Fabrication Defect

13 cases · 123 images

Crevice Corrosion in a Subsea System — Aspect Before Analysis

Product: Raw Material Capture method: Optical Microscope clear all

Fabrication Defect — sub-branches

Casting Defect 1Heat Treatment Defect 2Not according to spec 4Welding Defect 6

Results

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Quenched and tempered structure of the F22 steel forging, presenting about 230HV10 average hardness.
133
VIEW
ML00178 / Jan.2022
Cold cracks in Cr-Mo Welded Forging
M - CrMo SteelP - ForgingAp - O&G Well DrillingCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Base Metal
BASE METAL SURFACE - Ferritic structure, grain refined.
90
VIEW
ML00177 / Dec.2021
Cr-Mo Seam Welded Tube
M - CrMo SteelP - Longitudinally Seam WeldedAp - Fired HeaterCd - Not according to spec
Cm - Nital Etched Micrography by OMDf - Base Metal
Micrography of a transverse section of the forged bar in the center of the thickness. Ferrite and austenite. Coarse structure.
74
VIEW
ML00123 / Feb.2018
Non Qualified Superduplex for Subsea
M - Super Duplex Stainless SteelP - BarAp - Oil and GasCd - Not according to spec
Cm - NaOH Electrolytic Etched MicroDf - Transverse Section
Micrography, as polished, of the transverse section of the forged pin with the layer applied by a (thermal) spray and fuse process. The layer presented entrapped pores and globular oxides. It was melted after application by thermal spray (in this case using a flame) but the pin was not heat treated after the full application and melting of the layer and the base metal is ferritc-pearlitic.
51
VIEW
ML00110 / Jan.2018
Non Conformance in Spray and Fuse Pin
M - Low Alloy Medium Carbon QTP - Tubular ForgingAp - O&G Well DrillingCd - Heat Treatment Defect
Cm - As polished micrographyDf - Transverse Section
Micrography of a transverse section of the pipe, external diameter 33.4 mm schedule XXS, in the center of the 9.1 mm thickness. The structure is predominantly ferritic. Small amount of pearlite.
556
VIEW
ML00112 / Dec.2017
1" XXS Pipe Not Qualified For Low Temp
M - Low Carbon SteelP - Seamless PipeAp - RefineryCd - Not according to spec
Cm - Nital Etched Micrography by OMDf - Predominantly Ferritic
Micrography of a transverse section of the pipe, external diameter 26.7 mm, in the center of the 7.85mm thickness. Refined structure but not uniform. Ferrite and pearlite.
512
VIEW
ML00111 / Dec.2017
3/4" XXS Pipe Not Qualified for Low Temp
M - Low Carbon SteelP - Seamless PipeAp - RefineryCd - Not according to spec
Cm - Nital Etched Micrography by OMDf - Ferrite and Pearlite
Micrography of the welded joint fusion line presenting the liquation cracking. The weld metal is in the right side (bottom) and the forged connector heat affected zone is in the left side (top).
83
VIEW
ML00072 / Jan.2018
Liquation Cracks in a High Strength Joint
M - Low Alloy Medium Carbon QTP - Longitudinal Seam Welded PipeAp - O&G Well DrillingCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Cracking
The micrographic aspect of the cracks in a section transverse to the weld (the removed sample), shows that there are cracks with different sizes, the larger are filled with products that indicate they were opened for longer times.
67
VIEW
ML00071 / Jan.2019
Reheating Cracking of a CrMo Vessel Weld
M - CrMo SteelP - In Field WeldAp - EnergyCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Intergranular Cracking

