ML20154C601
| ML20154C601 | |
| Person / Time | |
|---|---|
| Site: | South Texas  |
| Issue date: | 03/31/1988 |
| From: | Chung Y, Manley R, White R BECHTEL NATIONAL, INC. |
| To: | |
| Shared Package | |
| ML20154C596 | List: |
| References | |
| NUDOCS 8805180240 | |
| Download: ML20154C601 (19) | |
Text
{{#Wiki_filter:. . ,. .. - - () FAILURE ANALYSIS OF DIESEL CYLINDER LINER EXPANSION BELLOWS Report for i South Texas Project 4 Prepared for R. L. Randels J ' By 0,,
), , , , . s Y. Ch g '
4 Approved NfN l2 v
\
R. A. White , Materials and Corrosion Group Manager j { l' Approved 7[ ,dN5/e[F R. A. Manley , Manager f 3 I l i Materials and Quality Services 1 4 Research and Development
, BECHTEL NATIONAL, INC.
SAN FRANCISCO 4 4 Job No. 14926-001 Tech. Report No. 8803-01 FA
, Log No. 0138177 BLN No. 8802-04 1
March 1988 , , 8805180240 880511 PDR ADOCK 05000498 P DCD ,
e i ABSTRACT O No 18-inch Type 321 stainless steel bellows removed from diesel liner expansion seals were examined to determine the cause of the failure. One of the bellows showed corrosion perforation and cracking in the convolutions and the seam weld. n e results of visual examination, metallographic examination, and microbiological analysis are presented. We corroded areas showed signs of iron bacteria (Callionella) which influenced the corrosion and cracking the stainless steel bellows. J 1 O 1 I l l 1 i I i 4 O 1 l I \ .t. I l
i
~h FAILURE ANALYSIS OF DIESEL CYLINDER (V
LINER EXPANSION BELLOWS CONTENTS i fagg l I ABSTRACT................................................................ i CONTENTS................................................................ ii. i
1.0 INTRODUCTION
................................................. 1 l 2.0 C0hCLUSIONS AND RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 j 3.0 MATERIAL ...................................................... 1 .
t 4.0 V I S UAL E XAMI NAT I ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 i 5.0 METALLOCRAPHI C E XAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 l 6.0 MICROBIOLOGICAL ANALYSIS ..................................... 2 7.0 DISCUSSION ................................................... 3 l l l I I
-Lt-
1.0 INTRODUCTION
() Two 18-inch expansion bellows for diesel engine cylinder liner expansion lower seal were received for a failure analysis at the Bechtel M&QS Laboratory. These two bellows, shown in Figure 1 in the as-received condition, had the following identification. [ Bellows No. 1 Bellows No. 2 C~B PN 2-OlS 118-001 C-3 PN 2-01S 118-001 1 DATE OF MFR 1-78 DATE OF NFR l-78 8B7155 882160 We performed visual examination, metallographic examinatfor., and microbiological analysis.
2.0 CONCLUSION
S AND RECOMMENDATIONS (1) One of the two bellows examined failed due to pitting corrosion and cracking which perforated the Type 321 stainless steel convolution. The other bellows showed no pitting or cracking. ; (2) Both bellows were exposed to fluids containing iron bacteria, which influenced the corrosion and cracking in the bellows elements and the end pieces. (3) The cooling fluids entering the bellows should be treated with biocide.
~#
3.0 MATERIAL The bellows material is Type 321 stainless steel according to the memorandum
- referenced beloa. This is confirmed by titanium carbonitride particles in the microstructure, which are a characteristic of this grade.
