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Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramcos
employees. Any material contained in this document which is not
already in the public domain may not be copied, reproduced, sold, given,
or disclosed to third parties, or otherwise used in whole, or in part,
without the written permission of the Vice President, Engineering
Services, Saudi Aramco.
Engineering Encyclopedia
CONTENTS
PAGES
Engineering Encyclopedia
Sand or nonmetallic inclusions, which occur when slag particles, or sand that
has broken away from the mold become entrapped in the casting during
solidification. These defects can occur at any location within the casting, and
they must be identified by metallography or scanning electron microscopy
(SEM) that employs energy dispersive X-ray spectroscopy.
Porosity, which is caused by gas bubbles that become trapped within the
molten metal and cannot escape during solidification. Examples of gases that
are generated during pouring are vaporized moisture or binders in mold sands.
Large pores on the casting surface are called blowholes. Porosity may occur in
individual regions or it may be randomly distributed through the casting.
Additional types of porosity are described as pinholes, interdendritic porosity,
and microporosity.
Hot tears, which occur primarily at corners or abrupt changes in casting section
thickness. They are caused by shrinkage and stress concentration due to
differential thermal contraction. Hot tears appear as cracks which are oxidized
significantly.
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Cold shuts, which are surface or internal discontinuities that are caused by a hot
stream of molten metal as it flows into or over an already solidified surface.
Other discontinuities can result when chaplets or chills inside the mold fail to
melt and become part of the casting.
The above defects represent some of the most common problems with castings. Since there
are numerous specific defects and there are sometimes different names that are used for the
same defect, the International Committee of Foundry Technical Associations (CFTA) has
standardized nomenclature for casting defects. The standardized tables are included in the
Addendum.
In the analysis of failures in castings, it often is prudent to radiograph the casting to locate
defects. If a casting had one defect that caused a failure, it often has additional, similar
defects. After defects are located, metallographic examinations and elemental analyses are
used to categorize the defects. Experience indicates that when defects are found in a casting
such as a valve body or pump casing, similar valves or pumps from the same foundry will
also contain defects and, therefore, these valves or pumps will require inspection.
Centrifugal Castings
High temperature tubing that is used in the petroleum industry is often centrifugally cast from
high alloy steel. The process involves the pouring of the molten alloy into molds that are
spinning at high velocities. The resulting product has superior properties compared to static
castings. While centrifugal castings usually contain far fewer internal defects, poor melt shop
practices can result in surface defects that cause failures. When orders are rushed, numerous
defects can result. In one case, a batch of centrifugal tubes was found to contain surface pits
and imperfections, hot cracks (formed while pulling tubes from molds), dimensional
problems, and weld defects (tubes are welded together to make up coils).
Processing Defects
Wrought alloy products typically are produced from castings that are called ingots. The ingots
are then hot rolled into semifinished forms that are called blooms, billets, or slabs, or forged
into more complex shapes. Blooms and billets are further hot rolled into bars and tubes, and
slabs are rolled into sheets. Final finishing may also involve cold rolling, cold drawing, and
extruding.
The above forming processes can create various defects, which are mostly surface-related, in
the finished products. The most common defects are seams and laps, where the metal is
folded over, which result in unwelded discontinuities that are similar to cold shuts. Rolled-in
Saudi Aramco DeskTop Standards
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scale, scratches, roll marks, and internal inclusions are additional defects that are found in
finished products.
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Failures that result from processing defects are analyzed through the use of ordinary
metallographic and fractographic methods. Defects in rolled, drawn, or extruded products
usually run longitudinally for great distances, and regions away from the failure typically
reveal indications of the defects. On the surfaces, the defects may appear as thin lines or
scratches. Transverse cross sections provide information on the nature and depth of the defect.
Seams or laps appear in cross sections as straight or curved cracks, as shown in Figure 1. In
this case, the defect was on the ID surface of the seamless tube, and it caused a catastrophic
failure. Defects do not necessarily have to run deeply below the surface to cause problems.
The sharp tips of the defects are stress risers, which promote crack propagation, and the defect
regions often provide crevices for contaminant concentration, corrosion, and environmental
cracking.
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Additional Defects
Refined metals and alloys have specified composition ranges or limits for various elements.
While occurrences are infrequent, cast or wrought components may not meet compositional
specifications, and failures can result from degraded mechanical and physical properties. The
manufacturer of the alloy is responsible for producing heats of material with compositions
within specifications.
Improperly applied and/or mixed (improperly identified) materials are more common causes
of failure than are off-chemistry alloys. Mixed materials can occur at the manufacturers shop,
fabricators shop, or at various warehouses and supply companies. In recent years, there have
been specific equipment problems that have involved substandard bolts and valves. For the
above reasons, compositional checks should almost always be included in failure analyses.