More from these cases

ML00178 — Cold cracks in Cr-Mo Welded ForgingM - CrMo SteelP - ForgingAp - O&G Well DrillingCd - Welding Defect
Tempered martensitic structure for the F22 forging base metal.
129
VIEW
ML00178 / Jan.2022
Cold cracks in Cr-Mo Welded Forging
M - CrMo SteelP - ForgingAp - O&G Well DrillingCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Tempered Martensite
Fusion line of the forging side, in the cap, showing the weld metal (to the top of the image) and the base metal (to the bottom of the image). The heat affected zone hardness is about 270HV10.
108
VIEW
ML00178 / Jan.2022
Cold cracks in Cr-Mo Welded Forging
M - CrMo SteelP - ForgingAp - O&G Well DrillingCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Heat Affected Zone
Grain coarsened martensitic heat affected zone. The hardness values about 270HV10 indicates that the joint was post welding heat treated (PWHT).
97
VIEW
ML00178 / Jan.2022
Cold cracks in Cr-Mo Welded Forging
M - CrMo SteelP - ForgingAp - O&G Well DrillingCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Martensite
Detail of the quenched and tempered martensitic structure at the heat affected zone.
64
VIEW
ML00178 / Jan.2022
Cold cracks in Cr-Mo Welded Forging
M - CrMo SteelP - ForgingAp - O&G Well DrillingCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Tempered Martensite
The columnar grains of the weld metal in the cap presented a martensitic structure.
60
VIEW
ML00178 / Jan.2022
Cold cracks in Cr-Mo Welded Forging
M - CrMo SteelP - ForgingAp - O&G Well DrillingCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Weld Metal

+1 more from this case →

ML00177 — Cr-Mo Seam Welded TubeM - CrMo SteelP - Longitudinally Seam WeldedAp - Fired HeaterCd - Not according to spec
BASE METAL SURFACE - The micrography (transverse to the tube) presents the ferritic/pearlitic/bainitic structure.
75
VIEW
ML00177 / Dec.2021
Cr-Mo Seam Welded Tube
M - CrMo SteelP - Longitudinally Seam WeldedAp - Fired HeaterCd - Not according to spec
Cm - Nital Etched Micrography by OMDf - Granular structure
BASE METAL SURFACE - The microstructure of the base metal is ferritic/pearlitic/bainitic.
74
VIEW
ML00177 / Dec.2021
Cr-Mo Seam Welded Tube
M - CrMo SteelP - Longitudinally Seam WeldedAp - Fired HeaterCd - Not according to spec
Cm - Nital Etched Micrography by OMDf - Grain refined structure
HAZ SURFACE
72
VIEW
ML00177 / Dec.2021
Cr-Mo Seam Welded Tube
M - CrMo SteelP - Longitudinally Seam WeldedAp - Fired HeaterCd - Not according to spec
Cm - Nital Etched Micrography by OMDf - Last Bead HAZ
HAZ SURFACE
66
VIEW
ML00177 / Dec.2021
Cr-Mo Seam Welded Tube
M - CrMo SteelP - Longitudinally Seam WeldedAp - Fired HeaterCd - Not according to spec
Cm - Nital Etched Micrography by OMDf - Last Bead HAZ
HAZ SURFACE
55
VIEW
ML00177 / Dec.2021
Cr-Mo Seam Welded Tube
M - CrMo SteelP - Longitudinally Seam WeldedAp - Fired HeaterCd - Not according to spec
Cm - Nital Etched Micrography by OMDf - Bainitic HAZ

