;l.c.g,,. ,
', , MAJORoggga r
{ . _ . T n
;.<
- w W :yt . . ,
'.K.r:n m f.,q - . . M. ', ,
(.~ . MINOR y, - 9;45 .
.J' i
,C *'W !' DAMAGE-
; . s,',:
-: h4?'- g .. Wj W
d::*j , ..a lrc, i : , ?.c .r. ..':. .
, 3 , ".
~
a v
. ..'...*fm' def.a . .:t -. 'i , L ,,~ ..:
k .; , O}5 t; _I
' S
.."tW ", '.' l. . . ' -
e .. I a - _ _
- l.Q'
} .{..Yn . ,.., ,- y
- ' "' ' l:':6 ',
.; c 't '
. .1 ,
vt M,.s,y:l' s
....,,e, a.
. ?
> , >. ... n .' * ...s:
. ,.s
. m. W . -
; ,c ' 3. ,
w',4,. t.. 1, e. .o s.**i . p. . , el; g 1 y'l,,y# of- # .al ..,,.'..- .- ,
. l4 th .
a4:en. . )- i< ev... e . .> c, . .. e . . , - :i,. es s,v. a
.n +
- 1- . t ..
p.c m.. . .f: e; , .., ..,..: l.5 SUPPORT TUBE NO:
=.
i p .,a.,i.1 y,,b. n 'M'z
,j;ip't",$v fy ',7.;
T f i'ir ,f-. "95.'f: i- ,;,' W.7 PLATE.
'.M.. . :'. i,t' . . . +
.r T, ROW NO. a2u + .' . h..: . .! *t . OL
':f c6W.",,9' V lI.i'-l.V ' - i NUMBERING E v Z- -
;.; Q.' y' * : ,- [q' g;3 .q.g3 PATTERN . ROW 75 ., , .R,0W
' ,.': 77..f.t:o.$g)6,; , . J q . LAND. q, ', ' - - - ,
.e
,y
. .' '. . 1;. I} ,
.u :
ql J.^sf'16'd; v.;!(.e ^pt..e ' % 7'(. ',),:a;. CONTACT. ' ~"' f ','\ ' ['l, , g,
. .' 's i t; ..y.y[\[.'[.:p ]ly ; ,lfg.',,j.j,.' MARK ,{f. .g[.,
,...... t . . v. . , 4 .
e; i . . . . j. . . t*,4 ; d ' y.t.a . e s. . r. ., .s',.,' 4,s i.: ,. ,, , g, q* . ,
. ( 4. , i , , ;.,
g,.g ., 7, , ,.
#M .
Schematic alioving orientation and location of damare at ,' . 14Lla nupport plate elevation on tul:e 85-127 r
-- 'O ..
W _4
. , ..u .. .... .., -
3.,, c . .t . ,v". u u ., 3
~ . . N.g. 4g ... ..
. 7. , .,
Q .. .
, . .., .. i ,
W
~
m . p '
, h
Table 1. Inside Dia=eter Measurements frem Tube 35-127 in the Vicinity of the 14th Support Place Inside Dia=eter, inches 3elow Land 3ottom End Mid-Contact Top End 3etween Land Under Contact Mark Coe,eset Mark Mark Contact Mark and "v" Croove "v" Groove
.5514 .5507 .5513 .5513 .5520 .5519
.5518 .5508 .5516 .5520 .5517 .5520
.5502 .5515 .5505 .5514 .5522 .5511
.5518 .5510 .5510 .5516 .5514 .5521 2.1.1.2 Sample Sectioning as the examination of the damage near the 14th support plate elevation became more detailed, the 2 3/8 inch long piece originally cut from the support plate region (sample 85-127-43) 4a3wese cut into smaller pieces. These cuts were made with a Buchler slow-speed diamond saw cnd many of the cuts were located by marking the sample with the aid of a microscope prior to cutting.
Figure 3 shows how sample 85-127-43 was cut and what the various pieces were used for. 2.1.2 Photomacrography
-After visual examination, 35 =n Nikon and Polaroid MP-3 cameras were used to take icw magnification photographs. The areas of interest which were photographed on tube 85-127 included the following:
Upper Tubesheet Interface Region
- 15th Support Plate Region
- ~4th Support Place Region
- Upper Tubesheet There is a distinct circumferential ring of black deposit on the tube at its interface with the upper tube sheet. This fearure is shown in Figure 4.
1333 227
t 9 Lynchburg Research Center. Then, lengths of the tube pieces were measured, the ends,of the pieces were matened, and identification numbers were placed on the top and of each piece with white paint. Figure 1 is a schematic showing the length of each piece and the location of various features of interest. The orientation marks placed on the tube prior to removal (Appendix 3) were used to orient the observed damage with respect to the W, I, 7, and Z axes of the see.m generator. The orientation of the damage is illustrated in Figure 2. This figure shows that the major "v" shaped groove runs parallel to the tube axis and is located above the lef t side of the support plate land nearest the W axis. The groove starts at 0.035" above the suppure plate contact mark and is 0.43" long. A plastic castics of the "v" groove damage was =ade for use in obtaining a sore accurate measuremest of the sv4 um depth of penetration. Both an optical microscope, focusing technique and micrometers were used to measure the plastic replica. In both cases a maximum penetration af 0.024" was measured. For a ocminal tube wall thickness of 0.0375", this implies the damage extends 64:: through wall at the maximum near the top end of the "v" groove. 2.1.1.1 Inside Diameter Measurements A 3rown and Sharpe Intrisik which =easures diameter by three point con-tact was used to measure the inside diameter at six locations along sample 35-127-!3. The particular Intrimik used was specified for diameters frem 0.5000 to 0.6000 inch. It was aligned with a 0.4999 inch I.D. standard prior to use. Four diameters were measured at different angular rotations at each location. Results, tabulated in Table 1, show no significant changes in diameter either under the land centacts or under the "v" groove as compared with a location below the support plate. I333 228
f 4 4. X-AXIS W- Z- : Y-j. s [_ Hardness
/
48 -IB 48-IA Microche tical Analysis (
/ 4 8-II f =
T_, y,1,c _co %,ung j I, 48-EB 48-III A s
- s. Metauography L e -
. Microchemical Analysis . 'I r-I.
~#
48-I7 . A .
.x ..
1 :~ -, ~ . . -
< ~ _3 . -
~-
, ,a .
Figure 3. Sectioning diagram of the 14th support plate region of tube l 85-127 t 1333 229' . e e
1 I. 'E..,, h._ Th'. - . .
- 3. - g h
.$ix n.< .
t' h
. k , w;.3.a
,$ ~ ;5 M 1 l
. 3. h .\ *<f Pr tX
- M1Mgb('
' ~
; 'M Ii.
..- e
,d'
- Vy Figure 4. - --
Black circumferential band of deposit 1333 230
b
... ~,
?d y -
~
I :ka
.) ~,
I gl i le r ' k , j.f 1 kl i
$5 '
lkik :
~*.
f 3! r i l d' ' Figure 5. Typical contact mark at 15th support place elevation on tube 85-127 There is no metal loss or other observable damage associated with this feature.
"'he surface of the tube below the tubesheet while speckeled in appearance is otherwise quite clean. The portion of the tube inside the tubesheet is slightly darker due to some stains and is otherwise relatively clean.
15th Support Plate Figure 5 shows one of the 15th support plate contact marks. his = ark is the result of black deposit around the lands and scme burnishing of the tube 1333 23'
d
=r 2 ff .
k - k
' kl.:Mg.
N _ '?_v:n 5 g.=-... . piti F. I i.*~ t
=_ ___. _.
Figure 6. Major "a groove" damage feature above lath ~~ support plate land contact on tube 85-127
- - . T ...- -. _ - .
under the land caused by vibration during tube re:noval. There are seme light scratches on the tube which also resulted from tube re:noval. 14th Support Plate
~he damage which was observed at the 14th support plate elevatica is shown in Figure 6. A portien of the support place contact = ark near the 'J-axis of the steam generator appears at the bottem of Figure 5. The series of dark lines which spiral up the tube frca lef t to right also appear in this figure.
1333 232
A more detailed view of this damage area is shown in Figure 7.
$g ,:a.r 22, 'FE41_ _^-. 1%
~
g, . --- g -4 ." .v y M[w N [ : 1y n v. DM W
<.:M- M. 'r ig ? 3 r' >
- 4.n -*p-m x h77.3 l 9 ry WM.. . ..
~
~* i Ud 'd u }i ,
l .g ' ~ -
-e 73~ .-
.h;,
1 - I -M ( *. rN s > 3
',_ =- M
.a
$nM -
~~ -
D$ sbr 1 aQ%' -_%: bi- Ar,$ Wh gc;E_ q
,-- - _ - ww. . - 1 ::-
,, ~m
, c ,,
f .gW ~
~
y*- 1 1
- --.- ~ - ~ . . . . . . . _ . _ . _ _
Figure 7. Finer detailed view of =ajor da= age area shewn in figure 6- - - ne "v" groove nature of this feature is accompanies by scallops, steps, and undulati6ns in the damage area. . nese features are very similar to those observed in the " candle flame" at the 14th support plate elevation on tube 43-108 from Cconee 1-5. (See Figure 3.) nere are seme additional small areas of da= age along the right hand side of the "v" groove and at the left hand side of Figure 7. 1333 233
e,,;; g y
==- - -
-.f . -._*
. I fi I
?W-fW r Y -.mcs gh&g$;'i-Pf_. 2-1'::-
i,.- e
~ ~I
- p- -r ~
e_
?Es - ._ g ; u
- w. , .~y- ,
1 mm .,s
, i -- .
c___ _ e l . _ _ _-~= u.., :w .4 5 - w. - a 2.2 : l
.6 '4 d *
. f. s
, th *
, . ,%g'_ - ., ,.
i -e ...
.. g . ,
- ,s . , . .
^' h . t? '_
MSSI M iz_.d f
- Figura 8.
"Candla flama" area from tuba 43-108
* 'T l D*" D .D 1
A m es e . Wl . 1333 234
2.1.2
~~ A s=all " ball peen" area located near the top of the lath support plate is shown in Figure 9. This damage area is smaller but nearly identical in appearance
-"< -fT
_.I [ W;.+. . - h, ..-[$e. MN 3
. 2 '; - !
.y -: Q ;}:h % f o.s *'
l
.'34. , y % -
.9 .=3 3n
,' N .w
;3W '.
h-
^2kA<T ~
y ' _;% w- DKD
&,L & h. .c yp &M:
~N ". cT t Ms
' ~ ' - '
~ -Y . " ~W - s YMf '%.p -~
~
\
,h5 - ' u. .N
-I n :. m _
^ -
t,~7.cs. .- -.--__+2.-- .y a - * . E-f -e_
%',- - ah- n m - x.. . - ,'- i.W !
.a q sr:snas; - y -< . .
r *'
*= .
~;. .. .{. [ j .~ + - E Q' S @ _r-r- - y '
- ':. sl3 % - ."- . . h".4* .
g
-- . . .. , .. O % -w .
.,..y Q.:' . - &- %*'.p ..: g=.'.p^
* . - %g Tg s (I $'?g?M $lf&.
.m ,
Figura 9. " Ball-peen" feature coincident with 14th support place broach on tube 85-127 - to the damage seen above the broached region at the lath support plate elevation on tube 33-117 from Oconee 1-3 (see Figure 10). Scme very shallow regions of damage appear near the top of this figure. Finally, a small damage fracture located at the top of a support plate contact = ark is shotm in Figure 11. 1333 235
~
J' j -T. _ _ ^ _ _ _ _ .W g, , l;- '
;G 6
_t
~l ,
l' ?' _ _ _ , - - - *:.- r.
, s .
j.' r i
- _- g, I
r- .
- 1:
- m q_ -
<P 4
". N-
^
.7 .I,
! 'i N . .' .o 4;
r
?
i c
- l BR[' @ ._
Figure 10. "3all-peen" area ' rem tube 83-117 1333 236
~- '
E 7 _ -:'. $&.m
- r. h t
~ - "
%3'T. W89 ad-E
- =3f-;-Q .
?:
' .? L-'W2h '
f:. . . , f .-1. $ 5 f* , 73.
~~
tb) f' n. q
' . =ry,g
~~. =
-- ^%; -
k3-
^
% bd
-r.# m s .. .. .
i Q._ - ~ t # 6 ',j . , e,. Eb 2< N cm ' cr .. =_~_- _
=-
Figura 11. Small dat: age feature at top of 14th support plata land contact mark on tube 85-127 o{D [ Mkm 1333 237
>2 g;pq2x: & _w._ wm
_ = " ' - _ a--r w.
^
--' A *'%,'EN- _
,. w A
e ~~- q f -d
- r. .
-^ e.,x._..:_- %,= %.:.s.e_ -..
*- - efa
._e .
l' G i e-
' ~
G _~N-- 3 ,, 3 3
- x:- 47e-57 9 c- M 1
-S-gh myw.x
= - _ _ .
-G$sf - }T--"WR _~
~
%>,% - _ _ . , _ ^~ ,
r g
.~~ 7 --~~- l a
.x . ~
Y- - _ y34 j p
- 'JWF?$m -__=__
i . ,
; l m.
l gm .- a i
#-^4= w M E m'
^
mmww- z _ F'-[MM
.ry-:ys l
e sigure 16 g 7 Th"-f _w.pg l
- "x 7 -- _ __ .. 14 .
, y --
IT r . .
~n. *fT.Nb-M- I
'w._----- -
%QC
- w w"--
_y,_ z-k.
% ^ ' ' - ~
- - _ ~ ,'WMYC
%M7_.rwhl.*.~r~ik U
Figure 1/.. y *
- , I u, . .pf -
nigure 17. g _ _ .
-? "= , 2
_ .. _1,_ _~ -~ __ -__ T+ e"- -
?[ 4 irgii 6 $ _ . _ ; _El
.s:- m .A R: .
ypte
,-- =
TTm=W-T'-W5?W so - aq- _'_, _4Figura 13. - WWe ' ^ _&ML . - R M L_ - 42k=%5. _w :
-= g _ -5yp_w~-N, _ .
- O'E
Figura 12. Macrograph of "r groove" showing areas of more detailed examination . D 1333 238
2.1.3 I-Ray Radiography The total inventory of pieces from tube 35-127 was radiographed to look for damage which might otherwise be hidden. Each piece was radiographed at two orientations separated by a 90 rotatica. A standard =ade frem a piece
- of Inconel 600 steam generator tubing with notches of various kacun depths was includel in each radiograph.
' m fnation of the radiograph negatives revealed the following information:
. The depth reference scribe was 1.050" from the top of the tube.
. The angular reference scribe was not visible.
. No pitting was observed in the tubesheet crevice region.
. No natal loss is associated with tubesheet tube interface.
. Neither the 15th nor the 14th support place land contacts are visible.
. The major damage area near the 14th support plate elevation is quite visible.
. The small " ball peezf area approximately 90* from the najor damage is 0.001 inch deep.
