ML20053D425

Summary of 820427 Meeting W/Util & Consultants in Churchill,Pa to Exchange Metallurgical Data on Facility. List of Attendees,Agenda,Supportive Info & Viewgraphs Encl

ML20053D425
Person / Time
Site:	Ginna
Issue date:	05/22/1982
From:	Lyons J Office of Nuclear Reactor Regulation
To:	Office of Nuclear Reactor Regulation
References
NUDOCS 8206040418
Download: ML20053D425 (77)

Text

{{#Wiki_filter:, [; v May 22, 1982 i FACILITY: R. E. Ginna LICENSEE: ROCHESTER GAS & ELECTRIC CORPORATION

SUBJECT:

MEETING

SUMMARY

OF APRIL 27, 1982 MEETING AT WESTINGHOUSE TO EXCHANGE METALLURGICAL DATA ON GINNA STEAM GENERATOR TUBES On April 27, 1982, members of the NRC staff and their consultants from Brookhaven National Laboratory (BNL) and Franklin Research Center (FRC) met with members of Rochester Gas & Electric Corporation (RG8E) and their consultants, Westinghouse and Bettelle Columbus Laboratories. The meeting was conducted at Westinghouse's Research and Development Center in Churchill, PA. The purpose of the meeting was the exchange of metallurgical data that Westinghouse, Battelle and BNL had developed from examining various tubes removed from Ginna's "B" Steam Generator (S/G). Enclosed is the list of attendee's and a copy of the handouts from the meeting. RG&E retained Westinghouse and Battelle to independently examine the tube samples removdd from the "B" S/G. BNL performed an analysis of portions of 11 tubes supplied by RG&E and Westinghouse. The three labs presented their metallurgical findings and discussed the results. FRC will perform an audit type review of all the infomation and provide an independent failure mode analysis to the NRC. The significant findings of the three labs are as follows: Westinghouse 1. The microstructure and mechanical properties of the burst tube and a l neighboring plugged tube were deternined and were normal for the mill annealed Inconel 600 tubing material. S oi f I i 2. There was no evidence of stress-corrosion cracking or intergranular 3/ l attack on I.D. or 0.0. surfaces of any tube, f // 3. All tubes displayed flat zones of 0.D. wall reduction with circum-p bM[0 ferential striations within the flats. 4. Thirty-eight of the forty flats that were studies showed cold work i on the 0.D. surface, indicating that a wear process produced the i flats. 5. The " fish-mouth" burst occurred at a flat where the wall thickness l had been worn to 0.008 in, from the nominal 0.050 in. original wall; t cold work was not identified on this flat. l l l o mce> 8206040418 820522 goaanockosooog .e_ .i. ...... i. anc ronu sis mao) Nacu oua OFFICIAL RECORD COPY usom mi-mm

l' 2-May 22, 1982 6 The fracture of the " fish-mouth" was consistent with a tensile overload failure. 7 The most severe cold work was observed on a concave indented surface at the bottom of a peripheral tube R44-c55, 8 Fatigue striations were identified on fractures associated with breakage of two of the previously plugged tubes. Battelle Columbus Laboratories 1. Two tubes were examined: Row 45 Column 47 and Pow 45 Column 54, 2 The tube at R 45 C 54 had been severed just above the tube sheet and just below the first support plate and was found wedged between the tube bundle and the wrapper in the vicinity of R 45 C 47. 33 At the bottom of tube R 45 C 54 there was significant cold working. The break near the support plate was a clean circumfrential fracture with fatigue striations evident. 4 Wear scars on the severed tube (R 45 C 54) matched with the wear scar on R 45 C 47 and indicated that it was in contact with several tubes in Row 45 at an angle of approximately 35*. 5 little cold working.The wear scar on R 45 C 47 was 50% through the wall and s i The ECT indication on this tube, taken in February 1982, showeo 49% tube wall reduction, which is a very good correlation. P Brookhaven National Laboratory 1. DNL examined the following tube samples: o the remaining pieces of the initial 6 tubes removed (includes the l rupturedtube) { o Row 44 Column 57 (bottom 9 inches) o Row 43 Column 59 (bottom 9 inches) o Row 44 Column 56 (top 9 foches) o 2 tubes from #6 wedge area 1 2. The findings of BNL's examination of the ruptured tube are consistent Westinghouse's. 3. Indications are that the ruptured tube bulged before breaking. omcr > sunme > oma> nac ronu m ommacu cm OFFICIAL RECORD COPY usam a

E +J 6' May 22, 1982 4 The break at the first support plate of tube R 44 C 56 was a fatigue fracture. 5. Dye penetrant testing of all tubes showed no indications of corrosion. 6. R 43 C 59 had a indication of intergrannular attack in the inner tube surface approximately 100 microns long that is felt to have occurred during the tube manufacture "pickeling" process. 7. There was a particle of Iron imbedded in the outer diameter of R 43 C 59 This supports the postulation that a foreign object caused the damage in the peripheral rows. The conclusion of all present was that all of the metallurgical results are consistent with each other. After the meeting, a tour was given of Westinghouse's facilities that were used in their analysis. Included in the tour were several mechanical tests being performed by Westinghouse on new tubes to demonstrate their theories on the initial damage to the periperal tubes. Original signed by James E. Lyons, Project Manager Operating Reactors Branch #5 Division of Licensing J A 9[ds mCW{g)U.s o,,,u, pc& ne.p. .4.W. s.'cc f/9 fz.. .3 11 j? ~ 2 om> y unc ronu sis 0a.803 sacu om OFFIClAL RECORD COPY uscro. mi m.

