Forging

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Crevice Corrosion in a Subsea System — Aspect Before Analysis

Condition: Damage clear all

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The location of the threaded fitting started leaking after less than five years in service. Although the corrosion rate was not high, the localized material loss in the threaded surface of the carbon steel flange allowed the connection leakage.
769
VIEW
ML00184 / Apr.2023
Dissimilar Steels in a Threaded Connection
M - Low Carbon SteelP - ForgingAp - OffshoreCd - Localized Dissolution
Cm - Aspect Before AnalysisDf - General View
The drilling connector, 21" diameter, presented a crack at the margin of the weld in the forging side (left side of the weld in the figure).
745
VIEW
ML00178 / Jan.2022
Cold cracks in Cr-Mo Welded Forging
M - CrMo SteelP - ForgingAp - O&G Well DrillingCd - Welding Defect
Cm - Aspect Before AnalysisDf - General View
Aspect of the cracked valve body, after disassembling and removing the internal parts. The valve is part of a lot that was manufactured by forging a cubic 170mm from a forged bar in SDSS UNS S32760, and heat treated (solution annealed) by the forging company. The fabrication using these bodies included the machining, fillet weld two inserts in Alloy 625, machining again, assembling the internals, and pressure test at 15,000 psi. The cracking occurred during test, only for this valve body.
676
VIEW
ML00134 / Aug.2020
Brittle Fracture of a Superduplex Valve Body
M - Super Duplex Stainless SteelP - Fabrication WeldAp - SubseaCd - Brittle Fracture
Cm - Aspect Before AnalysisDf - Cracking
Microscopic image by scanning electron microscope (SEM) of the ring surface that presented pites under fouling deposits.
522
VIEW
ML00124 / Feb.2018
MIC of a Martensitic Valve Ring
M - Martensitic Stainless SteelP - ForgingAp - EnergyCd - Brittle Behavior
Cm - Surface Aspect by SEMDf - Pitting
The macrography of a longitudinal section of the pipe and connector, at the welded joint, shows that the welding was conducted from both side of the groove, starting from the ID and finishing from the OD, ID later machined flush. The cracking was detected by ultrasonic test and the macro shows that it is at the fusion line, growthing into the weld metal. See the schematic drawing in the next figure
535
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 MacroDf - Longitudinal Section
Detail of the fracture surface, predominantly transgranular with secondary cracks of intergranular morphology.
831
VIEW
ML00078 / Jun.2017
Hydrogen Cracking of IN 718 Subsea Connector
M - NiCrFe AlloyP - ForgingAp - SubseaCd - Hydrogen Embrittlement
Cm - Fractography by SEMDf - Brittle Fracture
Visual aspect from the external side of the 14"ND flange butt welded to a pipe, presenting a through wall crack about 5mm to 10mm from the butt welding.
925
VIEW
ML00002 / Jan.2018
Preferential Dissolution and Cracks in SDSS
M - Super Duplex Stainless SteelP - Fabrication WeldAp - PipingCd - Preferential Dissolution
Cm - Aspect Before AnalysisDf - Through Wall Cracking

More from these cases

ML00184 — Dissimilar Steels in a Threaded ConnectionM - Low Carbon SteelP - ForgingAp - OffshoreCd - Localized Dissolution
The painting of the valve body was detaching at the vent location where the fitting was installed, not fully tighted. Three threaded fillets were outside of the body.
190
VIEW
ML00184 / Apr.2023
Dissimilar Steels in a Threaded Connection
M - Low Carbon SteelP - ForgingAp - OffshoreCd - Localized Dissolution
Cm - Aspect After CleaningDf - Painting Detachment
The austenitic stainless steel fitting was removed from the valve body and presented the sdhesion of oily deposits.
150
VIEW
ML00184 / Apr.2023
Dissimilar Steels in a Threaded Connection
M - Low Carbon SteelP - ForgingAp - OffshoreCd - Localized Dissolution
Cm - Aspect Before AnalysisDf - Surface Deposits
The cleaned fitting is sound. No corrosion, only surface stains.
121
VIEW
ML00184 / Apr.2023
Dissimilar Steels in a Threaded Connection
M - Low Carbon SteelP - ForgingAp - OffshoreCd - Localized Dissolution
Cm - Aspect After CleaningDf - General View
The threads of the carbon steel valve body is corroded. The offshore ambient is wet and chloride rich, creating an aggressive environment for the carbon steel threads.
99
VIEW
ML00184 / Apr.2023
Dissimilar Steels in a Threaded Connection
M - Low Carbon SteelP - ForgingAp - OffshoreCd - Localized Dissolution
Cm - Surface AspectDf - Corrosion
Not only the threads were corroded but all regions under the painting that was detached from the surface.
86
VIEW
ML00184 / Apr.2023
Dissimilar Steels in a Threaded Connection
M - Low Carbon SteelP - ForgingAp - OffshoreCd - Localized Dissolution
Cm - Surface AspectDf - Corrosion