2.1.4 Eddy Current Exa:nination A differential addy current probe similar to the probe used for in-service inspection was used for eddy current inspection of the damaged areas af ter the tube was received at the Lynchburg Research Center. Since this tube was no longer in the steam generator, there was no interference caused by the tubesheet and support places. Results of these inspections (see Appendix C) indicate-that removal of the tube from the steam generator did not change the 45-55". vall loss indicated by in-service inspection. 2.1.5 Scanning Electron Microscopy 2amage areas at the 14th support, late elavation on ube 35-127 vere extensively e:r= mined in a scanning electron mi;roscope. This verk was limited to surfaces in the as-r:ceived condition since the chemical cleaning process (Appendiz D) did not effectively remove the surface layer. Note that the scanning electron micrographs have nicron length ccmparisons in the icver left hand corner. The agnification is also shown nu= erica 117 at the lower left corner in a (number - pcver of :en) forsat. 1333 239
9mo m - 9-a . , 2.1.5.1 Major Damage Areas In Figure 12, the regions of the major damage surf ace which were examined are labeled with the figure number of the micrographs which correspond
~
to that location. Figure 13, an overall stereo view from the bottom end of the damage area, shows the undulations and scallops which are typical of the surface topography. Upset metal along the left edge and a darker appearance along both edges are also visible in this figur*. A higher nagnifications view of the upset metal is shown in Figura 14.
, l_ N f.f.l '
5 -l- :,'.$ '
} ?~-f.,
- $y,;. .., ._,
.i
~ .,g.,.p.,: 1 ..
. ,' lN T.$ ' ,'5 _ pg,I" i
,.. (.
,*- N-
>).'.,:$ ..%f ' ,s - .
V1
'l jg l ,
h ;
- .k fh
'pfM 7 '~
hh i I h Figure 13. Stereo view of icwer end of "v groove" This figure also provides a good view of the texture associated with the da= age surface. Note that the damage surface is smcother than the original tube surface. Figures 15, 16, and 17 show details associated with the surface of the "i" groove at three axial locations. At each location, the 500X 1333 240
$ 8 e
-e
. .. x 0
iner
=--
~ ' ~ ~
usur. 14. cy..e =. cat en 11. 1ere as. ce "< s:ee= " e ea 1333 241
j
,,3
, _. m n --
. % e w- c, 7 ' \*s %
7'K2** KTf:} g/ e. A ' g?g
- g *
- h '- ~'
- 1 .
y I.' s
'4 I
,,, n s.
. . , i -
e QI - k M f
.s N '
r n, .. e 2ki[M ds EUT2Ehh 'Wb
- b. 5000I magnification
- a. 500X magnification --
- T.~ ~ ~_ ^'Z'.-~.~., . . . .
Figure 15.. Features at top end of "v groove" area
.. c
~
.2 lW ,.
' ti .. -
.. g : ,
/
i
-egy <. .
*,.e
{
- .' . g=
- .w,
-.i. &4.* &. : ~ * ? i e *. ~. . k s.= w = = ' s i
' ~.
. c
- ..m u'
x.
= s. . . .w-.:M:v =. - n: eC=W-=?
.~. s .~ ,,... c .. p W J M fdiWdGm&2e<;$ ._ waegrigG;ii!> 5 m
** "I" *** " b. 5000I =agnificatica
~
- -. . . . '. '. ?. . . - - . . . - - - . . -
Figure 15. Features at siddle or the "i g:co se" area \ 1333 242
~
_3 4 h7. -/[)~fQ? %I"' -'
~ WY D f' 9 ~ L y ..
k
,' g ,
k
.. ; 1.+ a f6 N'?l4.s% '
'c - . , $. y$
f < 9& ' .= ... ? ( N: - '
.c :L_ . --
u; I. t f h .,g , - th
.~.. . b e5 . ,, Ks . .
- e f I
' n, '
- Ed-hkP__ '
f gy - __ -- _ # ww _ w_ ,__ *i= AAwir: [N 3-no y,- n k.N i
- _ -_.=__
Figure 17 _ . . . _ . . . .--=-- Featuras at bottom and of "v Froove" area Q.> g- %
,h L'~'&'bg, %E-N
,;EiSC?'"Kk:Ji M-~a i LT.; : ar JV r*~ - " Ii '
Q3 **
;= n '
y: ..,;
. -%g.N -r -
j
- h ,*, -~ ,_ v I}I ts .,. ,.
hnin -
- : : aw. w-s u :
- t. yg.<: M. p } . w .. . g W .. -
-Q;d;,y:c::eg,.
L A .it ?:~{
- f .,~- -
- - e
. . .a
(- 4 ? 2 %g f:~a. p~J.',
. V %., . z, :r.
_. m q>7 :- . , .
... g.y y 1
- b. ' '
. p
?
2Y
.~ . .m w u x ,g f n urus& _
a mamweaumm
- . _ . _ _ :. . na== 9- _..z -
Hiah sagnificarica (5000I) of surface features from " ball peen" da= age on tube High magnifica:ica (50COX) of surface 33-117 features fr:m " candle fla=e" da= age :: :ube 43-108 1333 243
micrograph shows a si:nilar surf e texture and the SCCOX micrograph shcws that a m'ixture of acicular and blocky particles covers the surface. here is a possibility that some sharp metal edges appear similar to the acicular particles in these figures. These features are nearly identical in appearance s those observed on the damage surfaces on tubes 33-117 and 43-108. (See Figure 18 and 19.) 2.1.5.2 Sc:all "lall Peed' Area An overall view of the s=all " ball peed' area between the land contacts is shown it Figure 2c
- 8 ~
$ k
' ' ~
ft ,(
-. - h* ..
,. . -y: 7.*4 ?.9 '. 'i *,,N T = '*gp?- i}
y"s ,
- _ . ~~. E - (}
~.-- , {4;)
#- _ t4
~
~~
% e
,. f' '
i- I t-d, y _-a-- [ IO ' A -- 4 . _ i* p- %E__ - _
,., q
_y
.ik?S -
. Wl, %5x. :p _ l~% ,
Figure 20. Small " ball-peen" area between land contac s on tube 85-127 There is 'a ring of material around the icwer and right edges which was apparently flattened by the tube removal process. The damage at this location is shallow, about 0.075" across in the longest direction,14 and does not have the well defined edges seen on the major da= age area. he details sho m in Figures 21 and 22 are typical of the surfact. near the bottom edge of the 1333 244
*]D ]} f D*}]D 6 v Ju oJu,Su.
- . 2 l M O M~ ,,lf% -
b .. T.9:'./,4)";.fY.'*W.?'
- p F # 4.si d
n ys .. - y N E', h N$ ey .Y, .? ,. _.y $ . ..yW% W } N._
~'
-- .- ;f. r.:-. ...
. ..? .
5*
. co ,N -
* . +f '
ik I Mi
.. % -y . M?' f '
b
~
. 3D.
%sp8% .4
.AA: ,
' ~
= I
_g ?M'is..,Qw??.~-
-W
- y a p , ,
WNJ m h h$- il % g7=e
- a. 500X magnification .
e 21. b. 500k gnification
~
Figure 21. Damage surface near lower right side of ,-
" ball-peen" area of figure i
',F A63 g - sm5sh k V $'M M '
k'
. gT .
l M-
- A s e n. M m-Nk -fe g" .
.A f ., ,
! .9
.. ^
.e: h~ ._ s.,.Qi.f
~~
Q "
,? ,p Nf;.'
. .. .- } .'g E=t.-
., -~.% O
.S Q?.$' p%y$~-
n - f V*M e. h-: <
- w. C rMf .s b '
..q. ? .>; .f. .>-.re ,
~y- . . ..
'- . .vE y
- n. . g..
9 %. . .o. g w mp; i m.-. , ..e - ~~ n h4= . WO N **Y ~~' k$I~ . . Y l' A Mh. .h -
. a. SCOI =agn.ification ' p f.p y g _. 50C0X =agnificatien . -
Figure 22. Da= age surface near 1cuer center of " ball-peen" area of figure
~ ~ ~
1333 ~24 T
s E f_T
% w~~
-.- %%. $. ric: G e w -WW4*PC__ _
= &,
.- h
. , Y%-w1 frww m--- u. % ~. 3 '*2
,_--. 2 5. @.
~
-_ w_,
e+ m- -- = s .
. -J _-g-n.
'.sn:= .m-_.39
..i , _ . 2**-
~ ~ .
- -;z --Qw 2Ws;:t9 .-m ;:. L v*,:=
- ~ Ww ;w&w .s m.--g:)i ;. ..c.- "93.~._~.*.2. ;5 - -m 7-- __ 2 7 @G + aM WQ - :.2 .s ,, ; .--**^~WQ p%'p'g %w9%vs=._
~ .
-- _ _ - - -m
- e==& g:5 ~- .,> _ w, _q AE ; _- W ,;,;r=_H 7 .-- ...e-- --
_& P a- f.- - - _ we=-w.1,G
= _ _ .
1-smwmE
~4 sw- =m-
.'s ~ ~ .<- .
4 -- -=:.w ,--- <m
--5:Y.iw Q32* 4 ;-56 W -- -
=2 .=. -
--- = ,#1%-R
%-%-y '-Q Q.Q
,,Er:S 'h-:- ' ~ ;h ^ _"E " ',reN ?
-:'%.C- ?-?d- % M.W .
& }
k .?d hy
^-M-'c-cr % =:- ' :-h'*-
L-%S; er, -c.:
?'
$ - Q' '.c..-.W
.* J -~~-
% -- P_ "%
lf. ~2. c-r
.wsw.c,yn -. .L > .. - --
w a . . w .. . n ~ ~ ,.,.
;,r . -.s w a r. ,-
s --
~--^
4 -- :=.%. n +,-= w
>;;. W. A.y M.,. m& Q i i % ,;; ,.-z @- - ;
- -==3
. s-
-M-+tc~e , -
m_.
.s ..h s . M .--. --
-.:= . M- : . . . . e.mp'~. K. .py
[Mw . .m
. . = .%.--- ~,
. . _. ww--
g ,- .; .: ; ---2::-1y W-_. " g-- -m
-w _scsR;t2*- - x..- ar
. ~ . ,m r . . _ _ , . - u w.a - _-
.. ,. . . e: ; uw, we..w.:: :e
, NW h;_-DI~.. -'
hM :~.;' ' ' .
- 3,,', ..'_
=~ = sE' =- w =x- 2
,-t~..x-:Q%~,... .s% %
-r .
.w-? - - --
. . '"Aq
~
$~h * ' _'- - . A . .c ,
- i- :. 2 om
_.1 . _ _ - -- . . , -4
. ' ' . .%.a.r %%~-
-- - ;;1. '2 -1.L- _ .
-% ,. an ' -
Yl7 E *mr,,- -
**Q
***E#fW, _ . - .------eiggg
-N .
- N hawg e.gure ag se* *O
*W Of small " candle fla:1e" area found on tube D A^ D *D 3'l l a A J W@ L 1333 246
" ball peen" damage. The 500X micrographs show features which look like overlapping met'al fitkes similar to those sometimes caused by fretting. he 5CCOX micro-graphs show the mixture of acicular and blocky particles usually found on the damage surfaces. Close ex mination of the blocky particles reveals that some df them are fractured and apparently stuck in the surface. In at least tso cases, there is a hint of some surface damage forming a path up to a particle.
The 50COX sierograph in Figure 22 also shows a slightly faceted region in the center where the " facets" are of about the same size as the blocky particle. At 1 Sm or less across they are much smaller than the grain size of the Inconel 600 base metal. 2.1.5.3 Small " Candle Flame" Area An overall stereo view of the smal* " candle flame" da= age above the support plate land contact (see Figure 11) is shown in Figure 23. This damage is oriented along the tube axis and measure approximately 0.C60 inches long by less than 0.010 inches vide. The edges of the damage are sharp and well defined like those of the "v" groove on this tube c.nd those of the " candle flame" ~ damage on tube 43-108. There is also a hint of upset metal at the lower left edge as shown in Fiipare 24.
.$2%,'
M w 2Ir
. a .w .
~
i
;bYhD . -
42*;f, 9 k * : f. . ,'- 3 q-n ..,i r T .M r s.5. g
~s . .w .u
. i* Ya -
.. T ,
D\ r S,G%.Q', * . _,; _~ W g -
- 22'{-
.- s-a. -- m s- .
M s 9 ' '..:- .. .C t. r p v -
;,. y W E.i ? h A L -N & % )? G h .... :- .. & ,
'.3.-Y
; ~. .
M .4.:= & f.%j.f-U-Q Y*;
,. . :a .
~.. l
$ :,4444.e . .. . ..
c
.. d .1
~ - R H -**
c- .7;hw.qg'~ .:.
.:;?.
"" ~
,. : 4 9
-.a --s*_ . -W : ._ . . ..
\ ---. .-
Tigure 24 Lo**tr lef t cormer of small " candle flame" of figure 1333 247
Oh 0hhhhh&k G 7. - v 4whg' ygg
.w f .3
..,b..
W pQ %}s'#R.h<b@ v
.s m[ W g % ' - -
- E f pv.g e, hS . m. -g., N?i i w w cq.9.t#
+ 4 '<q
+hig 9 1.,:.- c
.. ukp ,.
c f. -: p , 4.'.i2 yfu@r = ..
.. y ,:
r- - c.
+ -
. . ,_ y-.e.n%
s.- ;.T 9 4 c . sy; 2 l h ' '~. '
.? Q.i.;
,yrx - -
g "- .W.a, {'( .
'. ; g+ -.fy(%., -
.i x.$.sg.h,,_
/ s-g.e ., -T.,.
r" 9'/ i -- gET % 4; #t+J, %SD .i h c J.. y I... ]te '*
~
tfii b,- w; ;.- W- - c., .r
*.7 -__ ~"f*[". f %fx ' ^ , ,,- .
so g , '_'&p f, 4 _-~~ __
'Q' ,
Figure 25. Surface details of small " candle fla=e" of -- - figure 1333 248
The 500X micrograph, Figure 25, shows the surface has an " overlapping flake"
, The 5000X appearance similar to the small " hall peen" previously discussed. lly nicrograph in Figure 25 shows the mixture of acicular and blocky particles typica found on the damage surface.
2.1.5.4 Snall Pics A small pit shown in Figure 26 Iccated next to the land nearest the _ _=_ _.9S
- - - - - 7m w
mm _17 ' Npe~r =em ' r - %---q _? - __L - ap,,-
- g. _ __ 3 m ,,_ ; - N -jDC
-w
.---2 .. Q G _~ m
- , _la-__W.R' w .
c -~
--~
D I D D
- m ..
~= .
g A U
":5'L
-g- --
- =
[h yer h n w{ 93_ ~
~ _ g- :
- =__ 1-=
^ - -~_ ;
=-
m; 3A Figure 26. Sna11 pit next to top of land contact nearest w-axis of
,,, tube 85-127
'J-axis of the steam generator.
This pic is slightly to the right of the land This contact mark and near the elevation of the top edge of the support plate. em- ti c Mn. It appears to be pit is less than 8 mils across. shallow and it is surrounded by a dark ring of deposit. Some small pits were also located in the land contact mark near the 'J-axis as shown in Figure 27. These pits were faceted and relatively clean as shewn in the stereo pair of Figure 23. 1333 249
.y' ..
3 .. ,
*. [ -b4 . b ,,
l . .
\
- --^' % -4.'y.. i;,' *
=.x o
<.fI/ *
,s , .
