Corrosion Fatigue R. Barry Dooley and Albert Bursik
INTRODUCTION FEATURES OF FAILURES
Fatigue damage occurs in general when a boiler tube is Figure 1 shows a typical multiple array of corrosion fatigue subject to repeat cyclic or fluctuating loading although the cracks initiated from the inside surface along the neutral stress produced is below the material yield strength. The axis of an economizer tube. The initiation sites of these types of fatigue damage include, e.g., corrosion, thermal, cracks are associated with surface defects like pits or mechanical, vibration, and creep fatigue. It is important to other discontinuities. The wide cracks have irregular pro- determine which form of fatigue is active, because meas- files and are filled with iron oxides. ures to avoid repeat failures differ as the case arises. In this lesson, the focus is exclusively on corrosion fatigue.
Corrosion fatigue occurs by the combined synergistic
actions of cyclic loading and a corrosive environment. It is a discontinuous process with crack initiation and growth during transient periods. The excessive stresses may be caused during boiler operation by the restraint at tube attachments and by load changes (in particular during cold starts or forced cools) or during shutdown or restart of circulation boilers by thermal stratification of water along the tube length. Poor water chemistry and its excursions influence both initiation and propagation of corrosion fatigue. The key issue here is the breakdown of the protec- tive magnetite layer. The most decisive chemistry parame- ter is the pH (low pH excursions). Figure 1: Multiple array of corrosion fatigue cracks.
IDENTIFICATION Infig ure 2, corrosion fatigue failure of a low pressure econ-
omizer tube of an HRSG is depicted. Pinhole thick-edged leaks are by far the most predominant form of corrosion fatigue failures. In much fewer cases, Corrosion fatigue cracks may have different appearances: corrosion fatigue emanates as a long thick-edged crack. Note that not all BTF with a thick-edged fracture surface pinhole leak result from corrosion fatigue. Thick-edged fractures also thick-edged crack occur when thermal fatigue, mechanical fatigue, low tem- perature creep cracking, circumferential cracking, and thick-edged blow-out or rupture hydrogen damage are active. The most important physical The pinhole leak caused by corrosion fatigue may be con- feature of a corrosion fatigue failure is multiple parallel fused with a mechanical fatigue crack. In contrast to corro- cracks initiated on the inside of the tube. Upon metallurgi- sion fatigue, the mechanical fatigue cracks initiate on the cal examination the cracks are transgranular as they prop- outside surface and are associated with welds or weld dis- agate through the tube wall. continuities (e.g., the toe of a weld).