+18 more from this case →

ML00123 — Non Qualified Superduplex for SubseaM - Super Duplex Stainless SteelP - BarAp - Oil and GasCd - Not according to spec
Micrography of a longitudinal section of the forged bar in the center of the thickness. Ferrite and austenite. Coarse structure.
61
VIEW
ML00123 / Feb.2018
Non Qualified Superduplex for Subsea
M - Super Duplex Stainless SteelP - BarAp - Oil and GasCd - Not according to spec
Cm - NaOH Electrolytic Etched MicroDf - Longitudinal Section
Micrography of a transverse section of the forged bar in the center of the thickness. Ferrite and austenite. The ferrite amount, measured by metallographic method, manual counting, is 59%.
53
VIEW
ML00123 / Feb.2018
Non Qualified Superduplex for Subsea
M - Super Duplex Stainless SteelP - BarAp - Oil and GasCd - Not according to spec
Cm - NaOH Electrolytic Etched MicroDf - Transverse Section
Micrography of a longitudinal section of the forged bar in the center of the thickness. Ferrite and austenite. The average austenite spacing is 80 microns, a lot larger than the maximum allowed in the specification, of 30 microns. No detrimental phases were identified at the ferrite/austenite interfaces, but the ferrite phase presented a rough aspect. Higher magnification analysis would be required to identify precipitation.
53
VIEW
ML00123 / Feb.2018
Non Qualified Superduplex for Subsea
M - Super Duplex Stainless SteelP - BarAp - Oil and GasCd - Not according to spec
Cm - NaOH Electrolytic Etched MicroDf - Longitudinal Section
Micrographic detail of the ferrite and austenite structure in the transverse section of the forged bar, in the center of the thickness.
53
VIEW
ML00123 / Feb.2018
Non Qualified Superduplex for Subsea
M - Super Duplex Stainless SteelP - BarAp - Oil and GasCd - Not according to spec
Cm - NaOH Electrolytic Etched MicroDf - Ferrite and Austenite
Micrographic detail of the ferrite and austenite structure in the longitudinal section of the forged bar, in the center of the thickness.
55
VIEW
ML00123 / Feb.2018
Non Qualified Superduplex for Subsea
M - Super Duplex Stainless SteelP - BarAp - Oil and GasCd - Not according to spec
Cm - NaOH Electrolytic Etched MicroDf - Ferrite and Austenite
ML00110 — Non Conformance in Spray and Fuse PinM - Low Alloy Medium Carbon QTP - Tubular ForgingAp - O&G Well DrillingCd - Heat Treatment Defect
Micrography, as polished, of the transverse section of the forged pin with the layer applied by a (thermal) spray and fuse process. The layer was melted after thermal spray application and the layer presents a continuous matrix, but there are globular oxides and pores entrapped.
36
VIEW
ML00110 / Jan.2018
Non Conformance in Spray and Fuse Pin
M - Low Alloy Medium Carbon QTP - Tubular ForgingAp - O&G Well DrillingCd - Heat Treatment Defect
Cm - As polished micrographyDf - Surface Layer
Micrographic detail, as polished, of the transverse section of the forged pin at the interface between the pin and the spray and fuse layer. The interface presents globular oxides and small pores, entrapped.
35
VIEW
ML00110 / Jan.2018
Non Conformance in Spray and Fuse Pin
M - Low Alloy Medium Carbon QTP - Tubular ForgingAp - O&G Well DrillingCd - Heat Treatment Defect
Cm - As polished micrographyDf - Surface Layer
Low magnification micrography of the interface between the pin and the spray and fuse layer. Close to the surface, under the layer, the pin presents a ferritic perlitic structure, non conform with the high strenght requirement. Transverse section.
37
VIEW
ML00110 / Jan.2018
Non Conformance in Spray and Fuse Pin
M - Low Alloy Medium Carbon QTP - Tubular ForgingAp - O&G Well DrillingCd - Heat Treatment Defect
Cm - As polished micrographyDf - Low Mag
Micrography of the pin close to the interface with the spray and fuse layer. Transverse section. The fuse was conducted in high temperature and the pin was cooled very slowly, forming a ferritic-perlitic structure even for this high hardenability base metal.
35
VIEW
ML00110 / Jan.2018
Non Conformance in Spray and Fuse Pin
M - Low Alloy Medium Carbon QTP - Tubular ForgingAp - O&G Well DrillingCd - Heat Treatment Defect
Cm - Nital Etched Micrography by OMDf - Ferrite and Pearlite
Low magnification micrography of the pin in the center of the 25 mm thickness. Ferritic-pearlitic structure of the material that slowly cooled after spray and fuse application. Transverse section.
25
VIEW
ML00110 / Jan.2018
Non Conformance in Spray and Fuse Pin
M - Low Alloy Medium Carbon QTP - Tubular ForgingAp - O&G Well DrillingCd - Heat Treatment Defect
Cm - Nital Etched Micrography by OMDf - Base Metal