" ~
- g. f
- w. _ .g;. ;
,. A.- w O "
n'C hM m r- _ m.3- m". D ~;. . ._. -, ^ - s ,, . ,_
- s w.- 1 <
s .m
$ _, Q '
. - ^
r~ *ate
- =
t.__ ___._,_E ~ -
-a Figure 27. Pits in contact area of land nearest v-axis of tube 85-127 h ~
". ?-- '~
. -A ,
..n? [ ' _ _ . ., ,--
4
-g&?
g$3 _.-
-.. , . . . ~
_ gm
- g y} j w
if I. A nu.- . i.Q
~
f s a '. .5 4\ --) . 3 g, . b.., > , - r. - y,. o'. s .' .
*y . 4
. eb
, . m y. . - 3.- ,,
..c p =- <
R(. '
> s- ' . . - 3 <
E. ., g- * %
,7 ;
k W
, .. 'C;; ,
?
l _ N' -"- ^g..
. -3.Q*r-._m_ : -
--Z^'*-e-L rc-_- w/~- __
an. ~
.; T .p g,.#g
- MT s g9 g?w:. '
p;.y_'- ;;rs _qt _ w.- , m. ~ aye A.+w-An k.k Fir,ure 28. Stereoview of a pic frem land contact area. 1333 250
1 b
. .~ ~
- _ _ , _ _ me - ,..=m '
. p;i.g* "*MfeQ* l
- - - :=-
, Pf*~ _'_ .
T_*. , _ _ Y '
- peg Q' w** 3 - _ _ . ,
~f a ~ a&ulg'55 i
\
~'
s . M
- . ":.2 q Y -
.. ,~.,. 9? ~' ,L Y - -
;.i:[fe?}
1.-a n.8
~
#s
.c. . -
4- @ ~.gg'.
<8.vm 7 'y=/9 P .s_'. :3,I 37.
r ""H3 g7a Figure 31. High nagnification (3700X) transmissien electron stereo-micrograph of laboratorf ._----
- -- -- produced erosien.. --.
1333 2;l
+e Figura 29. Teaturas which resemble smearing of the
. 1 surface on sputtered samples frem 35-127,
~~
43-108 and 83-117.
,,g, .$. , . ,; n ~ ,-. _ _ _ _
c' W
~ Y
. 5*. - .,-
~
.?. 'sQ q :-RWA? l
[s.,m m >? .c-
- hh2 5 * ~ ~ ' . i$bf u
? ~~
.e-
*. (:;rp-s.M, + 's W - v + y.:.w I Mn Wow . "
's
'"8
$;.,.?ifd$ y ye L' .t'...
t h &. i, k s ? -
~-% . , . 2m .a;,
>- a =: 4 we.$. _'~e so
&w Q. ~. ..
N 'a' b ,. 3,.,e [~~ (,,.. ; .
+ 7 ;g* @, 1<MEIWCl _.:.3.$-a -
3me.!siy)-
"v groove" #
\
Figure 29a Tube 85-127 t
~ ' * ~
Mi D *D'3~} o . b-.
}
n
~ .
. s
. -; . - . ~ m
, p.
~ '
s s,... c. % Y ft f ,$
? , %ta .
h.~,4 ,- - %, 4 e s. {&.
' S g , 9 2,m,. Af ~..$e
<:x - A.4 -,,;
i
.'Qs-, ,e.g?gh. ~~ . w s
-r ..
- g. .
'Q .
. ,f bh+ . k
. t r4
, < .N .
+ -
?.W. 'Q' _
- w.1
' NWN'2'@'%
- .-i %.m-:h' .
R4 hu--%..
\ ~ n i. . .u+ . - r-u. ~_h igure 29c. ~ube 33-117 " ball-peen" Tigure 29b. Tube 43-108 "candia flame" 1333 252
! .. o m- ' '@- ~RM - i 1 .- . ,
. ~s y, %. _2Mg' -
*hy,,M. g-4 4'..
uY 's ,c-6 - x-2YI q Ner>. 'Mkx ~ [p$@,.
, 1 p .- ,
w y ..-
- s v -
p .
~
w- . . .
~
..'~
Figura 30. High sagnification (37COX) cransmission -- electron micrograph of "v" groove
- -- - . -- =..._. . _ . - - - - - . . .
~
1333 2s3
-2 .1. 6 Transmission Elvetron Microscepy (TE4)
Faxfilm plastic tape was used to obtain replicas of the folicwing dar. age areas:
- 1) "v" groove on tube 85-127
- 2) small " ball peen" on tube 85-127 g g,
- 3) large ball peen on tube 83-117 O g
[]
- 4) " candle flame" on tube 43-108 j
- 5) a laboratory preduced erosion surface
- The primary replicas were carbon coated, shadowed with precious metal, and then dissolved to produce a shadowed secondary carbon replica suitable for TDi
== == 4 am tion.
Unfortunately, this work had to be performed on samples that had previously been used for microchemical analysis. Therefore, a number of the surfaces available for examination had been cleaned and possibly ' altered by the argon ion sputtering process used in conjunction with the microchemical analyses. Figure 29 shows a ecmparison of TD1 micrographs frem the sputtered sv.rfaces of the s=all
" ball peen" f rom 85-127, the " candle flme" frem 43-108 and the large " ball peen" from 83-117. The cleanlinesc of the sputtered surf ace is obvious when ecmpared to a TDi of the as-received portion of the "v" groove (Figure 30) . All three views of Figure 29 show features shich resemble a directional smearing of the surface. There is a great deal of rese=blence between the sputtered surface of the "v" groove on 85-127 and (.71gure 29A) the " candle flame" on 43-108 (71gure 293).
An unsputtered portion of the "v" groove from 85-127 is shewn in Figure 30. While this surface is not as clean as chose shown in Figure 29, the same directional smearing of the surface is evident. This micrograph can also be compared to a micrograph frem the surface of a laboratory produced erosion sample (71gure 31) . The laboratory pecduced surface is cleaner and the features are more coarse in appearance and better defined. However, there are strong resemblences in terms of feature sizes and shapes. Note that the 500X view of the laboratory erosion surface (Figure 32) had much sharper features than the "v" groove surf ace (Figures 15,16, and 17) .
*J. S. Rovder, "Results of Limited Test Progr:ss to Oetermine the Appearance of Cavitation and Erosion 3cmage en Surfaces of OTSG Tubes", LR: 79:5543-74:01, Research and Development Division, 3sbecek & *i11cox Comp:ny, .Cliance, Chio, June 1979.
1333 294
I 2- .
- u, m 9 .,
u f . _ , ,
'h'jh'te 3 iq ( , -; ".h -
)-. klj
' ~
' (,J "' ~'J -
- h. %.e.:
er -
- w g.]
g D "
.h" ..I '
S
.x 4
g g. -
,56s whh% -
; -4%' '
i s.' I g. , I Q I I -.
-- di
- ' web 5 Figure 32. Scarming ekectren micregraph of laboratory - - - - - -
produced erosion (SOCI). 1333 255
~
Figure 33. Depth verses At:mic percent of ele =ents found is surface f- en tube 35-127. . D[D
. _ _ _ _ . _ . _ . _ . - WJ o_.
o D
.L a 60 -
60
- OIYGDI
. NICKEL w m z e.
p.i 4: % At % ( iuSE CMAE 20 , a 20 , j IAE % CMAK v i I t i 1 1 f f
,, -20000 -10000 , O 1CC00 -20000 -100C0 % 0 10000 L M TICM A LOCATICM$
30 20 ID OIRCMit71 20 . 20 . At f. . . At.7. 10 .
- % 10 ,
' DME TUBE " DMAGE
/
TUBE p f f I f f f f , e
-20000 -10000 0 10000 -20000 -10000 0 P:CCO 14 cl.S e d' t.o u h e I 30 . 30 ,
SILICCM ,, ALUMINCM DMAGE
' -- -1 *
- 20 . ggjgg NI*20 his /
t 10 - to .
;/
a
", e . 2p(*,*)
TusE - .- TUsE .% f I t i I f I i
-ICCCO ICCCO
$ - 20000 -10000 - 0 10C00 - 20CC0 O
[aesio1 h ' ? <: .-
- f 1333 256
2.2.1 Energy Dispersive X-Ray AnaI/sis (EDX) This technique utilizes a focused electron beam to induce x-ray emission fren the sample surface. The flux and energy of the characteristic x-rays are measured and used to obtain qualitative chemistry of the material being analyzed. Since the x-rays can escape from depths on the order of one micron (10,000 A), technique vill penetrate thin films. Qualitative chemical analysis was perfor:ed on many areas in and around the damaged regions on tube 35-127. The sample surfaces were in the as-received condition for these analyses. These analyses were performed on two different energy dispersive x-ray systems: the EDAX system at 3&W's Alliance Research Center and the KEVEX system at 3&W's Lynchburg Research Center. The cata were normalized so that comparisons would be made between data obtained on the two different systems. The normalized data, normalization technique, and location information all appear in Appendiz (( . A limited amount of data obtained from
" chemically cleaned" pieces of 43-108 and 85-127 are also tabulated in Appendix DEI .
~
The following infor=ation applicable to all three tubes can be deduced from the EDX data: The electron beam is penetrating the surfree layer on all surfaces and therefore the iron and chremium responses are about those expected for Inconel 600. The nickel response is lover than expected for Inconel 600. Silicon and aluminus are found on nearly all surfaces.
. Traces of S, C1, K, Ca, Ti and Mg were frequent *y found on all surfaces.
In general, the EDX data give the impression that the sample surfaces are reasonably clean. Analysis of various particles on the surface of 35-127 show the blocky particles typically contain CA and/or Mg and/or iron in combination with silicon , and aluminum plus trace elements. 1333 257
2.2.2 Auger' Electron Spectroscopy (AES)
~~
AES utilizes an electron beam to excite the surface of the sample and produce secondary Auger' electrons. Auger electron flux as a function of electron energy is then measured and used to identify chemical species and obtain semi-quantitative atomic concentrations. Since the low energy Auger' electrons can only escape from within~20 A of the material, this technique can be used to analyze very shallow depths of surface materisl. An Auger' instrument can be operated in three modes:
- 1) a static =ede where analysis is performed on whatever surface is available.
- 2) a stepped : ode ehere successive layers are alternately analyzed and then removed with an argon ion sputtering accessory.
- 3) a dynamic mode where sputtering and analysis are performed concurrently to obtain concentration versus depth profiles.
All three of these modes were used to some extent during this work. Oata obtained by these techniques are shown in Appendiz F. A number of locations in and around the "v" groove damage on tube 35-127 were analyzed in the as-received conditien. Also, one location inside the
=mm11 " ball peen" and one location on the adjacent tube surface were analyzed on tube 85-127. A limited amount of data were also obtained from danage areas en tubes 43-108 and 83-117 for comparison. Scme significant results of this work are discussed below.
2.2.2.1 Concentration versus Depth The instrument used for this work was interfaced with a miniccuputer so the data was analy:ed and plotted as the sample surface was being sputtered at a race of 300 A/ minute. Data obtained fr~m these depth versus concentration pro-files were replotted as a function of distance away from an arbitrary nickel equal oxygen reference point.* These derived plots are shown in'Tigure 3j . Positive locations are toward the base metal and negative IOcations are toward the outer surface. The data from tube 85-127 presented ;at Figure ;3 indicate the following:
- Due to the dif ficulty in locating an exact interface the nickel equal xygen atomic cc,ncentration was selected as an arbitrary reference poin:.
133t3 258
. The thickness of the surface layer on the undisturbed tube
;, is much greater than the surface layer of the "v" groove damage area.
. In the case of nickel, chromium, and oxygen, the change in concentrations from the refere e point to the outer surface is approximately the same for both surfaces.
The silicon and aluminum concentrations are significantly higher en the damage surface than on the tube surface. The iron concentration is significantly higher on the tube surface than on the damage surface. 2.2.2.2 AES Analysis As-Received Surface; Sputtered Surface (15CCA) LES rpectra obtained on the as-received damage and tube surfaces were averaged to obtain the data shown in Table I. . Examination of this data produces several interesting observations. Table 75 AES Data from As-Received Surfaces and 0 1500A Depth en Tube 85-127 Concentration, atomic : Element Depth Location 0 Ni Cr Si Al Fe Mg C As-ReceivAd "v" groove 30 4 23 19 2 22 adjacent tube 8 1 11 7 1 5 70 1500 A "v" groove 35 12 17 23 2 2 7 adjacent tube 29 3 1 18 14 4 4 26 As-Received small " ball peen" 20 2 5 17 11 1 4 38 adjacent tube 13 , 1 12 5 1 6 56
. The carbon content is high on all as-received surfaces with carbon levels on the tube surface exceeding the damage etrfr:es.
. The carbon content was reduced considerably by sputtering away 1500 A of surface.
. The outermost damage surfaces are higher in Si and Al enan the tube surface. This difference is more pronounced for the "v" groove than for the small ball peen.
. The ball peen damage surface appears to have a higher chromium content than the other sample areas.
1333 299
2.2.2.3 Comparison of AES Data from Tubes 43-108, 33-117, and 35-127
~
The sattples from 43-108 and 83-117 which were used for Auger' analysis had been chemically cleaned by a procedure similar to the one outlined in Appendix D. Thtrefore, there were some differences in surface chemistry between these samples and the major defect on tube 85-127. The data of Table 3 shev thes s differences consisted of slightly lower silican and aluminum content and higher nickel content on the cleaned damage surfaces ce= pared with the as-received damage surface of 85-127. A ccmparison of concent:ations at the arbitrarynickel=oxygeninterface(seeTablek') shows she chemistry of the damage aurface films is nearly identical at this location for all three tubes. The data of Table.N also show the surface fils thicknesses over the d uage surfaces from 85-127 and 83-117 are about the same. The surface layer of the damage on 43-108 is approx 1- :ely twice as thick as the others. 2.2.3 Electren Spectroscopy for Compound Analysis (ESCA) ESCA is perfor=ed with a slightly modified Auger' analyzer, yor ESCA, an x-ray soutce replaces the electron beam as the excitation instrument. '41th the x-ray source used to excite the secondary electrons, electron bonding energy determination as well as semi-quantitctive chemical analysis can be performed with the system. The electron binding energy information is of particular interest since it can be ecmpared with tabular data to give additional information en the chemical compounds present in-the analysis. Analysis depths on ene order of 20A are typical for this system. However, due to the x-ray source used for excitation ESCA requires a relatively large sample area. Therefore, it was impossible to obtain an analysis which was confined to the surface of the "v" groove on 85-127. In fact, the surface of . the "v" groove probably made up less than half of she area included in the cnalysis. Available sample areas from 83-117 and 43-108 were too small to use this technique. Jacc obtained by this technique are tabulated in Appendix G. Quantitative chemistry obtained by ESCA from the area which included the "v" groove is compared to the chemistry of adjacent tubesurfaceinTableh. 1333 2e0
TA3LE )) Ccmparison of AES data en as-received surface of rod 35-127 with the chenically cleaned surfaces of rods 43-108 and 33-117. Element Rod Position 0 Ni g S i_ g g g C, 45-127 "v" groove area 30 4 - 23 19 2 22 43-108 " candle flam " area 29 9 4 15 10 2 22 83-117 " ball peen" area 29 9 2 17 3 1 2 27 TA3Lc. Comparison of AES data frem tubes 43-108, 83-117, and 35-127 at the Nickel equals Oxygen reference point. Atomic percent concentrations
** * ~
Distance frem su.rface Rod to Ni=0 coint O Ni Si Al Cr Fe S5-127 5100A 34 34 7 5 9 4 83-117 4300A 35 35 6 5 3 3 43-108* 9000A 35 35 10 5 10 3
- Data corrected to remove carbon and titanium which are thought to have resulted frem Ti(C,N) being present.
