Root Cause Analysis of Surface Cracks in Heavy Steel Plates during the Hot Rolling Process

Bahrami, Abbas; Khouzani, Mahdi Kiani; Mokhtari, Seyed Amirmohammad; Zareh, Shahin; Mehr, M. Yazdan

doi:10.3390/met9070801

Cited by 20 publications

(7 citation statements)

References 18 publications

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“…This certainly has positive implications for the system reliability and service life of a gas turbine. Lessons learnt from a failure study will certainly be useful in planning failure mitigation strategies in similar plants/set-ups [21][22][23][24][25][26][27][28][29][30]. It will be shown that the failure, reported in this study, is a corrosion-fatigue failure.…”

Section: Introductionmentioning

confidence: 68%

Corrosion-Fatigue Failure of Gas-Turbine Blades in an Oil and Gas Production Plant

et al. 2020

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This paper investigates the root cause of a failure in gas-turbine blades, made of Nimonic-105 nickel-based superalloy. The failure was reported in two blades in the second stage of a turbine-compressor of a gas turbine in the hot section. Two failed blades were broken from the root and from the airfoil. The failure took place after 20 k h of service exposure in the temperature range 700–850 °C, with the rotating speed being in the range 15,000–16,000 rpm. The microstructures of the failed blades were studied using optical/electron microscopes. Energy dispersive X-ray spectroscopy (EDS) was employed for phase identification. Results showed that failure first initiated from the root. The dominant failure mechanism in the root was concluded to be corrosion-fatigue. The failure scenario was suggested based on the results obtained.

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Section: Introductionmentioning

confidence: 68%

Corrosion-Fatigue Failure of Gas-Turbine Blades in an Oil and Gas Production Plant

et al. 2020

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“…These cracks are large in size and simple in morphology and can be seen directly and clearly without treatment of the plate surface. [ 7–12 ] Sarkar et al studied the causes of corner defects and longitudinal cracks in the hot‐rolled plate of C–Mn steel. [ 7 ] The article concluded that the surface cracks in the hot‐rolled plate were due to surface defects in the continuous casting slab by observing the morphology of the crack and the inclusions inside the cracks.…”

Section: Introductionmentioning

confidence: 99%

“…Bahrami et al analyzed the morphological characteristics of the longitudinal cracks on the plate surface in detail. [ 8 ] The article concluded that the crack originated from a V‐shaped notch, which was located on the surface of the plate. The interior of the crack was in the form of an antler.…”

Section: Introductionmentioning

confidence: 99%

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Formation and Deformation Mechanism of Mountain‐Like Surface Crack on the Hot‐Rolled Thick Plate of HSLA Steel

Shen

Cheng

Wang

2022

steel research int.

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Mountain‐like surface cracks often appear on the thick plates of high‐strength low‐alloy (HSLA) steel after hot rolling, which have a serious impact on production efficiency. Herein, the formation cause of mountain‐like cracks is discussed using methods such as acid pickling and observations of microstructure and inclusions. The deformation behavior of microcracks is obtained by analyzing the rolling process of slab. The inclusions in the top of the crack are Type‐I inclusions with high elemental contents of K and P and Type‐II inclusions with high elemental contents of C. The inclusions in the sides of the crack are Al2O3. It is concluded that mountain‐like cracks are caused by surface microcracks containing Type‐I inclusions in the continuous casting slab. During rolling, the rapid deforming of side‐1 stretches the crack so that the unusual microstructure appears. The cracks extended in the rolling direction have Al2O3 inclusions. The mountain‐like crack with Type‐I inclusions in the top and Al2O3 in the sides eventually form. A single microcrack forms a single mountain‐like crack and multiple clustered microcracks form a continuous mountain‐like crack. To reduce mountain‐like cracks, reducing Type‐I inclusions to reduce surface defects of the slab is an effective means.

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“…In a research paper from the team led by Bahrami, A. [25], cracks were rather evenly distributed over the surface in the form of colonies of cracks. Samples were cut from the heavy plate.…”

Section: Introductionmentioning

confidence: 99%

The Research of the Rolling Speed Influence on the Mechanism of Strip Breaks in the Steel Rolling Process

Rusňák¹,

Malega

Svetlík

et al. 2020

Materials

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This paper evaluates the results of research aimed at changing the rolling speed and the effect of foreign particles in the steel strip, as well as the forces in the rolling process. It also compares the correlation of lab results, theoretical expectations and real-life observations. It supplements the already existing practices aimed at strip-break elimination that were developed and implemented worldwide. Records from a five-stand tandem mill were used for the data analysis. The historical databases developed based on incidents (strip breaks) since 2013 were used; the detailed position of each strip break was documented, along with defects found at the portions of steel strips that broke or the information that no defect was found. The paper contains an evaluation of metallographic analyses of the samples of the strip breaks.

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Root Cause Analysis of Surface Cracks in Heavy Steel Plates during the Hot Rolling Process

Cited by 20 publications

References 18 publications

Corrosion-Fatigue Failure of Gas-Turbine Blades in an Oil and Gas Production Plant

Corrosion-Fatigue Failure of Gas-Turbine Blades in an Oil and Gas Production Plant

Formation and Deformation Mechanism of Mountain‐Like Surface Crack on the Hot‐Rolled Thick Plate of HSLA Steel

The Research of the Rolling Speed Influence on the Mechanism of Strip Breaks in the Steel Rolling Process

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