+5 more from this case →

ML00112 — 1" XXS Pipe Not Qualified For Low TempM - Low Carbon SteelP - Seamless PipeAp - RefineryCd - Not according to spec
Micrography of a transverse section of the pipe, close to the external surface (OD). The pipe presented a predominatly ferritic structure.
43
VIEW
ML00112 / Dec.2017
1" XXS Pipe Not Qualified For Low Temp
M - Low Carbon SteelP - Seamless PipeAp - RefineryCd - Not according to spec
Cm - Nital Etched Micrography by OMDf - Close to the External Surface
Micrography of a transverse section of the pipe, close to the external surface (OD). The pipe presented a 0.2 mm decarburized layer, fully ferritic.
35
VIEW
ML00112 / Dec.2017
1" XXS Pipe Not Qualified For Low Temp
M - Low Carbon SteelP - Seamless PipeAp - RefineryCd - Not according to spec
Cm - Nital Etched Micrography by OMDf - Close to the External Surface
Micrography of a transverse section of the pipe, close to the external surface (OD). The pipe presented a predominatly ferritic structure.
31
VIEW
ML00112 / Dec.2017
1" XXS Pipe Not Qualified For Low Temp
M - Low Carbon SteelP - Seamless PipeAp - RefineryCd - Not according to spec
Cm - Nital Etched Micrography by OMDf - Predominantly Ferritic
Micrography of a transverse section of the pipe, close to the internal surface (ID). The pipe presented a predominatly ferritic structure.
29
VIEW
ML00112 / Dec.2017
1" XXS Pipe Not Qualified For Low Temp
M - Low Carbon SteelP - Seamless PipeAp - RefineryCd - Not according to spec
Cm - Nital Etched Micrography by OMDf - Close to the Internal Surface
Micrography of a transverse section of the pipe, close to the internal surface (ID). The pipe presented a predominatly ferritic structure.
22
VIEW
ML00112 / Dec.2017
1" XXS Pipe Not Qualified For Low Temp
M - Low Carbon SteelP - Seamless PipeAp - RefineryCd - Not according to spec
Cm - Nital Etched Micrography by OMDf - Close to the Internal Surface

+2 more from this case →

ML00111 — 3/4" XXS Pipe Not Qualified for Low TempM - Low Carbon SteelP - Seamless PipeAp - RefineryCd - Not according to spec
Micrography of a transverse section of the pipe, close to the internal surface (ID). Refined structure. Ferrite and pearlite.
64
VIEW
ML00111 / Dec.2017
3/4" XXS Pipe Not Qualified for Low Temp
M - Low Carbon SteelP - Seamless PipeAp - RefineryCd - Not according to spec
Cm - Nital Etched Micrography by OMDf - Close to the Internal Surface
Micrography of a transverse section of the pipe, close to the internal surface (ID). Refined structure, but not uniform. Ferrite and pearlite. The pearlite colonies appear in a network.
45
VIEW
ML00111 / Dec.2017
3/4" XXS Pipe Not Qualified for Low Temp
M - Low Carbon SteelP - Seamless PipeAp - RefineryCd - Not according to spec
Cm - Nital Etched Micrography by OMDf - Close to the Internal Surface
Micrography of a transverse section of the pipe, close to the internal surface (ID). Refined structure. Ferrite and pearlite. The structure is not uniform. There is a large variation in the ferritic grain size and the pearlite colonies appear forming a network.
39
VIEW
ML00111 / Dec.2017
3/4" XXS Pipe Not Qualified for Low Temp
M - Low Carbon SteelP - Seamless PipeAp - RefineryCd - Not according to spec
Cm - Nital Etched Micrography by OMDf - Ferrite and Pearlite
Micrography of a transverse section of the pipe, close to the external surface (OD). Refined structure. Ferrite and pearlite.
33
VIEW
ML00111 / Dec.2017
3/4" XXS Pipe Not Qualified for Low Temp
M - Low Carbon SteelP - Seamless PipeAp - RefineryCd - Not according to spec
Cm - Nital Etched Micrography by OMDf - Close to the External Surface
Micrography of a transverse section of the pipe, close to the external surface (OD). Refined structure. Ferrite and pearlite.
34
VIEW
ML00111 / Dec.2017
3/4" XXS Pipe Not Qualified for Low Temp
M - Low Carbon SteelP - Seamless PipeAp - RefineryCd - Not according to spec
Cm - Nital Etched Micrography by OMDf - Close to the External Surface