. 1333 241 9
2.2.4 Secondary Ion Mass Spectroscopy (SDS) SDS is in effect an attachment to the sa=ple cha=ber of a Auger' surface - analysis system. B is system functions by using argon ions to sputter the surface of,the sample. De secondary ions released frem the sample surface by the impact 17g - arjonarecollectedand analy:ed with a Quardrupole mass spec.tre=ecer. ~he analysis is a dynamic process which is carried out as the surf ace layer is being sputtered. Thus, the analysis typically spans a depth of 1000A. This technique detected .the same major constituents on the damage surfaces and the undisturbed tube surfaces of 85-127 and 83-117. Based on the corrected SDS peaks (Appendix )( ) the major constituents on the surfaces are: Nickel Iron Aluminum Chromium Silicon. nese elements are consistent with those detected most of ten by energy dispersive x-ray and Auger' electron spectroscopy. However, this technique seems to be more sensitive to sodium, potassium, calcium, lithium, and manganese since the lov levels of these elements were detected more censistently by SIMS. Since tube 83-117 was chemically " cleaned" and 85-127 was not,, it is difficult to make meaningful comparisons between the two samples. However, the surface of the " ball peen" area on 83-117 does seem to produce a seronger chromium response that the "v" groove surface of 85-127. nis is consistent with EDX data but is not supported by the'AES data. SDS data were gathered from inside the da= age area and frca an area or che adjacent tube surface on tubes 85-127 and 83-117. ne entire series of ele = ental l and complex ions observed by this technique are tabulated in Appendix M . Large peaks were typically =easured on all surfaces for the following ele =ents: sodium chromium magnesium iron aluminum nickel - silicon manganese calcium oxygen potassium Several complex ion for=s of silicon vere detected. nesewereSi+,Si[, S10+, and S10H*. CarbonappearedasCH(,C',C[,C},CH 22 Oxygen appeared as 0*, 0 +, O, O , OH+, and CH'.
~
In addition, Cr[ and FeO+ vere detected.
, 2 * .
1333 2A2 4
3 1 l At comparable sputter depths ( 1500A) ESCA reveals slight differences in the 9
) magnesium and oxygen contents between the damage surface and the adjacent tube surface. However, the difference in silicen andp,u alusinum contents of these two surfaces shcun bv AES is not seen by ESCA. -Conversely, tF.e difference in carbon w e'-
content shown by AES '.s not shown by ESCA. This[, probably z results from the j larger analysis area utilized for ESCA masking local variations and the fact that analysis can't be cen#ined to the damage surface. Electron binding energies measured at the two ESCA analysis locations are shown in Tabla h for major elements.* These binding energy results seem to Table f Electron 3inding Energy Cemparison for Tube 85-127 I 3inding Energy, electron volts
***"E Al Cr Fe l Locanlon O Ni Si ygt C i 1500A from surface 531.7 853.0 102.6 74.7 577.1 710.7 54.0 234.5 of "v" groove damage 1260A from outer 531.8 853.2 102.7 74.8 576.9 710.6 284.5 < tube surfa.e
- Table in Appendix C has listing of electron binding energies associates with the major cicments.
y _-
,- y , . -
2 1333 263 d 1 1 A W
indic to the same ecmpounds exist on the damage surface that exist on the tube
~
sur[ ace. Cnce again, this result is clouded because the analysis could not be centined to the damage area. In addition, there are several results which vere ieduced from the high resolution ESCA Cata (Appendia H) by Physical Electronics, Inc. personnel: . Large amounts of nickel are present as free metal. Of the combined nickel, Nio and NiOH are ruled out.
,k +%And+5
* 'ron is present in a huee oxidation states and as free metal.
Fossible ecmpounds include oxides, silicates, aluminates. Chromium is present as Ceg o). Aluminum and silicon appear to be in the same compound based on the relatively constant A1/Si ratio observed in the depth profile. Aluminum is oxidized. Silicon is present as a silicate.
. The carbon observed on the surface by ESCA and AES is either graphitic or amorphous.
m. Table , Comparison of ESCA and AES Data for 85-127 Atomic Concentracion, %* Technicue Location O g g M Cr, Fe 3 C ESCA 1500A frem"v" groove 38 6 12 11 3 30 surface 1260A from outer 24 3 14 13 3 5 8 25 tube surface AES 1300A frem "v" groove 29 3 13 14 3 4 31 surface ** 1500A frem outer tube 35 12 17 23 2 2 7 surface
- total not necessarily 100%
** average of four runs =ade at various locations
~ ~
1333 2e4
~
2ggJ Electea. 'D'.!rtr w en -
. anly a very few crystalline particle fragments were successfully removed frem ,
surfaces of the "V"-groove and the " ball-peen" by means of two-stage replication. Figures k and 35 2how transmission electron photcmicrographs frem carean replicas of portions of the damagelsurfaces, with attached particles of interest. Tne electron microscope was used also to obtain electron diffraction patterns from the crystalline particles. Analyses of the electron diffraction patterns obtained revealed the p:obable presence of an Fe 34 0 particle on the "V"-groove surface and of y-Al 230 particles on the " ball-peen" surface (refer to T2bl i. No other diffraction patterns were obtained. The replication procedure extracted fewer particle fragments than anticipated. This appears to be due to the relative cleanliness of the damage surfaces. It is by no means certain that the particle-types which were identified by electron diffraction analysis are relevant to the damage mechanism. To W 7 , , , Sets of Interplanar Scacina Values (A) V-Groove Surface Ball-Peen Surface Particles particles g v- A1.,0
-3
. 4.35 4.85 2.96 2.53 2.53 2.41 2.25 2.28 2.09 1.94 1.98 1 .71 1.61 1.48 1.48 1.37 1.30 i
1 1333 245
' kis
* ~
l
~
-.. $ yhy .
*- ' ^ -=
0 7: Nh gl l N:&.;h.??h;?$f[.Ys;ftk. *
- ?%
l}
~
n )_ ;h .
/ ,- ,,
$.. x, -
*S
$ pi
, f * ., frh M
-s 7y
' RW T ,
_ ' ' ~ ~ ~ ^.. '~ L, . . 4 ;4 w .
- o. ..
4 , %- v G_n . y ,
- %. 1.'.' y
- - g, ~
- y.. , _.y4,& ' ~ : j,,
p we y-_y . . _.z ,d' ,m
. # :, i
[. F j .y Figure 34. High nagnification transmissien electron .. */ 1 micrograph (18,000X) showing Fe 03 4 partkla -
, obtained frem "v groove" on 85-127. ~~ ' 55--- - - .x,, - . - '
r p-:- .s .,f.h5 :-Ly ? it. . c , dew- .=Fi&~W@- h?ik63 .g= -. 4 .(.& f:.e * :d. ' EQr-Sit _%s....b4 i H s .:- . i.r - F,:.yl.- w M :M W . ,, %.. C 6.95n 6 5. 8 . 9 . 2 ,' :" '
>,.> - ,w : r- -
f . .si ?... ..:% - ';.
- s. -s- .-q ' ~
D M et @.c4.-$?f=c 4 : ' => g e-..;r. s g-? %: ;- j - V9.:#:%.-
- s.f. mp;ft;-;w
~~ a,. E,...
^ :.y t'a. . -
.; j f..,&%
. ? . "Q,,.h.. .4.
~<
,Y -
' J.. .+.~s?.x,f.'.-l.f,
. .. i*,. - -
t _.5,.
~Tf y , '
}.[.'z .s y;. 3] fah .x f;. :,T~.
^i
~
1 , f'g*> ~ .h'
. . if.$ {/ c. u.X / f -
{o'" 8 - - _.
,< ;h,* i I
a' ' ab.
\
ff .* -- r y .E n/p l:.t'. W9p. .37 ',' '.l". .- . , 'I..i',,.e,.:%'.,Q,&..
- - b N .*: !:).t*4.E _. l f n T>,.';-?.i'.?--h . hC'1 u
,i /)j&].$9-k n
.i g. h .. /-.;x.. .;'. -
< :.. ; f,
.g,.- <.
.2 nf . .s_. e-Figura 15. High =agnifica:ica (13,000X) ::anscission Y,, '
e.f ' ' electren nicrograph shewing A1 23 O E*rti#l**
. =b:ained f r:m "':al!.-peen" on 35-127.
1333 246
J - 2.3.1 Electron Channeling , An electror channeling accessory is used in conjunction with a scanning electron microscope to generate a type of electron diffraction pattern from polished crystalline surfaces. The more perfect the crystal, i.e., the lower j the plastic strain, the sharper the channeling pattern becomes. Thus, the relative sharpness of the channeling patterns can be used to estimate the relative strain in a single grain of material. This technique was utili:ed on cross sections through the damage area on tubes 35-127, 83-117, and 43-108. This allowed electron channeling patterns frem grains very close to the damage surfaces to be qualitatively compared with patterns obtained frem other areas of the same tube and with the other tubes, W Since this technique analys'&s shallos regions, sample preparation to remove deformed surface layers is very i=portant. In this case the samples were: (1) cut with a Buehler slow speed diamond saw (Isomet), (2) mounced in epoxy, (3) lightly ground with 600 grit silicon carbide followed by 600 grit soft microaut cloth, and (4) heavily electropolished in a solution of 5: perchloric acid in mechanol at -20*C. The electron channeling patterns were generated by Dr. D. L. Davidson on a specially modified ETEC autoscan scanning electron microscope. This work was conducted under a purchase ceder to Southwest Research Institute. The larger grains ( -30pm diameter) in the microstructure were utill:ed for analysis. A ~10p diameter electron beam was used so the channeling pattern czae from a single grain in most cases. Edge effects, probably due to rounding of the edges during electropolf.shing, prevented working as closely to the sample surfaces as desired. The channeling patterns were . ranked into four categories based on an qualitative assessment of the sharpness of the pattern. With this system, a rank 1 pattern represented the 1 cast amount of defor=ation and was clear enough to derive crystallographic orientation of the grains. At the other end of the spect- m , rank I7 represented the most deformation and essentially no pattern was visible. The ranking of patterns by location is phm in Appendix and results from each l of the samples are discussed below. 1 1333 247
2.3.1.1 Sample 85-127 II -
~
~~
Channeling patterns were obtained at the locations near the major
~4 damage area shown in Figure.s ( . Rank I and rank II patterns are typical of the undisturbed grains in the bulk tube. Rank III patterns were obtain within 100 m of the surface in areas 1 and 4 and indicate some information on the side and at the botters of the major damage feature. Rank II patterns within 100 m of the damage surface at the junction of the damage surface with the outer tube surface do not indicate information detectable by this technique.
2.3.1.2 Sa=ple 43-108 Locations where channeling patterns were obtained near the " candle fla=e" damage are shc'in in Figure . With one exception, rank I and II patterns are typical of the material away from the damage area. Also, with one exception, rank III patterns are obtained within 100 m of the damage surface. Thus, mechanical deformation above that expected for the bul's nacerial is indicated near the damage surface. Two rank IV patterns were obtained frem this sat::ple. One of these came from very near the' inner tube surface and =ay have been due to an edge effect. The other one came frem near the junction of the damage surf ace with the outer tube surface. This one probably resulted from the mechanical Jamage which occurred at this location during tube removal. 2.3.1.3 Sample 33-117 Figured r. hows where channeling patterns were obtained near the " ball peen" damage on tube 83-117. Patterns obtained at distance greater than 100p m 1333 2A8
&~
". ] [ ._ . _z-- M'
^ "
. . -E -
@= NT, 9 _
~ -
- .~
_ w .. ,
.- T .g gw$,0 .
I*. s.s- - - - s
- i .'. :
s'12 o. 7'E.R j i ,'hf!:.?. ;lo ? Q> l$.
~
s :. P* * #-
.- &g ..k , . .. :i% ,..r '3
. .i .o< .' Q .~ .-
'%.?irG;;.\h'#M t. . y
' Q_
' r .N.W$ Y hj.~.Y $~,Y '.
c,-~_. " u = .f e - .-
.-.Y *..'l" Q ' N : N;s ,v. .*' x . -i .-@
' ^ '
1.
. . .. . e. ..
g
.?,
-- c y A: ., .-., Ws . .*1,..:;.%-
~'.
bSEd,TLy((
+ . .
v__
' '/ . .
.- - ... . b Figure 36. Areas of 85-127 from which ehmeneling patter =s were obtained.
~ =. .. ...-- . :- _ _ ,, , _ _ _
m~d'QI4Yf#as ar .&d;--AQ _gsg%,--
-~
-m zn,.
,,. gure 37. '
Areas of 43-108 fres #,1:h c'anneling _ pat arns were cbcained. 1333 2A9
em - 2 __
.. h 1-.p.
_,5m4 .- $%
, lw-m7 s
1"or :=d_w._m:nks= _- Te -
. . . . ~ :, -% .
' * *8
~$,.;khC-h.SN'Y _ . .bh.,h..
. ~
^
' :- _ '3 ;l?
; = - _
. w.
- W5
.~ '. ^ .,
~
~~ -
W n 4s .. a a_ s. .- _- - x._~g _ . . .
=~~ :_-
2_ ,
~ _, _
^ EN= . _ . ei
- m. Ah- e
."_u__.._._--.
Figure 38. Areas of 83-117 from which channe'.ing .,_ patterns were obtained. T Yh D " ]D P3DM S. A lnlo e e M k . 1333 270 i i, k
from the damage surface were ranked I and II and patterns within 1CO,mm of the -
- w. c re s damEge were ranked III. Once again this caedenc:e slw.s the presence of mechanical deformation associated with the region near damage surface.
For compari:soo, a pattern was obtained within 100 m of a cut surface sade by a slow speed diamond saw. The resulting rank III patterns indicate the amount of deformation near the saw cut is similar to the deformation near the damage surface. 2.3.2 I-ray Line Broadening Five strain standards produced by axially straining annealed and stress relieved OTSG tube sacerial knovu amounts were used to produce a calibration plot of plastic strain versus full x-ray line width at half maximum peak height GLTO . Line broadening measurements were then made at the five locations shown in FigureK . The x-ray beam covered a 1/8" x 1/2" area cad was only ThrA slightly larger than the =ajor da= age area.4 'feasurements were =ade at each location and averaged. The calibration plot was used to convert the average seasured line widths to percent plastic strain. Results of this work are tabulated in Table $ . Tabled 3ResultsofI-rayLineBroadeningMeasure=ents Ares %' Plastic Strain I 10.6 II 3.2 + 0.6 III 2.6 I 0.6 IV 2.6 I 0.6 7 0.9 These results show that the plcstic strain associated with the =ajor damage area (Area I) exceeds 10.6I. The plastic strain in Area II where the dark lines sweep around and up the tube was only slightly higher than seasurements taken from regions III and IV where there was no known damage. Oepcsic covering the land contact at Area 7 caused an unrealistically icv value of plastic strain. As an overcheck, a defect similar in gecmetry to the major damage on tube 35-127 was sachined into a piece of archive OSTC tubing (see Figure Ch() 1333 27I
.- -360* , I
, -- 1 INCH I 3
. - 1/2 INCH
. /g
. 2,,' . .
i-, a 4 -O I, , . 6 -l/2 1NCH
-1 INCH
.' 5 A -
a aL PW n 1 14th TUBE SUPPORT PLATE LANDS
~
Figure 39. Diagram of 14th Support Place Region of tube 85-127 showing locations shere x-ray line broadening measurements were nade. 1333 272
W ,
" & 5
~
4 %W' _ i , e* ~';
' Q [; .