Mr. John E. Maier May 22, 1982 CC Harry H. Voigt, Esquire U. S. Environmental Protection Agency LeBoeuf, Lamb, Leiby and MacRae Region II Office" 1333 New Hampshire Avenue, N. W. ATTN: Regional Radiation Representative 3 I' Suite 1100 26 Federal Plaza h Washington, D. C. 20036 New York, New York. 10007 l Mr. Michael Slade Herbert Grossman, Esq., Chairman 12 Trailwood Circle Atomic Safety and Licensing Board Rochester, New York 14618 U. S. Nuclear Regulatory Commission Washington, D. C. 20555 1 Ezra Bialik Assistant Attorney General Ronald C. Haynes, Regional Administrator Environmental Protection Bureau Nuclear Regulatory Commission, Region I j New York State Department of Law 631 Park Avenue 2 World Trade Center King of Prussia, Pennsylvania 19406 New York, New York 10047 Resident Inspector R. E. Ginna Plant c/o U. S. NRC 1503 Lake Road Ontario, New York 14519 i j Director, Bureau of Nuclear Operations i State of New York Energy Office Agency Building 2 Empire State Plaza Albany, New York 12223 [ Supervisor of the Town of Ontario r l 107 Ridge Road West i Ontario, New York.14519 i ,l Dr. Emmeth A. Luebke ll Atomic Safety and Licensing Board U. S. Nuclear Regulatory Commission I, i Washington, D. C. 20555 f1 i Dr. Richard F. Cole l.: Atomic Safety and Licensing Board l! U. S. Nuclear Regulatory Commission li Washington, D. C. 20555 l I i

RGE Meeting e il 1 Westinghouse R&D Center April 27, 1982 j NAliE AFFILIATION ~ j Fred Pement W Nuclear Technology Div.-Forest, Hills ~~ ~ Bob./Aspden W. R&D Center 1 ,j Bob Mecredy Rochester Gas & Electric i ~ I William S. Galloway, Jr. Rochester Gas & Electr,1c 4 ? ? Al Curtis Rochester Gas & Electric Bob Smith Rochester Gas & Electric i C. Y. Cheng NRC j Emmett 11urphy NRC -J. E. Lyons.. ;- NRC G. P. Wachte11 Franklin Research Center L. Leonard ' Franklin

• Research Center Keith Wichman NRC.

l Sam Reynolds, Jr. NRC Region I .i f Carl Czafkowski BNL .j-J. R. Weeks' .BNL Warren E. Berry Battelle-Columbus, James W. Cunningham .W R&D Center ' A. W. Klein W Nuclear Technology Div.. Forest H. ills Peter J. Kuch'irka "E Nuclear Technology Div.-Forest Hills 1 l W. R. Junker W R&D Center ) I Russ Cepko W NC00 T. G.:Satryan W NSD P. S. VanTeslaar W NCOD 1 C. J. Kubit 1 Nuclear Technology Div. I I I + t w g ..e p... . eenman -e e.emausse-e w e w. asp-ame-eye m.e.. .amese + e.*- 1 F ,/

y ~ ] .A i i 4 t i. Ginna Station B.-Steam Generator l Steam Generator Tube Metallurgical Results j April 27, 1982 Agenda p1eCfl Introduction f RGEE Research .t Westinghouse } Battelle i .i NRC Research ~ 'k u Conclusions )i Jti 1 J / 1 1.. i.- i ll 1 b i e I l ", 9 l e l a'r 4 W', 5 I j .m s. - _ -e-ev=,- - + -a-~ =--w"-- ' ~~- se w

o $e t Objectives of Meeting ti lt To present results of Westinghouse and Battelle metallurgical investigations i I To review results of NRC sponsored research I D i. i* u ss ld ia iI u i; iI (l i1 i l3 i l ~l li ,i if n 1-1 1 1 j 1 I -1 .] !1 I q' a Y

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Abstract Detailed microscopic examinations were performed on a section of Row 42 l; - Column 55 (R42-C55) tubing taken from the hot leg side of the R. E. Ginna "B" steam generator in the region where the tube burst. Five neighboring previously plugged tubes were also examined. All of these Inconel 600 tubes displayed on their 0.0. surfaces one or more axially oriented flat zones which contained circumferential striations. Thirty-I eight of the forty flat zones that were examined exhibited cold work I (0.D.) surface layers, a feature which is consistent with a waar pro-cess. The burst in R42-C55 occurred at one of these flits where the

I wall thickness had been reduced from the nominal 0.050 in. to 0.008 in.

Cold work was not identified on the flat that burst. Fractography revealed a normal ductile tensile overload failure at the burst. Fatigue cracking was identified as one mode of breakage of previously

j plugged tubes.

Normal metallurgical properties were identified for the burst tube and for one plugged tube. .i

