Toolbox Case Study 6: Paper Mill Hypo Washer Wire Mesh

Failure
By George M. Goodrich
Senior Metallurgical Engineer
Stork Climax Research Services
Introduction
A metallurgical failure analysis utilizes many tools to determine the cause for the failure
of a component. These tools include:
Visual Examination
Chemical Analysis
Mechanical Properties
Hardness
Scanning Electron Microscope Analysis
Metallographic Analysis
Facts concerning the utilization of the component
Each of these tools provides information that can be used individually or in combination
to determine the cause for the failure. The metallurgical aspects of the failure alone,
however, are only part of the information required to solve a problem and prevent it from
occurring in the future.
This document presents the sixth of seven case histories that have utilized the various
tools to identify the cause of failure. In most instances, however, the solution to the
problems that were created as the result of the failure related to practices that were
instituted where the component was being utilized. In one instance, the practices
involved inadequate quality control. In some instances, the practices involved utilizing
techniques that were unacceptable in the application. In still other instances, no actual
cause for the failure could be identified due to the practices that were employed prior to
utilization of the component. These case histories are real case histories and represent
examples of failures that are commonly experienced.

CASE STUDY 6 Paper Mill Hypo Washer Wire Mesh Failure

Background
A sample of the wire mesh used as a filter in a paper
mill operation was subjected to metallurgical evaluation
to identify the cause for "shiny regions" on the surface.
Photograph 1 shows an example. The stipulated
material for the wire mesh was not designated but
chemical analysis identified the material Type 316L
stainless steel. The service life also was not stipulated.
Photograph 1

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Documentation
Visual examination of the screen at magnifications up to
40X revealed that the shiny areas appeared to have wire
strands that were broader than regions which did not
exhibit the shiny appearance. An example is shown in
Photograph 2.
Metallographic cross sections of the wire mesh revealed
that the non-shiny area exhibited a weave with a
consistent cross section as shown in Photograph 3. In the
area that exhibited the shiny appearance, one side of the
weave had flat spots as shown in Photograph 35. At the
ends of these flat spots, metal had deformed around the
edge, indicative of wear as can be seen in Photograph 4.
Conclusions
This investigation revealed that the wire mesh shiny
areas were not the consequence of corrosion or stress
corrosion cracking. The flat spots identified on the
weave strands were considered indicative of wear
indicating that components in the system had rubbed
against the surface of the screen.

Photograph 2

Photograph 3

As a consequence of this evaluation, the client

investigated the operation and determined that the wear
on the screen was the consequence of other
components in the system that had become misaligned
and were mechanically in contact the surface of the
mesh.

Photograph 4

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