...s Q*I,7f 5-. . , . . ,
%%gD1
~, ;~-.
.i-1.^T (>iwie ? s v!..
1 .
?- i
(
.s t -
a (S' . i, I
^
I
.t
. 3 2
U
, s/s d3 ,-. M 4
; !*~--
l- .____\* &f m a -: bN5aEN30$$$ l 1 1 Tigure 40. Damage of si::Lilar geometry produced by 45 - end aill and used for x-ray li=a broadening.
. .: - a = .- - - - - -- __;_- _ __
1333 273 W e he e==. a.
'a Line broadening sessurements were then taken at the simulated damage and at 180# away from the damage both before and af ter a stress relief and annealing heat treatment. Results of these measurements are tabulated in I
Table . TablefI-rayLineBroadeningResultsObtained From Simulated Damage
" : Flastic Strain Flastic Strain Location Before Heat Treat =ent Af ter Heat Treatment Simulate? Damage 8 0.9 180 Away From Damage 2.7 0.9 These data confirm that the plastic strain measured for the damage is real and that it exceeds the value for a simulated groove made with a 45 end.
mill. 2.3.3 Metallography After the transverse cross section (sample 85-127-Y3II) was cut, it was carefully polished in preparation for electron channeling. A mieregraph of the as-polished surface taken prior to electropolishing for electron channeling is Wo do shown in Figure.M1. Measurements made from Figure $ indicate ebe "v" notch extends 62: through vall. This compares favorably with the 64 through wall measurement =ade near the upper end. of the damage. J I e e 1333 274 m
After electrop channeling was completed, the sample was reground to remove -
~
the ' rounded edges caused by electropolishing, ne sample was then repolished and elec.trolytically etched in 2* mital. A 20X =acrograph of the tube wall near the najor damage is shown in Figtre .%. Micrograph of s. be wall showing locations l IFigure41. of higher magnif.'estion metallography. Mg- .- __ Q p. - ~ ' - ;mw
~
~
~
, sp. -
_ gy S qmMy ,s i 3,=-- _ _ _
.==c--
- --- - fJ a72M:lStiGTV +R' r~sh--W Crain structures near the surface were examined for evidence of deformation.
Some typical micrographs were taken at the locations noted in Figure .h . Figure
~1L MS shows micrographs taken along the sides of the "v" notch. Deformation is evident at locations k f, and f. De direction of deformation as indicated V,5 by the grain boundaries is toward the bottom of the "v" notch. Figure MN taken at location A in Figure ib shows the. normal tube surface away from the damage. De deformation from right to lef t along the tube surface results fron the grinding operation used during manufacture. ne arrows in Figure M, ',
illustrate the direction of the deformation found on these surfaces. For general interest, Figure shows two views of the smooth undulating surface associated with two minor da= age areas at one side of the "v" notch. D
** .-eeame
Figura 42. ! Micrographs from locatiens C, D, & E of Figura 41.
. .** _u.q4 .,,.i.Ja
.z. .
'...<'. ?.-- O'a-i.e.- Q: ,* '* ~ '.' 'l
~. M . M -Q u - - -
' .wNf .......e- ' _ . . ,j, e-
- - . ' . N:'..? . .a .
*-J'< -
.: ;. i
- - W:
h.' #N-Y.N.t'.'e i=",; .'AT* 4 4Y~ %ti'hv .'. ,' M ..~ w=Ns: M L.%.s.'w' p '.-99?
- 1 - :~c 4 "T c~- '
&?fh.%e .?%.l. . ( I' .' :- ikW&a.'.M. ;, . - -
Dn 'WeW%b. . n [~5a+5f. f.W'.T **%%&.
~g. =.. ' ';. ~ ..-lib... .
Wh&il. ${w.$fC.N. .?-
-- w -
5.> Q h ,} $ -.3 ,' W5 ? .
~ '. .~- -
.-u."..l3
~
7:-h . ..l pyr - -v ~ - y- . sEpJ 6 . A. F ' '
.- ... .,.. ... . . .M;:- :.#.G. . ..
g..: e., .
"JM ~:W :- .
.-n . . . .
4s 9.~. +. . .
- n : .... , .+...; r.n- .
. ;-- ., "p . .e
. . :.. . . . p.. ..: , .:. . . . . .. ..- : . ..
v ga.~;g.L ~,M' .5 :-.g:-%- $.t...-7n.T;*- x. . . rx .v p - .."7:-MyMd.,8lMy-- ~ .
~
f.
< ..n;'~z.:, p',t[~.1:.; 'M;.h.,-Y,.~a'?.n.;*'Es,.
Q _ -- f*p.. 2n .
'~
*L' . :
..c:
=....
- n ::
= -r .
4 A. -1.;~
. . L... ,.;.~ ;
- .w W.an,.m ,'.-:2 go.-Zi:*g -.n%;e'.
. ' ' ' '. ~.m C . *,~ @ r Gp- 6
+n G .-
.s -k * .!:'- %.. %%
LW: r-- ~
-=
,pwcw a y .w-y* *~-: w .W-- s ~m$"
._ _ _ _1 EpC'w am:k:MLt ' ' _ _ _ _
Figure 424 . r Figure 42b.'\, '.' *
~ 'dicrograph from Iocacica C (2000X). Micrograph from Location D (2000X).
l __ _ . . _ _ _ . _ .- b..
.. -w. . .>.v. . ,i,. ..v m. e J s. 5.2..: '
~ -
,, .n .e. -
n y ..:,e a .m . p M. *;qi ' r.:. - a .. - M ?n.'h. ~2. :. %x ,g %@ f ey 3 m e ?. . - - 4 .- '
.c.c: Dr y -
7 g w S ' l.:a x ..s . . , . , .
., . .w<
.3 s. e .
N.
- r. . ,'.? . Yd~Y..-f
% v'Oi5'".i a.. .,N p
- h. 'g 2
MW
.,~
~
r-- s
, *45 e s
- 2. . .ff%uD.**.,.# ' .
9
.Y f, w... W - - Uc.,. m .:.
.h. E' . . '- .
Figure .42.e., Micrograph frem Locatica I (2000X).
- g7 _
~ =g .
g- g - ~~ ,
- - - ~
.. (~ .
W.W Y e- [e.b~ g.s N r.. - . - ~ ^4 N M v .- - ;m =
- T- r- .
g
~'
j
- ~, % u-%gg
' -M#d}g?M g
. 0 .~.5*. . -E . $ M31-M' .
.n&,;{.~.,h%[.N
- -c-g it.w N.
.s t. : . . -'. l'.. ~ t
{fw$ l Yh $? * '* o O'BR B$$$f r$-+gg IN c3
&* M
,. . f*
W J @k;&GJ
$&;,tt$%gM3% WA55k T
-s.,. ' -1 . , ~,. S' S _ . . .
I"#* '3*', Micrograph (2000X) at location A en Figure 41 . Mw.,=w-7 . - 3 . e ._
- ~. %.
. e.~. a. ,.
Wh m. a M & w~ gg.g=t.7==2
=;-_.~
, ~;Q- =. ~~~2 : :
%s%
A 2=s _~ -ws -- . .
~
6 = r '- .._ ___ M.4iE - 2M -J:L' W4
.,. p. .
m- # . 2
..e a"ssre&en u. --
g W'. essalims.
-we m~. . .
1333 277 Figure 44 Views of undulating surface associated with two siner damage areas (iccati:n 3 of Figure 41) adjacent to "v 3::cve".
' ~
2.3.4 Microhardness . Like all hardness testers, the machine used for this work measures pene-tration depth for a fixed applied load. ne penetration depth is then converted to a hardness nu:nber. In this case, the hardness tester was equipped with a diamend pyramid indenter and operated at a 50 gm load. The light lead was used so that readings would be taken as close as possible to the unsupported edges. The sample was cleaned, polished, and :ounced prior to the test to re=ove debris and any w rface oxidation. The equipment was calibraced with a standard test, block to insure accuracy in numbers and positioning of the diamond indentions. Using a 50 gr load and a 10-15 see application time, the Shi=ad:u micro-hardness tester gave hardness values which were typical of Inconel tubing when compared to previous tests, except in the area around th*e "v" notch. Tube.35-127 had hard areas reading 241 value at the notch tip and at the two outside face corners of the notch. The exposed faces of the notch had readings around 211.
- At a distance away from the notch, approximately 7/16", the hardness readings ,
were all around 211 from the outside face to the inside of eb tube. Therefore, the difference in readings is attributed to work hardening at the three positions on the tube: the two outside corners of the tube and the tip of the "v" notch as see in Figure D . Figure 45. Micrograph showing microhardness test
- locations and results from "v grocve"
- _. - . _ _ . on tube 35 -12.7., _ ,
200
~
211 '
.%\
~ -
I . ,11
~
a,9 35.' 211 a.,s% 211
,.o ,ss ,,1-
*9
^>%. ,.+ Y-9 e 1333 278
Microchemical analysis did reveal many interesting chemical effects _ associated with the damaged and undisturbed tube surfaces. Scme of the effects
~
from 85-127 thought to be of significance are:
- 1) The surface layer over the undisturbed tube is 3ss thick compared to a lg thick over the damage surfaces. In
. general, the surfaces are all relatively clean and deposit free in a macroscopic sense.
- 2) None cf the techniques revealed any large concentrations of known corrosive elements.
- 3) AES shows that silicon and alumin e contents are higher and iron content is lower on damage surface layers than on adjacent tube surface layers.
- 4) EDX analysis with its deeper penetration indicates that. bult chemistry of the damage surface and undisturbed tube surface layers are similar. This result is supported by ESCA electron hinding energy data at depths up to 1500A and by GS data at the arbitrary nickel equal oxygen reference point.
- 5) AES and ESCA showed high carbon contents on the as-received surfaces. The carbon content was consistently higher on the tube surface than it was on the damage surface. ESCA also revealed ';b carbon was present as graphite or amorphous carbon.
The source of the carbon is unkncvn but it may be a cont % D introduced af ter the tube was removed frem service.
- 6) ESCA analysis shcws that silicon is present in silicates, nickel exists as free and oxidized metal, chrom b exists as Cr 0 ,
33 aluminum is probably oxidi:ed and iron exists in h % 4 CJ'3 oxidation states plus metallic iron. Ccaparison of data from 85-127 with data frca 83-117 and 43-108 reveals that the chemical cleaning procedure used to clean 83-117 and 43-1C8 was not particularly effective in removing surface layers._ Pre- and post-cleaning visual examination of a piece frem 85-127 also indicated that the cleanirs procedure was not effective. Ionger soak times may have improved tN, cleaning results. . 3.3 ?robable Mechanism Table ff was reviewed with the results of the proceeding two sections in mina. Because of the evidence of significant amounts of plastic defor=ation associated vich the damage, erosion-corrosion, under deposic corrosion, and galvanic corrosion were rejected. Mechanical surface damage and generic tube damage were both rejected due to a lack of visual evidence consistent with 1333 279
j
, 3.0 Discussion and conclusion -
The objective of this project is to determine whether the damage observed near the lath support place elevation on tube 35-127 war caused by chemical or mechanical mech =% and to determine a specific mechanism, if possible. Table 10 was prepared as an aid in evaluating the results of the euminations performed en this tube.* The various an m!"=tien for =achanical and chemical effects will be discussed and related to Table 10 in an effort to specify a echanism. 3.1 Mechanical Effects Electron channeling, 3-ray line broadening, sierohardness aad =etallegraphy. were used to assess =echanical influences en the damage sechanism. These techniques censistently showed plastic defor=ation , associated with the "v" groove damage surface on tube 85-127. Comparable seasurenents were made en 43-108 and 83-117. All four techniques indicated sechanical damage was associated with at les.se one portion of the " ball peen" rfmmage en 83-117. Electron channeling and 2-ray line broadening indicate that mechanical deforsation is associated with " candle flame" damage on 43-108. In centrast the 11 sited sa=ple frca 43-108, metallography shewed very little surfacc defor=acien and hardness testing showed no near surface hardening associated .ith the " candle flame" damage. In spite of the lack of agreement among the four =echanical deformation assess =ect techniques en tuba 43-108 the visual similarity of the " candle flame" surface to the 85-127 and 83-117 damage surfaces provides a high degree of certainty that a
=echanical process is involved with the damage en all three tubes. It is absolutely certain that a mechanical process is involnd with the da=ane en tubes 85-127 and 83-117.
3.7 Chemical Effects
~he results obtained frem the chemical analysis are not as clear cut as these frem the sechanical azalyses. There was no obvious corrosien residue, like that associated with the corrusiot pit on tube 85-127, fcund in or arcund the adges of any of the damage surfaces. In fact, there were no obvicus visual indicaticns such as etching or pitting of chemical attack. Also, thin metal edges and asperities which are ordinarily =ost susceptible to chemical attack wera unaffected. ~hese visual clues along with the lack of ebvicus cor:csion products tend to rule cut che=ical attack. *~able 1 in the EPR1 S136-1 !ask Agreement has been expanded te include fretting ':e:veen the tube and debris as a possible =echanis: and sc=e =xpected results have been i:#cfied-in =c:.e aecau.