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6 1.0 Introduction On January 25,' 1982, a tube ruptured in the "B" nuclear steam generator ) of the Rochester Gas and Electric Corporation (RGE) R. E. Ginna Power Plant. The burst tube was determined to be three tube-rows in from the ~ periphery on the hot leg side at Row 42 - Column 55 (R42-C55). The leak was due to an axially oriented " fish-mouth" opening just above the top of the tubesheet. In addition, some of the previously plugged neighboring peripheral tubes exhibited collapse, deformation, or frac-turi. conditions which were not present at the time these tubes were plugged. A hole was cut in the shell at Column 55 and nine-inch lengths of the leaking and neighboring tubes were removed. Sections of six tubes were sent to the Westinghouse R&D Center, Pittsburgh, Pennsylvania for metal-lurgical characterization. These consisted of the leaking tube (R42-C55) and five neighboring and previously plugged tubes (R44-C54, R43-C54, R44-C55, R43-C55 and R43-C56). I 2.0 Nondestructive Examinations _ Prior to removal of each section from the steam generator, a yellow dot was placed on each section to define the tube surface closest to the perimeter of the generator. In the current examination this dot was taken as the 00 position. Each tube length was received in one or two sections, originally extending from near the top of the tubesheet to ten in, above the top of the tubesheet. Photographs of the leaking tube from Row 42 - Column 55 (R42-C55) show a p " fish-mouth" opening at 00 and axially oriented flats at 0, 60 and 3150 These flats had circumferential striations, Figures 2-1 and 2-2. Photographs in Figures 2-3 to 2-8 are of the neighboring pre-L viously plugged tubes: R43-C55, R44-C55, R43-C54, R44-C54 and R43-C56. lj Similar flats were observed on all tubes at various angular positions. 4 There is extensivh metal loss and apparent deformation on all tube sections. Tubes from R44-C55 and R44-C54 arrived in two sections. i Wall thickness measurements were consistent with a nominal 50 mil wall away from the flats and a wall thickness reduction at the flats, Figure 2-9, Tcble 2-1. Double wall x-ray radiographs were made of all tube sections at 0, 45, 90 and 3150 A Seifert Industrial X-ray unit was used with the fol-lowing settings: 5 min. exposure time,110 to 70 kV,10 milliamperes, 1 60 in. source-to-film distance, large focal spot, and Kodak M-8 lead pack film. Wall thickness reductions were easily seen; however, there i was no evidence of intergranular attack or stress corrosion cracking. t L S 0165s:10

.i Prints of typical radiographs on the C55 tubes are shown in Figures 2-10 ' to 2-12, together with diagrams which depict the locations and orien-tations of ths laboratory cuts that were made for microscopic examina-tions. The other three tubes were examined metallographically on transverse cross sections at elevations of 2-1/2 and 4 in. from the tops of the sections; cutting diagrams are not indicated for these three tubes. After cutting in the laboratory, all sections were notched at 00 on the tubesheet end to maintain orientation. ~ 3.0 Metallography The metallographic mounts are positioned on tubesheet maps in Figures 3-1 and 3-2 in an attempt to aid others in conttructing the sequence of events leading to tube leakage. Microstructures through the leaking tube R42-C55 are shown in Figures 3-3 and 3-4. These microstructures were etched with two percent bromine-methanol solution (only etchant used in this study). Cold work was not evident on the flat tha'.. burst, but was apparent on the 600 flat. The fracture face was not intergranular and was of the tensile overload type. The microstructure appeared normal and had carbide banding occurring to a greater degree near the I.D. At 0.0. surfaces i away from the flats, shallow amounts of cold work were observed and probably resulted from belt polishing in the manufacture of the tubing, i e.g., 0.2 mils depth of cold work at 2700 in Figure 3-4. Metallography on the other tubes is presented in Figures 3-5 to 3-17 and the depth of cold work on the flats is summarized in Table 3-1. Thirty eight of forty examinations of the flats showed evidence of cold work up to a depth of 1.1 mils. One of the two flats not showing evidence of cold work was at 00 on tube R42-C55 and was the flat that ruptured. The heaviest degrees of cold work were observed on the bottom of the concave. surface of R44-C55, Figures 3-9 to 3-11. Some transgranular i cracks were present and may have resulted from fatigue. Microhardness l traverses, Figure 3-18 and Table 3-2, confirmed that the Oo flat on tube R42-C55 had no detectable cold work and that 0.D. surfaces away I from flats and other flats had cold work (increase in hardness at the / surface). 4.0 Scanning Electron Microscopy Examinations were made of surfaces with the scanning electron microscope (SEM - also used to designate scanning electron micrograph) and with the Energy Dispusive X-ray Spectrometer (EDS). For tube R42-C55, the flat that ruptured had circumferential striations, and the fracture surface had some dimples that are characteristic of tensile overload, Figures 4-1 and 4-2. Fractography on a horizontal fracture near the center of R43-C55 sug-gested that fatigue contributed to cracking, Figures 4-3 and 4-4. 0165s:10, m-,

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. - - ~ ~ - I; Table 2-1 1 Wall thickness measurements (mils) at various positions l on Column 55 tubes 3 Tube No. Angular Position ( Ax ial 0* 45 90 135 180 225 270 315 position) R42 (1/ 2" below 50 54 53 54 56 57 51 57 i top) ] (1/ 2" above } bottom) 56 53' 53 53 53 54 56 56 r (1/4" above bottom) 57 53 53 53 52 R43 (1/ 2" below top) 47 46 51 52 53 51 48 10 (1/ 2" above 46 53 47 49 56 bottom) g i R44 l (1/2" below top) 53 53 51 50 50 45 30 53 (3/4" above bottom) 48 Ej (1/ 2" above botton) 46 l (1/4" above bottom) 36 5 i 5 ? .Ij s 8 ' te e

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-W1 @.'.:.,'- G., ',g,f f l'i, e -;s ).,,,.;l(s. l',y.}, =.. '_ q} ) ~-},;; ... %.M..* '.s%: ls-ik.7s. '+: r\\ ), h*.>,.,~ n %,*. g.9.?.. ' >'.,{T=., ;.". r p,.T...g, I ,.s. q ..8 .N.n.. e. .s.5[..- (:

4..