+8 more from this case →

ML00178 — Cold cracks in Cr-Mo Welded ForgingM - CrMo SteelP - ForgingAp - O&G Well DrillingCd - Welding Defect
Circumferential weld aspect. Two passes in the cap. This forging to pipe welded joint, 22 mm thick, was welded by an automatic process in a narrow gap. The pipe is to the top of the image and the forging is to the bottom of the image.
165
VIEW
ML00178 / Jan.2022
Cold cracks in Cr-Mo Welded Forging
M - CrMo SteelP - ForgingAp - O&G Well DrillingCd - Welding Defect
Cm - Aspect Before AnalysisDf - External Surface
The dye check image shows the detected crack, 50 mm long, at the margin of the weld in the forging side.
137
VIEW
ML00178 / Jan.2022
Cold cracks in Cr-Mo Welded Forging
M - CrMo SteelP - ForgingAp - O&G Well DrillingCd - Welding Defect
Cm - Aspect by NDTDf - Cracking
Macrography of the welded joint between the forging and the pipe, showing it was welded in a narrow gap, indicating by the arrow the location of the crack at the margin of the weld, in the forging side.
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 MacroDf - Welded Joint
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
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

+14 more from this case →

ML00134 — Brittle Fracture of a Superduplex Valve BodyM - Super Duplex Stainless SteelP - Fabrication WeldAp - SubseaCd - Brittle Fracture
Detailed aspect of the cracking, straight and presenting a brittle aspect.
122
VIEW
ML00134 / Aug.2020
Brittle Fracture of a Superduplex Valve Body
M - Super Duplex Stainless SteelP - Fabrication WeldAp - SubseaCd - Brittle Fracture
Cm - Aspect Before AnalysisDf - Cracking
Detail of the internal bore, showing a brittle crack through the wall.
106
VIEW
ML00134 / Aug.2020
Brittle Fracture of a Superduplex Valve Body
M - Super Duplex Stainless SteelP - Fabrication WeldAp - SubseaCd - Brittle Fracture
Cm - Aspect Before AnalysisDf - Cracking
Aspect of a section cut transverse to the center of the body. The crack is brittle, trough wall, and was arrested in the region where the valve body was welded to the insert.
105
VIEW
ML00134 / Aug.2020
Brittle Fracture of a Superduplex Valve Body
M - Super Duplex Stainless SteelP - Fabrication WeldAp - SubseaCd - Brittle Fracture
Cm - Transverse Section AspectDf - Cracking
Microstructural analysis of the valve body structure, close to the position where the cracking has occurred. The structure is ferritic austenitic, with a large amount of detrimental phases associated to the ferritic structure, probably sigma phase.
106
VIEW
ML00134 / Aug.2020
Brittle Fracture of a Superduplex Valve Body
M - Super Duplex Stainless SteelP - Fabrication WeldAp - SubseaCd - Brittle Fracture
Cm - NaOH Electrolytic Etched MicroDf - Sigma
Micrographic detail of the valve body structure, close to the position where the cracking has occurred. The structure is ferritic austenitic, with a large amount of detrimental phases associated to the ferritic structure, probably sigma phase.
102
VIEW
ML00134 / Aug.2020
Brittle Fracture of a Superduplex Valve Body
M - Super Duplex Stainless SteelP - Fabrication WeldAp - SubseaCd - Brittle Fracture
Cm - NaOH Electrolytic Etched MicroDf - Sigma

+25 more from this case →

ML00124 — MIC of a Martensitic Valve RingM - Martensitic Stainless SteelP - ForgingAp - EnergyCd - Brittle Behavior
Macroscopic aspect of the crack in the valve ring surface. A leakage was detected during testing after 6 months out of service and the inspection identified several transverse cracks in the forged ring. The valve was installed for one year, but it was not drained during the time it was out of service. The cracks were located in regions that were rusted and presenting a biological fouling.
50
VIEW
ML00124 / Feb.2018
MIC of a Martensitic Valve Ring
M - Martensitic Stainless SteelP - ForgingAp - EnergyCd - Brittle Behavior
Cm - Aspect Before AnalysisDf - At the Surface
Macroscopic aspect of the crack after cleaning the ring surface. Transverse cracks were identified associated to pitting corrosion.
44
VIEW
ML00124 / Feb.2018
MIC of a Martensitic Valve Ring
M - Martensitic Stainless SteelP - ForgingAp - EnergyCd - Brittle Behavior
Cm - Aspect Before AnalysisDf - Localized Corrosion
Micrography of a transverse section of the ring presenting a uniform tempered martensite structure.
43
VIEW
ML00124 / Feb.2018
MIC of a Martensitic Valve Ring
M - Martensitic Stainless SteelP - ForgingAp - EnergyCd - Brittle Behavior
Cm - Kalling Etched Micrography by OMDf - Martensite
Microscopic details of the ring surface showing the fouling at the surface and localized corrosion under the deposits.
42
VIEW
ML00124 / Feb.2018
MIC of a Martensitic Valve Ring
M - Martensitic Stainless SteelP - ForgingAp - EnergyCd - Brittle Behavior
Cm - Surface Aspect by SEMDf - Pitting
Higher magnification of the localized corrosion, showing that there are cracks at the margin of the corroded region.
39
VIEW
ML00124 / Feb.2018
MIC of a Martensitic Valve Ring
M - Martensitic Stainless SteelP - ForgingAp - EnergyCd - Brittle Behavior
Cm - Surface Aspect by SEMDf - Pitting