1333 280
single event or sill induced damage. Also, there was no detectable decrease in - inside- diameter and the deforned surface layer revealed by netallography was thinner than expected for thess types of damage. Frecting between the debris and the tube was tuled out due to a lack of visual evidence of relative motion on the damage surface, i.e., no directionally oriented scratches were observed. Cavitation was ruled out because netallography did not reveal an irregular surface profile like that usually associated with cavitation. This leaves particle armi liquid impingement as possible nechanis=s. Since the steam generator is thought to be in a dry environ =ent (superheated steam) at the 14th support plate during operation and since particles on the order of one micron in size are observed on and imbedded in the da= age surface, particle i=e/ingement aceears to be the most erobable da mite nechanism. 1333 291 1 G
*AAL&a lO ._
sinfE110F EZrtC*t3 ttst*1 rt* f5 A124710m 0F OSTg *11ag %=tif 47 MTR AUPPUET Ptd.Tg (LEVAT1ue Aa seesteed Samesing Electres . Mistseespy Af ter !fte reehssta ale Tlectrea Electree t ea? '.4ee "echeatae .,18 emales..ti er t res
= tee c,,* *bestes t t'e sa mt taalvets 7t t f ra t t ae chevine t t ne leenseunt u t ersha r dsees we t elletroen*
- 1. Medastaal twidense of a twidense of a statie 1erf ace later Caustseese Evidence of freedened lacrease to Crees anc%saica:
ourface stacle swees with event esta essa emessacry af preeems te deformattaa pesa tas1= harenese at aeformattee mass damage mese doct11e sustile emearist of damaged areas surf ace ever a thack restwo of surface ualees surface of 48* maartas of metal metal se e se rest layer name surface layer so f ormattee recryocallised asse of tone Le se rest of if maserial by stresa relief terne of tune recrysasalta= watas would thiskassa and ed by streme tamas decrease themistry relief ammeal to haresees
- 1. Canette tsee tridense of depeelt Serfase sameeres to Serface layer Pwn Camperee with damaget e.g. buildne stallar that af previanaly chsetatry of present le previeuely pit, taale= to that of emasised e111/ damage same se sortsee is~ ,= enanteed esil/
eten las surtouestas sehe enserial deses teet afete er name as asterial emesse La terne of rest of thisemass and rebe M atry
- 3. Particle Relatively depeait :hastile asperities Semical ese= Feas1 % Evidanes of Possible lies set likely to Mar see superf t-Lapiagnant free surface with for tearee partiales peettlee of compeemd sweerficial breahnias be usefei : tat suas puesthis usedded Serf ana will appear adheroes idensif tsa- determattee dependias se defarmatise particleo smeester la case of pertiales tien partiste stze.
fame sertialen veleetty. 6 is-71agment angle 4 114end telatawaly deposit asperstice say Surfa.:a laver tridence of time bread. Possible tsaresse .atay see super-testageant free serface wtth Ladicate eagle et dif f ars fram sueeviisial engag Lad 1= detectable naar ficial shia esperittee see= taptagsent serveending deformatise satise of surf ace et deformatise parshle with tube la tarse amar surface (disens tica damage 11teresere ' of thtaknese et damaged Chemistry arene differemmes are ensartale
- 5. Cavstaries talatively deposit Asperttime are (1 me as tvidente of Lias bread = Feuible ta= 987 see swer=
free surface with erpetted to be ansee) superficial eming Lad 1= tresse detect. ficial sais asperitiae campare= vertista deformation catise af de= enar serf ace deformaties ble eith literature amar surface formatise of damage aleeg with of damaged irregular arena profile
- 6. trootsu- twidamse that de= Ividemme of chem = Serface layer Chemistry Serfaea of de= time Stead- 3e viathis Correstas posit layer enrpts. taal attack. etsh- differe free esa of surfare saged arase ta estas is aos deformaties 18g7 diff ers f rom t er. pitting, ets., sal protective laver to relatively se= likely surToading tube om9 led with f!se layer la Chemie styptsal formattee free.
Ladicatiana try 6 thtaknese. 6 Laver too. N presence of taine terre.
= correstes prs = sien predents deste ta dessete en
- 7. Onder tridence of a Serfaes Ladies = Aryptaal surface May bals Se detectable se detett= Ne 'ia1ble dessett surface espects tive of chemical layer ta terne identify deferancias able de= determattee eerrestee er esvering attack, stanias. of chemistry terreetwo formaties ptttias, eaa. evne if deseelt eve '
%es bees lost.
May help ideo = tify correstve element (e)
- 8. Calvente forfa6s to clean Se differences Cerroetse chemistry of so foreise 1e detectatte to etstble 6 sonett 18 free as-recetoed surf ace film esepeende deformaties deformattee.
process ta estise Lf pretees to altered. by deseeted en aettwo galvania surfaea. diamelsesae
- 9. Fr$ ting faratened surf ace See as netwees Ladteattag relative befers fece coaststa= teidence of Identify Evidence of Evidence of *av see
*ste & estian 6 some set ezide 6 detria smeerficial sweerfietal seeerficial seserticial 3abria particles free estal partiales deformattee soformattee defersattee sa:e defereatise free racenei and statal near surfue
. - . - se.ar
. surf ace
..m.. se.ar
. . . surfme
. .f ..
particles area area area
.e
4.0 Recem=endations ~, 4.1 ebris Sacpling The fact that unidentified debris on the 14th support place is observed in the only steam generator where the t7pe of damage seen en 35-127 has been verified implies a conneetion herseen the damage macht.nism and the dabris. No connection betseen the debris and the tube damage could be established by this work. However, since particle impingement is the = cst probable mechanism, we speculate that the debris may be functioning as a source of or it may be simply deflecting existing particles into the tube. In order to confi:s or ds.ny a connection betseen the debris additional infor=atica about the debris is required. This infct ation will also be required in the event there is a need to remove this debrit from the steam generator. 4.2 Laboratory Simulation Some l'-4ted laboratory work started by BabcotA 5 Wilecx on the effect of impingement by micron si:e particle did act produce da= age surfaces exactly analagous to those observed on the mM ed tubes but seme similar surface features sere noted. These laboratory tests could be expanded to better understand the effect of:
- 1) Particle velocity
- 2) Impingement angle
- 3) Particle fluz
- 4) Moisture
- 5) Role of debris in the damage mech =Ma and to produce damage surfaces = ore siMU.r to those seen on tubes removed frem service. ,
4.3 Review by Consultants
?. G. Hammett, University of Michigan and Dr. A. Conn, Hydrenantics, Inc.
have previously studied the damage at the 14th support plate as c;nsultants to ) 3&W. At that time they were not able to say whether cavitation or i=pingement could cause the observed da= age. We feel that it would be advantageous for E?R1 to have these or other censultants review and coc=ent en this work. '" heir advice on any future laboratory simulations may also be of use. 1333 ?3
e Referencestobesupp15ed. 1333 284 - M
- O e
-e e
G
*O AP9smcss 1333 2R5 O
w
Appendi:r A
'Jorkscope for F.lectric Power Research Institute (?.PRI) Contract 1333 286 9
O
*- 0".t.a_i.1 E.If d f'.' 'Sh .
! Tollo-ing are the niercific proce. lures and ohj. ret.ives for . ach * :0.:
?.a s k procedures /Technicues Snecific Cb[e,cfives I
Recelot of tube and initial insnection
- 1. Unload cask. . Initiate examinatien. .
- 2. t1easure radiation Ievel 'Specify safe working procedur es.
of tubes. -
- 3. ricasure lengths, identify Maintain cample identification.
individual pieces and s' ark orientations. .
- 4. Visual examination and Locate and identify damage en as low pswer stereomicroscopy. received tubes. -
- 5. 35 mm and photomicrography. Documentation of tube condition and darnage.
- 6. X-ray radiography of entEre Locate cracks and/or areas of tube. ,.,, metal loss which may be hidden by deposits.
*/. Eddy current testing (ECT) Verify in-service inspection ECT examination._ indications without pi csence of support plate or tubesheet. -
II Microscopic characterization of g received defect areas
- 1. Tube ID dimen,sions at . Assess changes in inside tube support plate and tubesheet , diameter. Hav.c data for coinpa rison using ID mieremeter. with'ncminal t'ube dimension.
- 2. Cut samples. cbthin =amples suitable for scanning electron microscopy.
' ( No t e: 'Jork completed to this point. ) ,
- 3. Scanning electron micro ~ As received microsecpic damage scopy (SEM) and assessment. Evidence for ccmparison photography.
- with classic damage mechanisms and for comparison with .previously ebserved damage.
.. 1333 207
;tevision 0 Cat.ed a/10/79
." Page 6 of 10_
> - 'e
- s: . . .. ,
. , . f- .i . 4 se ; o. ai..- ..n.! !<
- 1. En.er gy d i>:In:r s! ee .T-r ay Preliininary quali tat ive .I to i .-!:at-1 an..lynis (EDX) in conjune- tion of chessical cle:sents .mr..civ ed Lj un wi th SEM cxamination. with damaged s6rfaces.
- 2. Cut sampics and clean ID. Ohtsin_ sampics suitable f or subsequent analysis.
~
- 3. Scanning Auger microprobe Semiquantitative snalysis of surface analysis. . ehemical elements in surf ace
, , layers of damaged surfaces.
- 4. Strip extraction replica Identify chemical compounds in f rom damaged area for deposits and surface layers within damaged areas in order to determine electron diffraction source and possible involvement in analysis.
- the damage mechanfsm. -
- 5. H1'crochemical surface Identify'the chemical nscure of analysis a) Auger electron . films and deposits on damaged ~
spectroscopy, b) I-ray surfaces. photoelectron spectroscopy,
- c) secondary ion mass -
" spectroscopy. .
- 6. Auger electron spectroscopy Identify the chemical nature of surface analysis on tube films or deposits on Inconel 600 surf ace surrounding damaged exposed to all volatile trestment areas. (AVT) water chemistry at Ocnnee, for comparison with surf ace deposits and' films from damaged areas. .
- 7. Examination of crsss- -
Evaluate ist'erface relationship section of previous 14th between surf ace deposits and rupport place 'dsmage samples damsged surf ace. (83-117 f rom Oconee 13) in I metallograph and by SEM. ,
- 8. Repeat 111-2 through III-6 . Direct compariion of data between for 14th support plate ,
all available _14th support piste damage on 43-108 & 83-117. damage specimens. to IV Microscooie charseteri$ation'of damage surf aces with resnect mechanical def ormation
- 1. Chemically cican. Rem'ove surface deposit to obtain
. clean surf ace for re-examination by SEM and.run X-ray line broadening.
- 2. Re-examination by SEM. Identify topology of damaged surfaces'by high resolution imaging to. help determine damage mechan (39,
"" Revision 0 33ted 4/ of; T
D "" "" D DU'"g"D"y ""({ A 1333 2R8 ? age 7 oft
- I . _.. ._
. 1e - -
.. .. : t.o . i , . .. ' ._
.ir r e,, ma s ( . .n .
V T- st.: ne tj f e t,-h.n .yet cri r.it ion of wehanical da rra ria.it.J on a r. :s w i.ie.e4 . sith da -a Je rurf aews *
- 1. Section through dramage, EJaluate reint3 cnship between polish etch, and examine in , damage. shape and microstructure.
metallograph. ,
- 2. Microbardness of . cross- Cetermine extent of mechanical sectjon. deformation, if any, associated with damaged sur f aces.
~
- 3. Electron channelina analysis netermine mechanical deformation of electropolished estal- distri.bution (en a microscopic lurgical cross-section.*- scale). associated with damage in
.,. the microstructure, adjacent to damaged surfacer. .
- * ( No te: This work 'is experimental and'may or .may not provide usef ul .da ta.) ,
VI Mechanism postul ation, future work , reporting, administration
- 1. Compare data from tiihe Provide data bane for hechanism -
85-127 with that f rrts pos tul a tion . 83-117. and 43-303.. -
- 2. Comnare data with extchd, Cetermine probable cause( s) of results in Table 1 and tube damage. ,-
postulate whether mechanism ~ ' ' is chemical or mechan. cal. ,
- 3. Reconmend follow-.on EnrE. Discuss follow-en , work needed to fully characterize mechanism (s) and determine _
. paeliorating action... .
t
- 4. Revie<; meeting at Duke Keep interested parties informed
. Powe *
- Co. ,. Charlotto, NC. and document results of the above
' examinations.- -
- 5. Report e. re7ults at CrnI, -
Palo Alto, CA.
- 6. Pindl Acnort.
I - Lo f
~
1333 299 f
. Revision 0 Cated 4/10/79
. . . . . . . . . . . Pac.e 3 o f_.10
Appendix 3 Documentation Data for Tube 85-127 1333 290 t s e
l'! TOP OF TUBE BEFORE CUTTING r W D .. . ~ 7 (%d %- % f//j' b~ ' llN
/
3" DEPT 11 TO / a SCRIBE POIiiT ON TOOL
/g% 4
' (C-SCRIBE LINE y/ / -
IN PLANE THRU / ;. / TUBE & PARALLEL 2ft-1/2" DIM. RECORDED TG LANE ON MANWAY/.- IN PROCEDURE, SIDE OF TUBE / MEASURED FROM
/ ; ADJACENT TUBE j - - - - -
/ /
- - / .
j , t ?.
/ ~
f .
/ I333 291
- 4. / / .
/s 1 FIGURE I ANNULAR AND AXIAL LCCATION SCRIBE f1 ARKS ON TUBE # 85-127, Mf OCCHEE I-S OTSG i
CWC !
. ,,j,, ,1,p, _ _ _ ..
4 e.
V
'\
- TOP OF TUBE BEFORE CUTTING-
.I #7N., -' ~
(Q.;5 ) ' g Y / /, b~ '
/ / /7
/
./ -
I 3" DEPT 11 TO SCRIBE POINT
/ f w
CN TCOL / e "' ,N ', '
/ ,
/~, ) ;$ '
SCRI3E LINE y/ f IN PLANE THRU /.
/.
TUBE & PARALLEL 24-9/16n DIM aECORDED TO LANE ON MAtMAY/ / IN PROCEDURE, SIDE OF TUBE ,
/ MEASURED FRCM
/. ADJACENT TUBE
/ /
- l - / .
/ / '
/i .
/
/ -
/
5 // l /5 FIGURE II ANGULAR AND AXI AL LOCATION SCRIBE iMRKS ON TU3E # 77-18, CCCNEE I-S OT3G W./ 1333 292 cu,c,
* .._ =_...,_ -,,. ._ ~~ ~ 2,:
" " ~r.~ ..~ ~._'.~~~.-- . . _ _ . ta l,- ,1. . - .
Appendix C Results of Eddy Current Exam Dats 1333 293 e
?
e' e
.rcrs *.2C-128 Research and covelopment civision ,
LYNCH 8URo I! SEARCH CENTER babcock &W*ilCOX LYNCMauRo, viRomlA L L. L SCHN, COMPONENT ENGINEERING, NPGD g* O. M. SCHLADER/H. L. WHALEY NONCESTRUCTI'/E METHODS & INSTRUMENTS SECTION, LRC Cust. '1PGD Al* N*- er Ref. 6322-01 HOT CELL EDDY CURRENT ANALYSIS CF TUBES 85-127 AND 77-18 OCTOBER 10, 1978
. h-~~~d=**
The hot cell analysis included three regions of two tubes from Oconee I-8:
- 1) UTS interface area c,f tube 77-18
- 2) 14th S.P. area of tube 8S-127
- 3) 15th S.P. area of tube 85-127 Each region was scanned with both differential and absolute eddy current probes.
UTS Interface of 77-18 At the UTS interface, the differential probe produced the signal in Figure 1. The signal originates just left of the small loop on the right and then makes a large c:,unterclockwise curve. After nearly returning to
. its point of origin, the indica @n proceeds clockwise producing the,small, _
loop. This signal' resembles previous lane row UTS interface signals except that the vertical cocponent is larger than usual. Tnis vertical component of the large loop and the tail of the signal at 3 could possibly indicate some wall degradation. Further scanning with an absolute probe produced no recognizable indications. 2,g:.'i 12 4 . L~
-n^
D D N . n. ,.
._. c.
FIGURE 1. UTS Interface, Tube 77-18, Oconee I-B, 9/78. 1333 294
L. H. Sohn October 10, 1978 - Page 2 I 14t$S.P.of85-127 Curing the ISI analysis of 85-127's 14th S.P., a depth of 45 - 55% of the wall w.ts reported by LRC. After analy::ing the flaw in the hot cell, we found : hat the eddy current call on this flaw remained at 45 - 55% of the wall. Figurr. 2 shcws the fTaw f adication produced in the hot cell. The shallower angle at the bottom of the signal indicates a shallcwer depth at the lower end of the flaw 28 - 30%. However near the top of the flaw, the depth increases to 45 - 55%. The steeper angle on the upper lobe of the signal represents greatar wall degradation at the top than at the bottom. The amplitude of this flaw is attributed to both its depth .nd geometry. In this case, the defect is longitudinal and this is indicated by the bowed shape of the signal. . . .
~-' h;._?. # by
. ..F? . %
M* V Y .