A,%

,d

.. !-lll., k .p p f i.?,.,[. n,,,,,,,,,J., a. 'T It % ', M i .>. g, " ?s! '

h. :$ 9..5

• i,3

.5 $ h em [ Y ~ a- .v_1, Q-r "s%g[. ) 'v}W .. w.= v .w .. r. 's. 1'. s. * 'A.1?. g<,,e(r,4'T-fy't""TiK 3 }.a g'.,; 4 t.,g a %. N tp.,. .,e $. 1 5 S v4 Y } % f ,- b; (*; l 1 a -s " '...; ~...s.(._.~1,... i... ..'.'a..,,. j t' 9 s .%,+f... j .;.o s..... 4 ?. m.. . -... ~ - x.. s a 4.r ..m +r .,w y?..~ , e 1. ~m.. A.:.<,m. ~- 1 i l l Fig. 3-6. OD surfaces 4" down from the top of the section frem Tube R43-C55 l RM-94673 p L

o ~r-- ---~s-j,'5,y;y. hf,*h. [,, D.*.. l.. Mf,. [ ' k;U, {@h. 6'.;,, '3 ,.j ).".; s ',.., ',"k pf;.D; ,..b.. . ~, m W. U,.'

• f,- ' q.t

..'s l. . t. = ,. Ij 8.-t J y 3.,(,1.. ,.4 . f We fil--:.

• 1; (Q. ' ','.t y,.'.'.,

- (.. s c, 1. ..) 51 p .f. .!. q.- i Q. .[

f'l' ~;',. -.

,.p. hq. - ? '~ ~ .,:*) ..i ?. lQ- &? iO ? b 1f.:,. w 1: +..,.: 3 [ k h; N,...,,, Wiw [T%. ~ >4 ;y 3.',(' { *,7, I l U -:. W*T.g.:a22, -u.w,e t. W _g.';d .a..Wer.,; . v.b *lf,j* p;.y First polish y ~ .p J 'M'./,~','.3. '.;*='~ ~..E'A' t /.J** :- t.3.'c"*e 9 ,4'[2,i UD.I O_ and etch ls E ' q'i,... .-9 A I N 3 J*~ 4... i ' '.'f .Q .g : p,,. &_-%;>;..l,-).;*:*.. - 4 00 5

• ?

? p ~- .~jy f$ %'. ' b ' .. 'h'hM$[.dk;>,f,bdj 1 After removal of i'- ' S'. .',.Q[. fp, ',$k j and additiona1 f,.h:,0W1'^i:?.. 0.025" ,/*. W 2.. ,: 4 ,~ ct.. .d"- '. 'p).%p.t,c*;o..'.\\.. "m.%..,?q i p%>. w.L~S4: m 's a.'. n % g?.sd:? M th* >.%

n a

NWn,

4. h 9

Fig. 3-7. Four inches down from top portion of Tube R44-C55 i i RM-94674 - - ~ - ,.u...----,

---

.-1

^^^

1 I a i ( L, L _L L w,.LMC'z., - W w.i'~~M3_~ m .} *. 7 -:-- W E. O ** '., W $.~i!- 'f '. U: ~ if.Q. Q, . :.'./ _" .; t.. ' ',' n .b, N k]J

• f

3 .N' i hc: . s., ~.\\'*.

\\ ;j,

(...?.

y;; Q*.";-g: -

. ~. ;;..:- s; 9:. - ,&.~. 1 g- ,.',/. 2.y.:x '. g,..-;.... K.g.:..' -b ..p*. :.- t-***p, y. ,~.\\ 1: - * * '.i - \\ %., .1. c.j. :.. ~...q.v.~-.. e 9Lj... ; x u ~ t. . V, v. -.. y_.:t-m - 1,v. y .a. ~ ,n. L. i3 .d '....,../..;,: q e n.:.e .i. ,..,.....n. ,w c..n s.. .w \\\\. w).my.w e-qa- -,- \\ 1;,,..... : '

• g...i Sa8..,,,

[( l } N ? ' l_N w l,. 'Yl~,%., ,4

., gw'g, '.A ;-, @%-

t , 1.jt %q. + Z y .. q.. h ? c v & )T 1*,, i G, 4 r w.L .,l ',...g..kc re 1. p 4 f G} . y.

ze,!;

9.,..

k;

Q

._.'::;?- ? 9.:. -;g . ' J.ft;,. . t.Q.. L m s y:: f:r/? W }",Q,( 5.*.

• H

..S. ':., I. a e' 1 ' -s t V e - ,.,h '. ~,, ' .- y,./,.. r, /, \\. .... m' \\ w n j,' / '.*S,' ^ ' ' VQ(.Y.M'^7Q'I2/j M. /. (K~.[i

' _ ;, 4. I);-[$ $

Y j,%. s

• f. l./?.f. Q.? 'Y h.*

.~ ?' f: -.c s.. 7 1 + .a ta f y.,; d'. .[T.. g, 4 .[. 1 # r/~.I' .3 ,...j

u

.rg.. s 'd*.-{15 b.,[ N. J - .1..]. 5.. 3bd c c..s .m,n-q"f.. f. ; - s....- x y 9, a ..-j%, Y - ?.. ~,. : s s ,.7. g-5,.s. s.;-} l-

x. ;.

.'.t W&.e ,2 ...,. m. ,1,W w.. . f$h._paJ. bihh ihjh - Nh7,7v,NiNd NM-h'h ( 6 j Fig. 3-8. Meta 11ography on transverse cross-section down 6" from top of top portion of Tube R44-C55. Similar I results were observed after polishing an additional 24 mils. t RM-94675 t. .-w w-m y e, g. W

if.- M A +D. n '3..b4WF.:,. ,. c y Y i i.s .g. b ,6 ~M'- pr g p I' [. t-N: l l] i + . c g; _. ~ ya: - t M. &f.?hY h&*.$ '5. ~ ~,;"'6ShNY ff whj?k5f ?'}hh ~ ~.