Welded pipe and tubing have failed in service due to poor welds. Quality problems with
electrical resistance welded (ERW) pipe in particular have resulted in failures.
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Structural Discontinuities
Types of structural discontinuities are as follows:
Porosity and Slag Inclusions, which affect the soundness of welds just as in the
case of castings.
Incomplete Fusion, which results when the weld metal does not fuse to the base
metal or when successive weld passes do not fuse to each other.
Incorrect Weld Profiles (Figure 3), which can result in incomplete fusion or
slag inclusions when successive layers are deposited. Improper profile can also
lead to stress risers. Undercutting, underfill, and overlap are common causes of
failures.
Excessive
Convexity
Insufficient
Throat
Excessive
Undercut
Overlap
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Weld Cracking
Cracks occur in the weld metal, base metal, and heat-affected zone (HAZ) of a weldment
when localized stresses exceed the ultimate tensile strength of the metal. Cracking is often
associated with stress risers at discontinuities or mechanical notches in the weldment.
Hydrogen embrittlement often contributes to crack formation in steel. Cracking also can result
from insufficient preheat, excessive interpass temperatures, using the wrong filler metal, rapid
cooling, or poor fit-up.
Cracks can be classified as either hot or cold types. Hot cracks develop at elevated
temperatures, commonly during solidification of the weld metal. Hot cracks may be
associated with impurities and high restraint. Cold cracks result from thermal stresses
developed during cooling and are often associated with hardenable alloys, high restraint,
and/or hydrogen embrittlement. Hot cracks propagate intergranularly, while cold cracks can
be either transgranular or intergranular.
In multiple layer welds, weld cracking is most likely to occur in the first weld layer (root pass
or root bead). Unless the cracking is repaired, crack propagation occurs through subsequent
passes as the weld is completed.
Three types of cracks that can occur in weld metal are as follows:
Transverse Weld Cracks, which appear perpendicular to the axis of the weld
and, in some cases, extend beyond the weld into the HAZ and base metal. This
type of crack is more common in joints that have a high degree of restraint.
Longitudinal Weld Cracks, which are found mostly within the weld metal and
are confined to the center of the weld. Such cracks may be the extension of
cracks that were formed at the end of the weld or in the root of the weld.
Crater Cracks, which occur whenever the welding operation is interrupted and
a crater is formed. The cracks are usually star-shaped and progress only to the
edge of the crater. However, crater cracks can be initiation sites for larger
longitudinal and transverse cracks. Crater cracks are found most frequently in
alloys with high coefficients of thermal expansion, such as austenitic stainless
steels.
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Weld cracking that is caused by hydrogen embrittlement can also occur in the HAZ and base
metal. This cracking generally occurs at temperatures below 120 C (248 F) and
immediately upon cooling or after a period of several hours. Such cracking is known by
several names, including underbead, cold, and delayed cracking.
Lamellar tearing is a form of cold cracking that results from high stress in the
through-thickness direction. Lamellar tears are generally terrace-like
separations in base metal that are caused by welding thermal stresses.
Inclusions are often associated with the cracking. Fractographic examination of
the cracks reveals a fibrous appearance.
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GLOSSARY
billet
bloom
chaplets
centrifugal castings
chills
Solid pieces of metal that are added to a mold to increase the rate
of solidification in regions of the casting. The chill becomes part
of the casting.
cladding
cold cracks
(cold cracking)
cold drawing
cold shuts
crater cracks
Cracks that occur in the final molten puddle that remains at the
end of a weld pass.
defect
extrusion
flaw
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forged (forging)
Heat-Affected Zone
(HAZ)
hot cracks (hot cracking) Cracking in weld regions that occurs while the region is at high
temperatures due to welding.
hot tears
indication
incomplete fusion
lamellar tearing
misrun
nonmetallic inclusions
porosity
quench cracking
rolling
shrinkage
underbead cracking
Welding Procedure
Qualification Record
(PQR)
Welding Procedure
Specification (WPS)
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workmanship
wrought products
(wrought alloys)
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REFERENCES
1.
D. B. Roach and F. H. Beck, Performance and Reliability of CorrosionResistant Alloy Castings, MTI Manual No. 5: Phase 1 Causes
of
Unsatisfactory Performance, and MTI Manual No. 6: Phase 2 Casting
Discontinuities, Materials Technology Institute of the Chemical Process
Industries, Columbus, Ohio, USA, 1981.
2.
3.
The Making, Shaping, and Treating of Steel, Tenth Ed., Association of Iron
and Steel Engineers, Herbick and Held, Publishers, Pittsburgh, Pennsylvania,
USA, 1985.
4.
5.
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ADDENDUM
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