One-way Fluid Structure Interaction modelling methodology for boiler tube fatigue failure

Botha, Marius; Hindley, Michael P.

doi:10.1016/j.engfailanal.2014.10.012

Cited by 12 publications

(7 citation statements)

References 11 publications

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“…Othman et al [23] and Purbolaksono [24] have identified the failure of superheater tubes by performing finite element method (FEM) and by using an empirical formula in addition to visual inspections and metallurgical examinations. Botha and Hindley [25] have described the modelling methodology for boiler tube failure. Ahmad et al [26] discussed the failure investigation of the rear water wall tube of a boiler using a method of calculating the hoop stress.…”

Section: Highlights • Bulk Chemical Composition Of Base Alloy Has Beementioning

confidence: 99%

Critical Failure Analysis of Superheater Tubes of Coal-Based Boiler

Gupta

Chattopadhyaya

2017

SV-JME

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This paper highlights a methodology for failure investigation of superheater tubes made of the material T-22 of a coal-based boiler. The process includes visual observation, the identification of sampling locations, the determination of the bulk chemical composition of the base alloy, microstructural investigation using optical microscopy, the exploration of finer structural details using a scanning electron microscope (SEM), the evaluation of hardness over samples obtained from different locations, the fractographic analysis of different failed locations, the X-ray diffraction (XRD) study of corrosion products adhered to inner surfaces, and the determination of the nature of the failure. Within a span of four months, three successive failures of superheater tubes were reported. The tubes were observed to have undergone significant wall thinning. Microscopic examinations using SEM on the failed region and a region some distance away on the as-received tubes were conducted in order to determine the failure mechanism. Layer-wise oxidation corrosion (exfoliation) in the inner surface was observed. Apart from major cracking, a number of nearly straight line crackings were observed in the longitudinal direction of both tubes. Close to cracking/bulging, void formation/de-cohesion of grain boundary indicated creep deformation under service exploitation. The failure mechanism was identified to be a result of excessive oxidation corrosion along the inside wall to reduce thickness, the spheroidization of alloy carbides and the coarsening of precipitate as well as creep void formation along grain boundary leading to inter-granular cracking with material flow near regions covered with thick scales. Moreover, there was a drastic reduction in bulk hardness of alloy and finally 'thin lip fish mouth' fractures.

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Section: Highlights • Bulk Chemical Composition Of Base Alloy Has Beementioning

confidence: 99%

Critical Failure Analysis of Superheater Tubes of Coal-Based Boiler

Gupta

Chattopadhyaya

2017

SV-JME

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“…An important phenomenon in a wide range of scientific and engineering disciplines is the interaction between multiphase flow and elastic structures, such as an aircraft wing with a sloshing fuel tank (Gambioli et al, 2019(Gambioli et al, , 2020Mastroddi et al, 2019Mastroddi et al, , 2020Titurus et al, 2019;Saltari et al, 2021) and the impact of ocean waves on elastic ocean structures (Gomes et al, 2020). Accurately simulating a multiphase fluid-structure interaction (FSI) can help reveal the mechanisms behind important and complex real-world phenomena, allowing for important design considerations, such as how to protect an elastic structure from fatigue or failure (Botha and Hindley, 2015) or how to achieve active/passive control of a system (Ducoin et al, 2012). There is significant demand to develop an efficient and open-source numerical tool for the investigation of such phenomena.…”

Section: Introductionmentioning

confidence: 99%

A High-performance Open-source Solution for Multiphase Fluid-Structure Interaction

Liu¹,

Longshaw²,

Skillen³

et al. 2022

IJOPE

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A multiphase fluid-structure interaction (FSI) framework using open-source software has been developed, utilising components able to run on high-performance computing platforms. A partitioned approach is employed, ensuring a separation of concerns (fluid, structure, and coupling), allowing design flexibility and robustness while reducing future maintenance effort. Multiphase FSI test cases have been simulated and compared with published results and show good agreement. This demonstrates the ability of this multiphase FSI framework in simulating complex and challenging cases involving a free liquid surface.

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“…[16][17][18] The method of computational fluid dynamicsfinite element analysis (CFD-FEA) coupling calculation could be used to accurately simulate the temperature filed, thermal stress field, and thermal deformation degree of the component in practical application conditions, such as pressurizer surge line, engine exhaust manifold, cooling jacket, and so on. [19][20][21] Creep behavior is one of the important characteristics of TPVs, which mainly affected by ambient temperature. [22][23][24] Therefore, the long-term creep behavior of TPVs needs to be considered in the early stages of product development.…”

Section: Introductionmentioning

confidence: 99%

Polyamide 6‐based thermoplastic vulcanizate for thermostability: An experimental and theoretical investigation

Jiang

2021

J of Applied Polymer Sci

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In engineering cases, nonuniform temperature and pressure loads will cause greater thermal stress and deformation of the structure. The creep of materials will also accelerate with the increase of temperature, which greatly reduces the service life of parts. This study improves the vulcanization effect and twophase compatibility of polyamide 6-based thermoplastic vulcanizates (TPV), and the elastic modulus of the material was increased to resist deformation and creep. The compatibility and mechanical properties of the materials were analyzed by dynamic thermodynamic analysis. The temperature and stress of charge air pipe are numerically calculated by fluid-thermal-solid coupling. The results show that at 120 C, the strain of TPV is less than 3%, and no plastic deformation occurs. Based on the principle of time-temperature superposition, the long-term creep behavior at reference temperature is predicted by stepped isothermal method through short-term temperature rise creep experiment. The creep strain after 10 5 h at 60 C of TPV grafted by maleic anhydride (TPV-g-MAH) is only 2.8%, indicating that it has good durability in the application of charge air pipes.

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One-way Fluid Structure Interaction modelling methodology for boiler tube fatigue failure

Cited by 12 publications

References 11 publications

Critical Failure Analysis of Superheater Tubes of Coal-Based Boiler

Critical Failure Analysis of Superheater Tubes of Coal-Based Boiler

A High-performance Open-source Solution for Multiphase Fluid-Structure Interaction

Polyamide 6‐based thermoplastic vulcanizate for thermostability: An experimental and theoretical investigation

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