O

.. A $. %c1bEs vic.x < 's-g$1IDbMCs2 'O Fig. 3-9. Meta 11ography 7" from top of top portion of Tube R44-C55 i l l l i RM-94676 . ~

v^ ~ ss f @~ t hMM5W[}~_d c V ..h kj, s l %Y,~i.-j Q ' k V -: k l ) U -2 h h-1:. f'47 .w & & ';, "4 1 af ph:$ f'9.', ~ T I ,-{ ? ^ A- ~ Y ..,t';; 7% l[ l ur [. ?' ?i ' ' ,I } 4 ^ ~ ^ b ^5 (* Ss! 1

, ' + *. * ;,. jLT,:, f

.{Q%,j sy ,1c, _ e,, 4;y; ^ f:'~ p'- [ M(

• W. g u l Y 1

W 't

y'

.g f.y '. =ggi 'N . ]E!. hug E 1 s- ' .!,Q. Tf.g . a.n

e 5

- gy#5 } ~ ~ ~~ d 4em af gj' e 7, ~. A .. fj g j. ,j t ^ ~ 'dre.y fWig; L f.- , gr i -+ gw yh Q f J J f Fig. 3-10. Continuation of metallography 7" from top of top portion of Tube 244-C55 2 i l 1 i j 4 RM-94677 i . ~ - ---_

Tn:.1%'M%yy a W CD s E3fg['hg5kkk%d3 @@?50] % t&@$EWWY%Eds k = =e a E F i w >4 4 [jg,s gt q;?ff,q ra. >gs 79Cep#$"%q-: t7 A - .' _T ; _. ' n - -

$h.p;;

" ?d Mj l', c .. i ? t -7/t,- ?' ~, ' ../_l # R'shE:S@hj.hp Q:an.,'[i}ff ll;..l'% Ily:.hst .V8 w.. D_ %%74:6Ew@a...:. N4

%G= p.29 Mh4Mf. 'wla M

4'.. om%sw?!addh p wT U u.T: .4 AD g

• g ar ID.g{w' C-M' A-:

u- . N.; .- s-N..fj ~~~,v f 3t,. 1 1 l; Fig. 3-11 Meta 11ographyattheOD(0*)8p"downfromthetop I of the top portion of E44-C55 1 1 4 l RM-94678 1 1 1 ~ ' <~-we e ,m ~ l

~ 3 e t $h5 kIY . ']; h' -- = _ E ~" . _Z '.?f v,, ..,y b.Q' ges.. L.

n q q~a f '" M W ",. R ; y k

7 a. x, n. 2 -.k

• WQp

.,,4 s' *

• • w j

.,, X /n A Oq

f. {.

R... s ~- .11. sr.f. h.., - -'/ - .s 't , ~\\ ~. ..p*.O ?c. ' a r s !. I. 1 v. r..,... a; s. ' k,-f _ p* .' *g g. .' 1 M.y .'T:r '? 4 , " _. f.'7 k,..s.e' ^y f,.1* !&^ [, g M. ?. l= %.. y, g? ,'c. *<. n -: T-,. ::fi..-

, x: 3 b) f,.y y~$j'%,:!;.

~L_

g *.

-, ggj '? ' -]. /..,

k.,

_.',. >.,. s m.5-h _ s.c..gi5af .. _., - - - - = e;. ') }r. r ~ ) Wh...w:J;... n 6 4* M ($2 .. _R 9. 4., 3 Fig. 3-12. Metallography 2 " down from the top of section from 4 Tube R43-C54 I i. e i RM-94679 l i -n= =-.=.==

~_- i o 1, I a f, ..'I ~jD i ~,. x? .. C.%. -Q' .s.. z--. ,i J-p g,. 4 ;J.i - u i. s,,... - +- - ) ,')J - A-Q-

.:.3-Q sg'

' ; "'f, -5' t

• ' r.

b.\\ 'k].}:y. ~,

' s ?

.,. _. ' ~, ' ' j .;!).'68.,&TN WQ' .I 8*.% ) :9? W$ ,." ~ ; V s ~s j ;' f*. ^

p. d 1

.y .I-V> M y <' p .f p .a t. ? .2, .g, 3

.,a.

-y....; 5. - t ::.rge

- c.

. ::;e.m:.. .... f' e .c f,T ', .;;g;*-&- . ~. Q);? !~... N).,.,- m

u ;

~%.)5 4

r -

r . s y _. _ _\\.

f. b*

'h:g* 4&hOQ [fh 'i' l_ i5. ~k.t 3Db 'JX P I Fig. 3-13. OD surfaces 3f" down from top of section from l Tube R43-C54 l! 1! RM-94680 l i 3 ... _ _ _, __ _. + --~e

. ~.__ l i I i l i r w e.;;; ),;') 'Y '; : . 5,- h! Ol* A ~.q:: h: ::l,..h.:R....f y 9 ..i a.i.p t  :.:.. a.s y

n

'/ ""h'. l 1 Q[- g ,"* Y. ,e .f Q.! ,., E -[.1 - l 't l+ J .a s. .a/. V ~x c 3.. . i aj... .m s .g'.Et g# m - .end. a ;; j.;., s g3 . vs % V' M 2,:: ' :- \\ Q + ./ n. ') %",Q . s i. u a A4 e j'- ._-f',. ', f j ,1,.{,. -}-:R A}{-}":y hff. . [- 8 m, in -.. t =O , t ~ e,,; +.- (-w.a v. -o..s. y ji h 284 j g ,,4...,3 9 ; g n :' yy . ; g, 1 f_f.?x\\ : mg.m. E q. v : ?. n.,3..; 'i. i.a. 'Y \\* W w 2.L1 .s %.... e.;. y 1+ .c e.. w

' t h~ M)W,f[

f'.&"7:.7&:.'yggQj4.].d.'-)_7l$ l t i j ;. D Is.}!i. bx9.. W3.s _ 4 .).