4.0 VISUAL EXAMINATION Bellows No. 1 showed holes in the convolutions of the bellows element; Bellows No. 2 appeared to be frei from corrosion pits or cracking. There fore , visual examination focused on Bellows No. 1. ' l The two bellows have a drain hole near the bottom (Figure 1). Using the drain hole as a reference point (6 o' clock looking down), Figures 2, 3, and 4 show the inside surface of Bellows No. 1. Perforation in the convolution can be seen above the drain hole in Figure 2(a). Brown corrosion products, sometimes with nodules, were found throughout the inside surface. One ) prominent example of corrosion nodules is shown in Figure 3. The edges of the j end pieces which were welded to the bellows element showed numerous cracks 1 (Figure 4). A closeup view of the perforation in the convolution of Bellows No. 1 is shown in Figure 5(a). In addition to a hole, about 1/2 inch diameter, the seam weld in the convolution was preferentially attacked. Much of the weld metal
- Memorandum from T. T. Phillips to R. A. White, 2/12/88.
1009m .
- - ~ - _ - - - - - _ _ - _ _ _ _ _ _ _ _ _
1 fell off during saw cutting of a section containing the seam weld. < Figures 5(b) and (c) show this area surrounding the seam weld af ter flattening (_,) the convolution. The outside surf ace around the perforated hole and the corroded seam weld showed colonies of brown tuet. The metal with rust cracked - when the convolution was flattened (Figure 6). The same phenomena occurred on the outside surface of the corrosion nodule shown in Figure 3. The holes in , Figure 7(a) and (b) are the perforation caused by pitting corrosion in the two ' black areas marked by the arrows in Figure 3(a). The rusted areas cracked when . flattened (Figure 7). Figure 8(a) shows an example of corrosion pits in the wald metal and cracking in the top end piece of the bellows. Figure 8(b) is the area where the corrosion perforated the convolution wall. Numerous cracks can also be seen in the corroded area. As mentioned before, Bellows No. 2 showed no corrosion pits or cracking. Only a few scattered brown rust spots and some brown film along the bottom inside corner were observed. 5.0 METALLOCRAPHIC EXAMINATION Figure 5(a) shows preferential corrosion attack to the seam weld in the Bellows No. 1 convolution. The bottom area of the seam weld was saw cut for metallographic examination. During saw cutting, the corroded weld metal fell of f as can be seen in Figure 10(a). This specimen was flattened, mounted in a molding material, polished and etched on a plane parallel to the inside surface. Figure 10(c) is a micrograph showing the seam weld with its top and () bottom portions consumed by corrosion. Figure 11 presents micrographs of selected areas from Figure 10(c). These micrographs show that the corrosion preferentially attacked the weld metal, following the interdendritic solidification pattern, and that numerous transgranular cracks developed. Figure 12 shows examples of transgranular cracks in and around corrosion pits in the base metal near the sear weld. Figure 13 shows extensive branching in one of the cracks along the suges of the end pieces which were welded to the bellows convolution. l 6.0 MICROBIOLOGICAL ANALYSIS ; I 6 Corrosion products and surf ace deposit were collected from the following l locations and analyzed for iron bacteria. The results are as follows: Specimen No. Location Findings 1-1* Corrosion products with Short Gallionella fi' aments ] nodules (Figure 3b) 1-2 "Dirt" at the bottom corner Gallionella filaments directly below the drain hole (Figure 2a) I 1-3 Corrosion products near No positive identification the seam weld (Figure 2a) of iron bacteria O 1009m ; l
. , ~ . - . - . _ . _ . . ..- . - .
Specimen No. Location Findings i () 2-1 Brown film at the bottom corner below the drain Short Gallionella filaments hole (Figure 9a)
*1-1, 1-2, 1-3 from Bellows No. 1; 2-1 from Bellows No. 2 7.0 DISCUSSION The results of the foregoing examination and analysis clearly indicate l that the corrosion and cracking found in Bellows No. I was influenced by iron
! bacteria (Gallionella). The following features support this conclusion. (a) Preferential crystallographic corrosion attack to the weld metal (Figures 10 and 11). 5 i (b) Brown and black corrosion products with nodule formation (Figure 3). (c) Corrosior,and cracking in colonies on the outside surfaces where perforation occurred (Figures 6 and 7). (d) Concentration of corrosion pits in the welds. L I (:) i l I l l l l 1 l 1 1 ( l l 1009m l i
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