+2 more from this case →

ML00072 — Liquation Cracks in a High Strength JointM - Low Alloy Medium Carbon QTP - Longitudinal Seam Welded PipeAp - O&G Well DrillingCd - Welding Defect
The liquation crack is a hot crack in the base metal (at the HAZ) that induces a solidification crack in the weld metal.
66
VIEW
ML00072 / Jan.2018
Liquation Cracks in a High Strength Joint
M - Low Alloy Medium Carbon QTP - Longitudinal Seam Welded PipeAp - O&G Well DrillingCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Weld Metal
Micrographic detail of the cracks at the fusion line of the welded joint, at the connector side. The cracking presents morphology of melting regions of impurities at grain boundaries of the large grains of the heat affected zone (HAZ).
57
VIEW
ML00072 / Jan.2018
Liquation Cracks in a High Strength Joint
M - Low Alloy Medium Carbon QTP - Longitudinal Seam Welded PipeAp - O&G Well DrillingCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Fusion Line
The HAZ presents microcracks at previous austenite grain boundaries. These regions melted during welding and generated cracks associated to low melting temperature phases.
48
VIEW
ML00072 / Jan.2018
Liquation Cracks in a High Strength Joint
M - Low Alloy Medium Carbon QTP - Longitudinal Seam Welded PipeAp - O&G Well DrillingCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Microcracks
The HAZ presents microcracks at previous austenite grain boundaries. These regions melted during welding and generated cracks associated to low melting temperature phases.
43
VIEW
ML00072 / Jan.2018
Liquation Cracks in a High Strength Joint
M - Low Alloy Medium Carbon QTP - Longitudinal Seam Welded PipeAp - O&G Well DrillingCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Microcracks
Micrography of the AISI 4130 forging, 5/8" thickness, close to the welded region, in the longitudinal section.
42
VIEW
ML00072 / Jan.2018
Liquation Cracks in a High Strength Joint
M - Low Alloy Medium Carbon QTP - Longitudinal Seam Welded PipeAp - O&G Well DrillingCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Base Metal Left Side

+7 more from this case →

ML00071 — Reheating Cracking of a CrMo Vessel WeldM - CrMo SteelP - In Field WeldAp - EnergyCd - Welding Defect
Micrographic aspect of opened cracks, filled with oxides.
63
VIEW
ML00071 / Jan.2019
Reheating Cracking of a CrMo Vessel Weld
M - CrMo SteelP - In Field WeldAp - EnergyCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Cracks
Micrographic details of opened cracks, filled with oxides.
56
VIEW
ML00071 / Jan.2019
Reheating Cracking of a CrMo Vessel Weld
M - CrMo SteelP - In Field WeldAp - EnergyCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Cracks
Micrographic aspect of thin cracks.
59
VIEW
ML00071 / Jan.2019
Reheating Cracking of a CrMo Vessel Weld
M - CrMo SteelP - In Field WeldAp - EnergyCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Cracks
Micrographic details of thin cracks.
63
VIEW
ML00071 / Jan.2019
Reheating Cracking of a CrMo Vessel Weld
M - CrMo SteelP - In Field WeldAp - EnergyCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Cracks