09. 3?:b Ofl

, ' ^, f_;_. :f tq-Q.e,w: nw... ~u79 s_ f;. 2.g;g. n '. d '... S* \\ +. U n n :..' '. 1;. n.

,wf..

u s L ,J 6 M..,k e....3 @

• h

+ = = t sn y A k-If Iib ?t((h$$.4 ;;i ,k.. e.,. j f,j,%

f ; 4.

r p. i M. r : M *; h h3 C L'.. J Fig. 3-14. Transverse cross section 2h" down fro:n the top of the top portion of Tube R44-C54 RM-94681 l ~ ~ ' ~ ^ -. rur ' ^

,,- ~ _ f_;';h g f ,- 5 ,' $ ~. is, s .me ../.w, v % 93 9 ix:.. ,((9.; c- , g'..' Q't * - 5Y N ' .- \\.. .n F];k ' M N ~ ', kN _. '~ I gd -s .4- - s .w }.,i5!

4

{ ~ ,5. '!.. ; c. b)% .s; <. / ;,j i*

~ ' ; : ~X

• 1

- 3 .. g., % + #f, 4 g s. .T L. l 7 _'.. p'. of t-,- ' '..;) - ,s. . - : 3. . :., q y, q. 3;3 l Fi. e sd s. - L:F ) i -{ 1 n m \\.. j. g. 4 T, t, (p.. j l.'.. _ e g s. ,s - -y4 a my L <:>v l. y yt %A y- -w- .f y[.,., --jj. ,e 4 ..- m -t ap.s 7. s g ~~ ? . i / - l

~ x., ~

/ .it. p .. 1 . d ' p.gg_p. (, s ha;...S,}.IgMQ;.:f,.j g l/ j_ ", W~; h.* ch. % ~t. ..L a :. L' ^: n-w.v, : r. y.t_q f.e,W.*j%.; f;, St Nfh,I -h~.' ,"f." ~ i ,;,, ;?. }ry _t sdb.>. + n-s-3 1 M..\\ y,,y ih LA',..2 i 3 Meta 11ography 3 " down from top end of top portion Fig. 3-15. 7 i of R44-C54 e } RM-94682 s,. r

l i

y.c l

/ \\ w-., n

t.

.. u ~... ; ~g y, .,. a .. n. t ; - \\. E ~i [h N J,;- ' 5.

• f f

4. c.. e,.y..3,

,n... c qc., 3, -...,,. m .i, A .f .~ f ,h Y ' 4.,. \\, [ [~ \\ E [.* ;. k.'b h ~* !.

., f -

.:a.f7. - se , ' 2 :%. e%.. ,, !) y;.).,,., 4 4 . - e "x q,g... ?:,r '...,.- 4 J. y . <p.;'s. ~qif. .y. :. , I p. kn N13' $d. 9.; > m.g= nm ph.. ra - -.. ~ :.r -.. - e* 3 .Af.f*Q)h} Q. l,7i. i c -eW, u,. 5- # 4 .. x v: Q.

-t, :>r / g.+ m.

r ~ o "g

g.,

'.: a A r.Y.@p '- l.,'.,si.> /..,). - ) h Fig. 3-16. OD surfaces 2 " down from the top of the section from Tube R43-C56 RM-94683 i ~.,. - -..

I l 8'

i j

,e....-

4.., %

j".. ' ' ..J. ~ T 9j T s. l.;Q _ .y .., g - s

• v'

~ a E ,t s

s'

'1 } (l@,@,.A j~ /. 4 .;g.w

;g -

2 Q v.-c..;g' y,<g'.y.3 k [.l.'...) '~ se ~ db- .?. i ../.. q.w 3 .. V-f. y 2.Luri .... W 3 ' e'? t w,

3.../

.'vtK.. s. e. ie 'e .Ju:s s.g :. vn, r

y:.

M ...,. o. } L. A:.. .:o jf. i -w .Y'NkY f m '..O

5...

,?:.1 [ 9;;;;q.'p / .i l)b ?"YfY5 W &, &u?.~ 4 6 :iv.i$ WM ^3. -: ?:'< C .) ?-[g

• ftR"'3 n

,y Q " *q 'W C.,a..e..v.b: - F. g l % u_,- c-f F_ '~

-a

<,.=.. n _., p 3.. %..a)d, y. . c a.....:.\\

n.,

...y a .i Ga,wn. F; y, 1 a ..~ .l T..Q_j5Y. 1~;/ % ; v. g... n -.c.

i

.i 3 OD surfaces 3,' down from the top of the section from Fig. 3-17. 7 Tube R43-C56 l l

[

1 RM-94684 .i ._, ^ ~

s f Table 3-1 Depth of cold work to the nearest 0.1 mil on wall reduced [ areas (Tabulated v.alues are angular position-max. depth in mils) Tube No. (Approximate l Axial Position From Top of Tube Section) R42-C55 2-1/2" (0* - 0.0) * ( 60* - 0.4)

• 4" (0* - 0.0)* (60* - 0.4)

R43-C55 2-1/2" (30*-1.3 ) (225*-0.5) (270*-0.4) (330*-0.2) 4" (30*-0. 3) (4 5*-0. 5) ( 225*-0. 5) (300*-0. 4) R44-C55 2-1/2" (60 *-0. 5) ( 225*-0. 6) ( 270*-0. 3) 4" (7 5'-0. 2) * (105*-0.2) * (150*-1.0) ( 200*-0. 6) (27 0 *- 0.4) 6" (105*-0. 5) (150 * -0. 8) * ( 270 *-0. 6)

• 7"

( 90P-0. 0)*(180 *-0. 5) ( 240 *-0. 6)

• R43-C54 2-1/2" (3 0-0. 9)
• 4" (30* 0. 9) * (19 5*-0. 5) (315*-0. 5)