W' . G_:W 2V 7 :%%yf - FIGURE 2. Differential Indication Above 14th S.P. Tube 85-127, Oconee I-3, 9/78. With the absolute probe et 200101r, we were able to easily locate the fl aw. Figure 3 shcws several of the signals produced when scanning. Each downward loop represents one scan over the flaw. Our best estimate of depth with the absolute probe was 40 - 60%. n n:= wy;.;-w2:
%~,w-
.- Ar-
.g.
j. kI
@h\tqiy +t v:rtcgsgo g $N
._, , \
t' y y-5-y"g: q-'
,LA-
%:.. ) { p"': M y 1 /r W' 4'Q rx:.p4 24 , 17, .uO,Iagggs$
6 FIGURE 3. Absolute Indication Above lith S.p. Tube 85-127, Oconee I-3, 9/78. 1333 2o5
1
- L. H. Sohn -
October 10, 1978 Page 3 , 1 15th S.P. of 85-127 A scan of the 15th S.P. region generated two very small ding signals. One indication appeared at the lower edge of the S.P. and the other at the upper edge. The absolute probe produced nothing of sigiificance. O A. M6 i D. M. Schlader g H. L. Whaley cc: G. E. Abell L. H. Bohn R. W. Bonsall A. E. Holt R. N. Kubik C. W. Pryor R. E. Ricker M. A. Rigdon F. J. Sattler A. E. Wehr neister 1333 29()
*e Appendix 3 Chemical Cleaning Procedure 13aa 297 t
t O
l . :-l'9 . . ' Ressorch .and Ce - 3 p m e nt. 3ivisio n ..
.. .' .- . ..__s .
. LYNCH 5URG E!5u2CHz CENTER. .: ..
.,.,.,.., . ,. ....,..=
.. ._3. .- .- .-m . ~ .V . - -l
- m. . - .
"-.. s.L .
- . ~.
. : :: - ,.....s JCk*p.%.,n+t[COX .'.q._K. ~ . . n. <.t,a_cu.sgo, s
... w. z. .
s.s.,. ,.t. .- *
-= & h.
. . .. ,:.. - a.__ .: ac . . .. ,s . . .: - '% a ~.M u
-- . . . . . . 7. ..
bh.W ; .e,h N.'hhUb f 1' ').
. :..r.:-:+5::C; .; p',% -y.y.Ib. hh.;r . N '.,:; $hb)
'h'* ,.. - Y.-Q..*w.;N.3'
;;~. .
.?k3. ..%,, . itQ~Y. .M~' ,. V.'.;-J} -M 2." *Nf -ry ,.w n ~. C .s' % J.:T".22,.F -4 9, - ~ .-y.c;.
.N'.n .
r 3.: .; - . - : I _5 yh @ ,g,.g.~>.w. . . 30
? .. -. ,. . .. .
.t--.-
~JCE~ N.,F.
~ ; , '. g- -M- n... , %e .
L*.UW7U. 3: tw g-Y gA jr. M g.h. .s v 9. ,fge "me
,., - i-j,="- . y; ;s:cj:3 g ,
., y n wmx.mu;
< .. . . c.?
' .cr,it.;
f -gg &f .Er Re
- a. p g . m .w
; D .hD:XXR-b @ ~f.,-2;Scimbd:=f - w +y. p9h M- ., g .u. Ms:i? & ,E.,,.,,,_
Cw+.isa.m .3._ qv:.Se.p-W-W- QM W M.. .r,- ~ . n M. 2 0fYe'-d'Nd9 93 1'. N -$ 'hk-. -4' ' . N @. .
~
'f4'~~Q9: M w.dr.4c: .i g g* 6- l-79 :-e-gf6;. 9&; p-ctjg# J -
' *fN5.N'~-[MN' TMMNfy'.&M;te;.u-g-
.;"TU3E .'
~~
yP-- g:2.cy,.,E'Mf$~,M.-.ig s-
'" -ANDIG., TEST-#pe: 3Qsy:; d. ,m.
f . ..%i;1. t . v.:. .,
. .a.cw : v -
hes,t
% ->--5 %. W- ar.ee w .S;c wr.41.g$h&; W ,-,. it;lr es... m .
q
;st 4,'..d
- 3. w 6;,4;@
. .. .Nk ;*,,@@S}y(.hi',4%:$ '
&.u .- -%' .n F r0n. - g 4,A-14.5 &.: f...'. Q ',q m . ...
l' n. G. G.; ./ c ...- < w g"E&.j.h.Wg~ s-s%.; .me&.+y4, .~.
&k?rr% ..
.(.M.,m %f:,,..~Y sa m -j;n . Q &-yE
.5 v -
i W~. @ M+%@8W>&gyWQ'&wMS@3:M ,~ !
- f ;c ,
Sh' # '&k% .y;g=&y-a.Mg&:.;kj' 5pc.%. __., WWV-Q*,.Qtt M f ybS.5'$. -
.;w.r. . Tube..&p&&.cleane st&
sam le *&%'g.Q'%&Ui-?Q? . i $Mys@...:_4- g.y
~.
N:.70w.eab.h'.WM@eM. $b'&' WahEWh#sI,;W; : 2 2 . . w p .,
'E ,s 4 %ee.i-
. :P: :W'"% T "4,6. ,= % *
'3 First . . 2.: Step
- .; * : f'.k y,-h.. i :. y,;$.. :,4,- ..f4Kv.--
. . - ,,,. ?r '- - go.lutii:in m us'ad -
O.M 4e,..r.
, W- - -
3evA-145 ;-yqW.WT :-Y 'y
~10.%+ED.T..A.;T:
r-q4
. . - j p
.C.M ...,4. d-
'4 -W, '
. e < :, ;- ,,
*~,.-
u 0. i.Q.b.,.* W$f C.C -
~. 5Ydji.Eiid1';6J.M,l, e..ho.l.d'e'r p7.ag+dt;;%f. 2.".'r .-U,
- 4,*;-M-.r*
e., 7
" ..y .
i
$,' '. *",*"1,'['
O %sWO& -$:N,..4**M3 9- .
.V.r .
M:end.ed,,,b75.'.s.ei)3. efl . r
% ' .i' M J.t',-t M '. D- i -2 ater sp . f,'.c.%._on :- sa=p rap , idly')
e "D, ,r',p'w.a$.x p y$_3Q'A n- 3 ,. {. W Tuoe.- sample plac.ed.x
.m - n,.be e CC;for*
- s. V
$ggfg'ggr'-
.o . . .
j.- . - p%.. . ,ed . i,.th magn.3,ti.
' Solu _ tion. Sitrr to a ,c,Qst gtrer. (mode.ra. t,e.3: f w,'O4 gghM}G<'g}gg,1-1/
.: ..Solut gn ,ea. h ted : -QO.C,1.n fi @.g p=%"r-M.
r hr. 3eaker covered
' E-Qhs'.*Q,t,apf j h l 'during n t %
;*Q:%g;g' tesME.
.vith'4'va@cc$%%rstfl/2 -W N .h W'
'C' %- f
- < ~' , h&th".'C**;'.tQ.Ce.gY,1M. g ass hh s W i $% M 8 tib 44f8kh.$$:d'%.gu'-Ng k@kk@$f?$k,$Ms=. McA. l,;fyr*fiMforne kM-h$$. 7WFdiWMq$
i4 9-W e,1,e,3,tgqu N
? '5$SkS**Sfep'. .M.I*Cheng'n isedg%$r-10%5CE@h**S-5tp 2,1 ' , Second.
-59
.4 scrutio N N-E M M 2 5 E S F s McEi@@- :m@N
'* T ..'2-
@~ 4Mame 'ae@at.ng..procedur.c6g$e T-
$5E e used. as above
~-~- *W;M
.r, EV-5 -
ws MIIS+3: 0&& A r
'U'Q. . %n' ce
.,.2 2 .-w< ,'
'K:.*.Q
' -w y.s .[
~
. ? -
%:L. f* -wsaWr. # %.e sX&'s' .M.?" -i . f*=
- :'h% - # - ;:W.gib 5E,&e : .- -
10:. a'N . s ,%;.&,e.7@.
~ i
=.* s' 4* -Qq.f~.T--;.g
- r. . 5-Q
***'-s r a ai#es
~~'0;,.
J.':G;'?-3.?,
- y..;rQ' -['s.'T.*.*N.P.%
09w" '*g ,<:"f A .f
+
43 *rs .a,i5s'
'b,:q:
.:q,,M,-=-@--.p?-0;Q:
f-h.4f.s. .~.9'y
~ .ssC%g.
m s,'.ur
- r .:'
.NS .- . .:t.;r
-=.-Qe;*;.u- f. ,. ar9%Q, -:.;; /.Mi *W.
as'.:. Q',..c=? %. w* %. .~,;.:h; - - e.:,s<,-F<d. r 1-p";:a. , f.,;* T) ,W;-qh.
- e. ** *':'" . .
M .
'QFQ. .c= 7l'-g,M- .;"a
- a- ;.:y
.. " id-,c' -
Q:.'s .f%'. =m.M:<itM.
- m? > < . C >'. 5'- %NM,,,xy,%y;;'.fd,O:.4;-Dv G O'.'Q
.,. 4, . :
$MM.%y;r[a.-ef;* ;@
<~..:c.~ - ' '
.- e' .:. .
$ 2 M.. '.;;'g.- ' .$-[..
^
.. .;.[ 'yJ"y. .~ ,.- ;*d,ED.*?.*#M.*j.r?
; u e: n ; -r O;y:8 MM;*Ql'qurQ2p*ag _!g.g=%a.'*;.-%. .*4:-
A-4 DN
- *b***'=
' s ==.,;-=.-,*s s-a* g - -
- :i .: .-c% v m.:b -
~ : 7v> '%j':a[,,s$ih e hf. ;es J*W. .- / *.g ::r*'**
', , A4i5 ,'. *"'D.
- W, M*A , h, 8m.;
, gs%;
"#f .a s* '
- I'
~
~
. Zy;.*
c
- ;-'O. Ys , f?.D-.S=. .
es 4. a;. p : {~4'*f, .~; .$.*kYl *;l>f.
, $.b. : ;.7. , s..,,,z . .. ; m -
.w .QG f. Y,es, i . . .-% ..-..~** ~4,;h; - *f$5 - C'* M4.f..
;.- , . . c e ,h. ~: _. 2 .
- .e-.g : .:-. a. . . .
,.' ~
* * " . ' . *t..***;"..:?; .m,,&*
*&. ; *.':*j%Wf",cQ.>J;,:'T * . .;yss* * .::.,,;
CA - . %
.-n
- r= .
yf.,
.f .. .s. ~ -. T-- y .: :..:..:,_ ...;y y'.:::s;. Y- ;;q. **. s.. m; .j'.:~.*-.:.:p.:; ;Q;:~;;%
.:..-.....;s.....-..
-f,,,.
.=.C"- -m. .
. :l :.-e., l. . , - q , e.gm;Q*,,'.s; t,*r,,r ; -+~ *
* ;;. -> y--v.,a
*..+; .
-v.~~.;
, b . .
s~. m, - .... r .-u r.-
. +
.A. 4 , , .
p ..-'..%..
..rM.w*.ec c
.:n.,-;.. -e. -..= n. :f> .x:'.ylg.-lw:' y.>g;, '. .;g~, .. . ~. .
4.: x. '%. ,~, ~ . g.u. .
- 3.,
. c_ .t ~=
,,r., -:-,_o.--p.,z':= > :% .: . .
. .v. . s z . , . m .- - , . ~.,, m. ,x. - r. .,.% e:.;.:,.3'. '4 + %..K r. :',' .;. - c. .,,.. : - .1
%.** w .- .- a ,-
, 7 r.,: 1.,.'s:C r:.'*..- .. .;.
. a ~ ,,-:Q : ,. ,L';a. .-- '. y.. .: 'W . . . .c-:'i Wg.'.,,2.%. L;.q
- . ;c_ . y
.~.M..e.aii.=
._ : .~.W.'c.'.:
.%..M+:; ~ ' . ~r W,;f., ;.
' :: .>n.5 ,.
-;..'.,:. ;::;.% ~ >.,L.:::' f,,,.s. g.g -- Qc .';.;_ . .. ~ - +-. -
. < -.' , ; :. . -1*~g--.
. . ~ . . - - . ,.c.. -
* : .: g . .. ....l .q , ,
- &,.-;..n , , c, - a.y ,y
.r -.
. . . w. . .. ..:. . . : .u. . ,,,a . . . . ,. ;~.-,-... -..:. .:., . ..: -
<~. ,~r ~ . j
, .. 3 .- . . . - ., . .
~
z , ~. . -.
- =. . .. .-
~.. ..~.s
. . n . .
- . . . . -s.> : m..,..
. w :: . r . ..-
. . . . ~ .~; . .
. e.. .
q . gq 1333 298 w da. L
Appendix E
, ~
. z. .
g gt6M(4 Y*g \y5is (T UN 1333 299 t O e e
9 8 4 e 9 o O mea
%O c - ,mw ..
.e
^2' h c.- .o_
s N , 2' . . , E,fl~ . ,.. __ M d % o
, F
= I
*w
* .___,e_
.. ~
.L * -
. g e.*
- w y' -
*. WA o ,
- ~a .
e 1333 300
d Table E-1 EUX data '-
- Fe Cr Ni Si Al S C1 K Ca T1 Hg hbe H '>- 12 7 "v"_ groove area 1 (figure 10-3)
.12 .25 .45 06 03 02 - 02 02 02 01 tube surface
.13 .23 .49 .07 .03 02 - - 02 - 01 Intermediate damage surface interior damage surface .13 .22 .24 .14 .08 03 - 03 03 - -
blocky particle el adjacent to the rolled edge 08 12 24 12 04 03 - 03 .34 x - 06 .07 .13 .~45' .02 03 02 .02 02 16 blocky p. article #2 adjacent to the rolled edge -
.59 08 .09 04 02 .01 01 03 01 -
blocky particle #3 on intermediate surface 12 "v" groove area 2 13 24 50 .08 04 - - x 02 x - above ridge 12 .22 .49 09 05 - - 02 02 - - below ridge "v" groove area 3 (figure 10-5) acicular particteu 12 .24 53 05 04 .x - -
.02 - -
"v" groove area 4 13 23 .48 08 04 .01 x 02 .'02 -
" ball peen" surface near upper edge central locattor in " ball peen" area 13 23 50 07 03 x -
01 .01 x - Hedr InterSectioll of major delaage and " ball peen" .13 21 .46 09 .04 - - 02 03 .02 -
.14 24 .54 06 02 x - -
majoc damage site of Jutersection "v" gaoove area 5 , tube surface 13 .26 .46 .05 03 - - -
.04 x .-
U .13 .22 .50 06 03 02 03 02 - u major damage uurface near upset nietal edge - - U .11 .24 .52 06 03 - - - 04 - - upset metal edge along damage surface grevice formed by break in upset metal edge 10 .21 .43 .14 04 - - - 04 - 04 u
"v" giuove area 6
.12 23 .53 .06 03 x 04 x bottom of "v" groove I
see .