R44-C54 2-1/2" (60*-0.9)*(90-1.0)*( 270*-0.6 )(300*-0.9) 4" ( 60* -1.1) * (10 5* -1. 0) * (180 *-0. 6) ( 27 0* -0.7 ) R43-C56 2-1/2" (0*-0.3)* 4" ' ( 0* -0. 5) *

• Shown in photomicrographs on transverse cross-sections s'

nj, - e.,,. 7 .p,.-- .---,n,

's s n t _. : i -T ..ce- ,, v,w 7 $0 ;

. k.-

i 3 -; *- A. ;A,.. :Ax f' ~ :.Y'; g#.4'C %.. - l ~' . 4V (.11 i = g' A. tu. qw. ?:,4 4 v110ftjSphrs%t l! ,2 51DOTHSb617.Y317 3 1 'l -%13263ES,e y,T

-g :, m 1);ikt 6

!!!!!!!!!lIlll I!!III I Ii

• ALWiME. su; y r-F

%. - -s-g 4 2 ,r.- 3J g t .k i Four inches from top of R42-C55 ,1 1 -y. e. .%~ ' E l 1 i a

a. ; u.m e. +..., : q' m

\\

• H rI.

" m/h.79,, w'.s.w. % j g .' i 1 g 1 )1 !J 1 ii c. 4 l 'M= r' ~ ). j i Four inches from top of R44-C55 ) l' Fig. 3-18 Locations of Knoop microhardness traverses r d k j 1 RM-94685 i .....-.,..,.-..-.-.._-_::'~~: - -.. -.,. _

* :^

~~~ ^: 1

. =. . = } Table 3-2 Knoop (100g) microhardness traverses at various locations on Tubes R42-C55 and R44-C55 i Tube Position No. Remarks % Depth from OD surface ] in mils ] 1 2 4 9 14 19 R42-C55 1 Flat 224 228 231 237 2 Flat 180 194 195 192 ] 3 No Flat 258 224 229 211 R44-C55 4 Flat 321 300 223 224 254 5 No Flat 364 261 312 289 261 209' 6 Flat 321 312 248 214 226 194 1 4 I 4 4 i \\

i l

i t l l 1 '. h 4 lt I l l u

l j ! t

r. d&W:;$.&,1

&hS$ '., M yk ~ V ?^ N 5 .<:.y f f n'G p.- ~ t h^ y~; sG v&, J:,l '1[*. s %.n !n w,h w..ps. ,~ i. r i, %Q, Q"&.L;, i

• • l,5C

. g.;,', l

• Y Q

l .. t : - t ~

1. ea,.,go. 3.r ~

-s. j h5 ..'s&".]IA (i 'f+ '~-(* *, - ' '? "?51 ~ 34.g r -Q.. *

• p.. g.;

A -- g(.,. a ; ,EJ)y,..f ~' W S.e .....q.,< Wik,fy % $.'V00<,}1n y?,( e. J

• 't..j
• i l

%- p Wt.7.:~t-g .fi Y y p: } rG - -- a. <- :,.. a = _ _,z mnt \\ lj riat ll reacture face i iI \\ g* \\ y1C.}I -d i t %.g . 4. 1 I' s0. t am.' ns : ' i' {e! \\\\ .? .hl .'u q 1 A f-j', )j 4 4,-

t -

• k-i

u. }

%) i 4 mG .a i e !I _,.y i1 j.<' 'I Fig. 4-1 SEM's of flat and fracture face above center of fish mouth crack on Tube R42-C55 i \\ 4 kj PM-94686 i, '~ ~~-+-e.--

a w ~.% M p y ka} /

• W**--

~^ g 77 e ) b i jhp l k I 4[ Z jg 7 '!M 3d-Q i ,gg(' ' ' M IM.4-~ ~ f + T* Q .h 1 Center of fracture t' f *Q:-Qh* *:'4fgif&' ' f .ho% ".* 4 &y = ;

e,r r

& y' g/) liulL"g f i W. ~ l f r$ d' py: ');/j .1 ~( l-l;-* ~ $$;.l?,f '^ ~ ?. 4?;,Sr* 100 ~ ~ .. ~ .e { Tfg af h-- Flac on OD c, Fracture surface { T ; ^ 6 N$< 7dh ~ .- %w<! t n b A ?J, I-r 400 / pm e t i Fig. 4-2 SEM's of flat and fracture surface at center of fish mouth crack on Tube R42-C55 h* RM-94687

. Yk5lhfyi DYWU$IN&YWY:1 MSN p. .,[ 'fq & M,t.25".:.'f** W :M w m. j

• ~ "

. N.~. p?[. .g.,y a h gr ,;,,h, pe[ k y, __,(_-__,,e-a w c I' ' L ruk _ ,h_f'_%_TarIMM'%Md[hN6N

1. d i

Higher magnification SEM's on next figure >2.%=T-K&iVWR.Mpq!v.avn w"TQY' @hho.E oo .-% m:~ k-:e..

.: ~~ ". : 4/:s. : -

_ N x%4.% }f;, - ' .oc-e,. %. -. .(/ n as. .g p 4 ' } 4 .3 h..,.. -. N Y.. C)q%,. b _.T.% . #.4..

b. ',-@ kN D

p s;r.q. 9c.% .,E 7 %...'.Q.N -.Q [ h "b N_[g'NbN i l n s. [-. Fig. 4-3. SEM's on horizontal fracture 'N surface of specimen from ^ Tube R43-C55 ,j N 1 ,j -? 4 , EJs Jgw 1 l i s-wm i ^' i,' [. - g., ggg y.m s .. is,.,,, m W l

1. A ele 3,nhi M 4

n RM-94688

l ~ I" " i

• 118"**

S [.._, g J. ?!_-d. ' p,WD2, _,,. V ~ Of f.' ? .M } -r 9 't t/84 W hS[& ? (;..22--r. An ?' g, rY.., -T;'A 1 F sg[1 @9.,ij@ 4 >? h ,- ] I[ i - - = -= _ .. 3 ~. pg\\ kg' k h.'.MM lI \\ ?h*( w

T f..

~. x,D,:g'/ .. ~ g_ gwe2 t- -_y__p_. l Fig. 4-4. SEM's near peak in prior figure and on fracture face. RM-94689 ^

1 } " NEh , _ k)k % + _- _ %- o O._, CSMCT+ ohm 3 rY.~.~,.M;yy -~~ wheM l sw3r v- -? w 6 r- .4 - ~ .a w-Ml -"D N I g --___m y &aGF--_-i^ M. ~ h i 't ) Element Weight & Line Percent '[l I Al Ka 0.93 i Si Ks 1.69 CR l l HI Ti K. 0.39 9 Cr Ka 23.59 Fe Ka 13.20 (( }l Ni Ka 49.25 l. i (' Cu Km 5.23 jf 2n Ks 5.63 ${ t i I e p i TOTAL 100.00 Q[ y{ l [y ]y b-A !bkv.+e.,;',. ;2;,a ap.....c%o.,,,s n-l l t i Fig. 4-5 EDS analysis on lower lef t area of 270* flat that was 1" down from the top of top portion of Tube R44-C55 (Section 7A). i l l l i I ! RM-94690 4

J Cut surface t 0.1

• I
• 1

,? m, .P' i f,. ldY ~ G. 5 r-h ti 1 il h j 3 f >135' <135* Axial Axial Fracture Fracture ll l! Fig. 4-6, Fraccography was performed on two axial fracture i surfaces 1-1/2" from the bottom of the top portion 1 of Tube R44-C55 \\ l t RM-94691 i

l

'l

l ld AM ffjf

. a. Y. -f it. TW

• j.

t, fjy.s.M8+3 4 I 2,1 'l

). ' i i

S [. ,1 e Y.*. h' 8 ? .t. 1, ::. I .F ', ' v. , =.. p ((,!,'l 3 } rj r .l! .,f

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W.; ~ y l-r _ s.,) j s~ 1 I,., M YbK*I 22 ,, ( i...- j Fig. 4-11. Fractography on bottom fracture surface of Tube R44-C54; Area 1 (lef t) and Area 2(right) I RM-94696

N CR I T CR FE NI NIhdessRudhdmanem Wb 6 L - - - -- i z 1 t i j EDS Analysis ASTM Spec. SB-163 h; Element w/o w/o ] & Line h Cr Ka 17.0 14.0 to 17.0 Fe Ka 8.5 6.0 to 10.0 Ni Ka 74.4 72.0 (min) l b 4 ) i 1 1 1 1 ( Fig. 5-1. EDS spectrum and analysis for principal elements on I Section 1A from Tube R44-C55 g l (Included are ASTM specifications). \\ \\

j I a l J Table 5-1 Mechanical Properties I f l a Tub e No. Knoop Hardness R Yield Strength Percent (!OO g) (0.2% offset) Hardness Ref. (2) Ref (3) Elongation (4) l R44-C55 206.6 88 56,000 62,000 >28 r i R42-C55 171.3 80 45,000 45,000 >28 l

1) Converted by ASTM E140-79

2) Correlation establish on 24 tubes of Inconel 600 by R. G. Aspden 3)

Estimated by correlations established in Inconel alloy 600, Hunting Alloy Products Division, the International Nickel Company, Inc.

4) No fissuras developed when bent around a 3/32" dia. mandrel-calculated values.

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i i i i i i i i i i i 70 a - 65 x ) n 60 o .cg c 55 o O O b O [ 50 o/ko I 'E5 8 8O O e 45 --O E Vf Slope: 1,423 psi /R8 o o 40 g .o 35 i l j i i i i r i i i i i 72 74 76 78 80 82 84 86 88 90 92 i Rockwell "B" Hardness .l Fig. 5-2. Correlation of Rockwell. "B" hardness and yield strength on 24 heats of Inconel 600 tubing and estimated strengths o'f two Cinna tubes (dashed lines). i I -l i $i 'l i ee p wvQmem SOM wam _W" Y-

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~ llARDNESS DATA - TUBE R45C54 NEAR IUBE SHEET DEPRESSED WEAR AREA, 180* TUBE, 90* FROM IUBE,ilEAR [UBE WALL WEAR AREA, BREAK FROM BREAK WEAR AREAS SUPPORT PLATE ID RC 30 RB 77 RB 72 RB 72 RB 63 33 90 94 69 85 34 90 93 89 80 36 94 98 82 84 ] 37 OD 98 OD RC 25 84 82 89 84 38 39 OD 87 82 OD 40 OD 79 DLSURFACE OD SURFACE RB 98 RC 25 94 29 -l 98 27 98 27 RC 24 fl4Battelle ( coimbmadoratories le

i I EDAX IN DEPRESSED AREA 0F TUBE R45C54 i RELATIVE INTENSITY OF ELEMENT, PERCENT AREA 3 AREA 4 AREA 1 AREA 2 (MIDDLE OF (BoTTon 0F ELEMENT (ABOVE BEND) (JusT BELOW BEND) DEPRESSED AREA) DEPRESSED AREA) a FE 15.3 17.0 14.2 13.2 CR 33.3 27.6 31.7 31.8 i l NI 47.3 .43.6 43.7 44.8 i Cu 3.9 11.7 10.2 9.4 OBaHelle ( wumbus uboratories 4

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