Tal>le E-1 (continued) Tuije 85-127 (contJnued) Fe Cr Hi Si Al S C1 K Ca T1 Hg Pggtlele analysis 4 "small candle flame" area (figure 10-2) particle 1 .71 03 13 13 - - - - - - - particle 2 13 08 .70 08 - - - - - - - particle 2a .28 21 38 _j)_
.l _ _ -
particle 3 .19 11 33 .27 11 - - - - - - particle 4 .22 12 . ,3 0 25 11 - - - - - - particle 5 .24 .17 .38 16 - - - - - - - particle 6 .18 18 .38 .19 .07 - - - - - - overall area Ju figure 10-2 19 18 .40 ,18 ,06 - - - - - - W LN LN U M CD N
*/10,000 count spectra i.e 4
Tablu E-1 (continued)
- Tube 85-127 (continued)
Fe Cr Hi Si Al S Cl K Cr T1 H8
" ball peen Area" (figure 10-7) tube surface below damage (I) A. R. C, .16 27 .52 .b3 01 -
x x 01 x - tube surface below damage (II) L. R. C, 16 25 .54 .04 01 - - - - - - central location in damage area (I) A. R. C. .12 ,24 .57 .04 01 x - x .01 01 - central location in damage area (II) L, R. C. 11 .21 64 .03 ,.01 , - - - x - - roughened are et top edge of damage (I) A. R, C. .12 23 ,60 03 01 x - x .01 x - roughened area at top edge of damage (II) A. R. C. 12 .26 .54 06 02 - - x - x -
"umall candle flama" area (figure 10-10) larga part of " candle flame" above land .21 ,21 .48 05 03 x -
01 01 -- - umall upper section of " candle flame" .17 20 .50 05 04 - - x .01 ,03 - unidentified features on surface above " candle flame" .11 .21 .55 08 .03 - -
.01 .01 - -
"umall pit" area (figure 10-13) small plc at upper edge of support plate .11 .26 .50 .07 03 - -
.01 .01 .01 -
dark band around plc .14 .19 .37 .21 05 - -
.05 - - - ',
poliuhed croma sectlon Inconel 600 base metal tube 85-127 .10 28 .62 - - - - - - - - B yer on surface of "v" notch bulk analyals of $2pm thick layer .02 .02 .05 .36 .34 - 08 .12 - - - u LN Lsr C U i.i i
s Appendix F Auger' Eltetro: Spectroscopy (AES) Data
. 1333 304 O
r
O
- 6 e
e g 1 W ; J s- O d. ,
. J m 3
Y Y . 'e ?? t- 7 ...a 'mT 5 d % % i lp-" M'.'J.
.n v.-v.pirM
^
. Gv *Rsm=lp^ W_ 4:.. .
}
4 {. ';#c .., . .M; OtMT, , '; f. , 1 :..f j . ,? ' }. . * *
* ^ '
l . . _, 1 c .:
. . .rT 1- . Iw.ggr m.v.q g
5 q.
- g. _+
ip , , :w~-4@*
- - R4Q,p$g~K -
"~y,r; s,.3,gef.
.i ..-
.D.
~
j:., 4,.
. J.
3r.n M % y'~..
" x.:,.: . .>.
- f. i s 1 % # '** .V-Q. .>
r } ,d ~ ** * .Q %--kom t -
._i e s .
- y. R*y;
....,.r.'...,'1 e.c s -:M r. , - . . ; .g
- c. i.-l. '-'*-T' '%.i- s ~ "
~ -}# -
.Q . - , .. . >J: gi .-f ' = -4~ ,"1 g'
%- :. w- -
'+.s ;n
. -~-9:m.s ::
- - 0 Egm f-1. Ucamw eR ase.s b AGt daf'-
1333 305
Table F-1 Derived AES - Profile Data for Rod 85-127 - Maior Defect _ , , , _ _ _ _ . _ . . . _ _ Location, A O Ni Si Al Cr Fe Mg C Outer Surface -5100
-3600 26 10 26 20 2 2
-3000 29 14 27 19 2 2
-24C0 35 18 20 14 4 3
-1200 38 24 12 8 7 3 Ni = 0 Crossover 0 34 34 7 5 . 9 4
+ 900 27 39 7 4 10 4
+2000 15 51 5 3 11 4
+4000 9 58 5 5 14 5 Tube Surface - Adiacent Ni/0 Crossover 0 35 35 3 5 10 5
-1000 38 33 4 5 9 5
-2000 40 31 4 5 10 5
-3000 40 29 4 6 10 4
-4000 40 28 4 5 10 5
-5000 42 27 4 5 10 4
-6000 43 25 4 6 11 4
-10000 46 21 4 5 11 3
-15000 50 13 5 7 11 5
-20000 49 7 8 11 2
-25000 34 7 8 6 3 13 16 t
1333106 9
~
1 TA3LE Fjk Auger' Electron Spectrescopy (AES) data frem the as-received surfaces at at 1500 A depth in tube 35-127. Gast Element Location Dep'h t 0 Ni Cr Si Al Fe Mg C "v" groove as-received 30 4 23 19 2 22 adjacent tube 8 1 11 7 1 5 70 "ssall ball peen" area as-received 20 2 5 17 11 1 4 38 adjacent tube 13 1 12 5 1 6 56 "v" groove L500 A depth 35 12 17 23 2 2 7 adjacent tube 29 3 1 18 14 4 4 26 1333 307 i. 2 e
- Tibni fr3~ AES Analysis of Red 85-127 _
Chu+. %%er Inside Cavity Area Death C 0 Fe Ni Al Si sg Ca, K 3W1 1 0A 34 26 3 4 15 17 3W2 2 0A 10 34 1 4 22 28 3W17 6 1500 A 5 37 4 16 19 16 1 1 1 3W19 7 1500 A 8 35 1 11 25 17 1 1 SW21 8 1500 A 11 31 1 8 24 21 2
. 3W28 11 1500 A 5 37 2 12 24 14 2 1 p3L.t< *,
%r4at.s 3W4 3 0A 80 4 5 11 3W5 4 0A 75 7 1 6 10 3W6 5 0'A 57 14 1 1 11 11 5 3W23 9 1500 A 31 29 3 3 14 la 4 2 4 10 150a A 21 28 5 3 13 23 3 1 2
$5- 12,7
]Chut 5)ggg tuTube b"Surface C 0 Fe Ni Al Si Cr !dji K Ca IW40 . ok 56 13 1 1 5 12 6 2 3W41 , 19eo A 3 51- 8 11 7 6 9 1 1 1 In Cavity ,
3W35 0h 38 20 1 2 11 17 6 4 3W38 ~ - "940 5 l333 3gg
f
/
T*b68 44 AES Analysis of Rods 43-108 and 33-117 . 0 Cr Al Fe C 5 Na K C1 Ti 43-108 Ni Si 18jt Oamage - As Received 29 9 4 15 10 2 22 Tube - As Received 27 8 5 7 8 1 43 1 1 0.5 Damage Surfact at 13 15 3 7 4 2 4 48 0.5 2 9,900A Damage Surface at 9 42 12 3 3 4 3 19 1 2 19,440A 83-117 Damage - As Received 29 9 2 17 8 1 2 27 0.5 1 0.5 1 Tube - As Received 29 2 4 12 14 1 41 0.5 2 1 Damage Surface at 19 51 11 4 3 5 2 1 11,100A J e o e
f 2' s. b le T&$3 Auger' Elect cu Spectroscopy Data ,
, For Rods 83-117 and 43-108 :
Rod 33-117 Location 0 Ni Cr Si Al Fe Mg C
-48000 30 20 2 18 70 2 2 13
-36000 43 26 6 10 7 3 3
-24000 44 28 7 7 5 3 2
-12000 41 32 3 7 4 3 2 0 35 35 8 6 5 3 2
+12000 31 39 9 5 4 4 2
+24000 20 43 11 4 4 3 2
+36000 23 46 12 4 5 4 2
+48000 20 49 12 3 4 4 2 Rod 43-108
-9000 33 16 3 18 9 3 3
-7800 35 23 4 15 11 2 2 5
-6600 38 25 4 14 3 3 4
-5400 43 28 6 9 6 3
-4200 43 28 6 6 5 3 2
-3000 43 28 8 8 5 3 2
-1800 43 30 8 7 4 3 2 17 .
0 35* 35* 10* 10* 5* 4* 4*
- Carbon corrected data. '
1 1 Ji 3 ?i 3 1 0
Appendix G Electron Spectroscopy for Compound Analysis (ESCA) 1333 311 E e e
e e e
*e O' L
h j
~
- f f* l 5 Y b{ *
) .. -.--M- 2 -=
, _ ,g-*py. .. .
-W i 1 . .'
gl
~- .. : Mrs ,
y g % .
,J- ,- .
9 l 5 g E % f~.'-.*
.;,:* ..=.'*-+ ^
.' "^ l-l :.,*.."._
f.- ,{. j '
.-e. a 0,.'. ?
e Q * *.
~ .k . ~ %.1 '-
=
- m. -
( .h+.. , 5 ~ ' ' V 1' ' ' , *.. 7,. .~., W.
- l - A.? '~
,' g ,
f
*}':~
f q
. .. ,_ W.; . Q T:. m. ~.c" #r -k'aS
~. -
AM g g[4 ... .---:.- .~_~ ., ... . - r, .
,__ . . - an .g
;- . .- .g
- s. g,. far - ..
. . ~ . .
"}.c.
' -4
& .t- h - ,.'. 4 l M _ Dr.
hen $nsh ud b Ares ph,4 X-13 I hate G l. Reu. and1 244 kr EscA dc4 c.. 1333 312
hie 6.) EscA dah. {rm 4ube, 43-Wh Tube 43-108 Fe Cr Hi Si Al S C1 K Ca Ti Md "canidle flame" area .11 .24 .53 .11 .D2 .01 - - - - - tube surface adjacent to " candle flame" .12 .43 .31 .07 05 .01 - -
.01 01 -
data.{mAb.t5tg Taste (<-2 acA Tube 83-117 upper " ball peen" area 10 .30 55 . 0'4 x - - - - - - mid " ball peen" area .10 29 .55 .05 - - - - - - - top part of " lower ball peen" area .11 29 59 -
.01 - - -
x x - bottom part of " lower ball peen" area 10 .27 .56 .05 .01 - - - x x - tube surface adjacent to " ball peen" area .11 .35 .49 .02 01 - - - 05 01 - W U u V
-- ,. O t
** $30 0
nao EE
< m c.
EE 55
- r- as=
< ns ao .-
M = 3 - = n
- Iron Netal , Orygen in g a g Transition Metal g lv Oxides 2
,o Iron in 3,u Orygen in Oxides g
- Te O NO " of Si and Al n 23 n w cm Q o o Iron in $ Eickel
~
, FeO -
, Metal ,
cc 5
$ bgnesium $ Kickel in c
, Metal
- w Nio y bgnesium in Mg0 g
w Silicon in Silicate Ion ( p Pyrolytic or 7 Amorphous Carbon m m y Aluminum in h 7 Altminate Ion or n
- MO E 23 s 5
B e o a
~ ,
y Chromium Metal y
. , o E
. o O
y Chromium E. s-
, Cr 0 p 23 4o C
L
=
b e. O E O
Appendix H
. . . .W . A
' s Q
_.w -
.. -- v_ A * - -
MCO% 7en MM dONT b 1333 315 I 1 9 9
9ff Efft I I- -I I s. . I !! 1 .: i.
! I. I.
I.- -
'! !. I,
'g *I 'I t
'se i i
.s .-
I. I. I. a I. - s t I .E I.
-e :
I. 3 I . .
. I.
, I; I; Ia I a .
E 1 I. 1 i
. ! I I 1. . . .
. g a I I I I I I I i i i i i i i -
! *: I. I, I. I, g gg
'1 E E 5 = i i i i = ;
2 '8 I. I. I. I I I . 4 I : i i i
, g
- - I I I I i 'I I I
- i i i i i i i 3
- I I j I I.
- 2
- I. 3 . I.: I. I. I.
I :fr
= : . =
'I. I Ie I I s I
! 3 e g. ,
J I.- 2 i
.! I a
I - I-I.: I..
- . I I I I I I 1 i g j
- i i i e i I I
. I I I ! I*
i e i e . I i i
! ! I . I I I
- i ' ' i i e i
- I I I I I I I
.i i .i i .i .i. i.
! . I. I. I. 1 I I.
3 g s. 2 2 E . . 5 E. - . I. 3 I. I. I. I. w .
, I.
2 : E. 3 =. . . I I I ! ! ! I w 1 a
.' i i i i i
- i. ,i ..
# 3 : = .I =
s r i. s n
\r,'
3YY O,. lT O U O
. .I . .I I
I -
!I a A ' '
3 y ! .I - o
= !. 1 I I.
s. I. . e Es.I 15 . [*E:l{j E 3 }2 .33 ~ E!I*}ii$Iii}
- !J H 2T 113 f: " b JJ ___
e f a
*ep.-
-{phte $lLQ( Ion 11 eld Corrected Secondary Ion Hass Speer.roscopy Data for Rod 85-127 and Rod 83-117
- ruhe 83-117 Relative Amounta Lit Hat Hgt Att st+ g+ Cs+ T1+ Cr* Hn* Fe* Hi*
outside surface 21 188 9444 14000 11500 230 163 410 6200 8333 16500 93300 lower right corner of damaged area 3 108 161 3467 5000 16 ' 83 134 5700 eJ? 6700 227000 in area of AES profile 5 88 467 4733 2917 5 80 200 6500 1467 6250 160000 Inalde surface - 31 311 410 245 14 11 63 980 - 645 13900 t;nhe H5-127 "v" groove in AES profile area 17 125 1889 10200 5500 700 513 140 3300 2933 10000 133000 top end of "v" groove 41 273 4444 14000 2433.1 2050 1100 170 4500 6733 27500 687000 outelde surface 10 58 1244 4800 3833 380 295 51 1070 1567 5600 85000
- l'eak heights were corrected for machine sensitivity to the listed elements U
U (js *I ~ s e el 6
0 9 a
' ~
AvnNw/ I staea enAcauw Arg 1333 318 e d I
o IABLI T1. Ranking of Ilectron Channeling Patterns frca 85-127 . Distance From Distance From Dama3e Surface Outside Surface Area Pattern Rank LLs to m 1 1 I 160 2 III 70 3 III 50 380 4 II 240 5 II 250 6 II 250 2 7 II 500 260 8 I 500 260 3 9 II 600 85 10 III 600 50 4 11 I 500 850* 12 II 500 850 5 13 III 110 540 14 III 80 540 6 15 II 80 125 16 II 80 80
- Located within 10 of inside surface O
t e 9
e IABLI D . Ranking of Electren Channeling Patterns from 83-117 .
~
L Distance From Distance From Damage Surface Outside Surface Area Pattern Rank A m 1 1 -III* 635* 300 2 III* , 635* 300 2 3 II 125 300 4 II .125 300 3 5 IV 70 300 6 III 70 300 4 7 II 350 650 8 I 350 650 5 9 III 675 850** 10 III 675 850** -
.* Located within 10Qan of diamond saw cut
**Within 10% of inside surface t 0 Q$ 0$11k 1333 320 m- _
2 IA3LZ C. Ranking of Electron Channeling Patterns from 43-108 . Distance Trem Distance Frem Damage Surface Outside Surface Area Pattern Rank na A.cn _ 1 1 IV 85 100-150 2 III 100 100-150 2 3 II 400 450 4 II 400 450 3 5 I 800 850* 6 IV 800 850* 4 7 . II 100 m 600
*Tocated withis 100g of inside surface.
on 3a G
/ N _ _ _ _ _ . . _.}}