+11 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
Schematic drawing presenting the longitudinal section of the pipe and connector at the welded joint
105
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 - Identification drawingDf - Longitudinal Section
Hot cracking at the fusion line of the connector side, in a welded joint between a forging and a pipe, in a macrographic sample. The region of the heat affected zone of the connector presents a dendritic aspect suggesting that the forging reduction rate of the connector was not too high and did not broke the cast structure.
110
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 MacroDf - Welded Joint
The connector was welded to the pipe from both (internal and external) sides, a PWHT was applied and the part was machined. The UT indication was detected during final inspection.
78
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 - Aspect Before AnalysisDf - General View
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 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

+11 more from this case →

ML00078 — Hydrogen Cracking of IN 718 Subsea ConnectorM - NiCrFe AlloyP - ForgingAp - SubseaCd - Hydrogen Embrittlement
Brittle aspect of the failure of the conector in the male thread. Both sides of the fracture.
96
VIEW
ML00078 / Jun.2017
Hydrogen Cracking of IN 718 Subsea Connector
M - NiCrFe AlloyP - ForgingAp - SubseaCd - Hydrogen Embrittlement
Cm - Aspect Before AnalysisDf - General View
Micrography of the longitudinal section of the forging material, presenting a granular austenite, precipitation hardened.
84
VIEW
ML00078 / Jun.2017
Hydrogen Cracking of IN 718 Subsea Connector
M - NiCrFe AlloyP - ForgingAp - SubseaCd - Hydrogen Embrittlement
Cm - Kalling Etched Micrography by OMDf - Longitudinal Section
Fractography by SEM, showing intergranular and transgranular fracture micromechanisms.
72
VIEW
ML00078 / Jun.2017
Hydrogen Cracking of IN 718 Subsea Connector
M - NiCrFe AlloyP - ForgingAp - SubseaCd - Hydrogen Embrittlement
Cm - Fractography by SEMDf - Brittle Fracture
Micrography of the longitudinal section of the conector, at the fracture position, showing secondary cracks from the fracture surface.
63
VIEW
ML00078 / Jun.2017
Hydrogen Cracking of IN 718 Subsea Connector
M - NiCrFe AlloyP - ForgingAp - SubseaCd - Hydrogen Embrittlement
Cm - Kalling Etched Micrography by OMDf - Fracture
The micrographic detail of the longitudinal section at the fracture surface shows intergranular morphology for the secondary cracks (longitudinal to the forging axis).
64
VIEW
ML00078 / Jun.2017
Hydrogen Cracking of IN 718 Subsea Connector
M - NiCrFe AlloyP - ForgingAp - SubseaCd - Hydrogen Embrittlement
Cm - Kalling Etched Micrography by OMDf - Secondary Cracks

+3 more from this case →

ML00002 — Preferential Dissolution and Cracks in SDSSM - Super Duplex Stainless SteelP - Fabrication WeldAp - PipingCd - Preferential Dissolution
External surface aspect of the flange showing preferential dissolution, responsible for nucleation of the through wall cracking.
245
VIEW
ML00002 / Jan.2018
Preferential Dissolution and Cracks in SDSS
M - Super Duplex Stainless SteelP - Fabrication WeldAp - PipingCd - Preferential Dissolution
Cm - Surface Aspect by SEMDf - Preferential Dissolution
Detail of the region at the flange external surface where the material is suffering the preferential corrosion.
177
VIEW
ML00002 / Jan.2018
Preferential Dissolution and Cracks in SDSS
M - Super Duplex Stainless SteelP - Fabrication WeldAp - PipingCd - Preferential Dissolution
Cm - Surface Aspect by SEMDf - Preferential Dissolution
Macrography of a longitudinal section of the flange to pipe weld, cracked in the flange. Pipe thickness, measured, is 5 mm. Flange thickness at the welded region is 7.5 mm. The macro was etched using NaOH solution, electrolytic.
181
VIEW
ML00002 / Jan.2018
Preferential Dissolution and Cracks in SDSS
M - Super Duplex Stainless SteelP - Fabrication WeldAp - PipingCd - Preferential Dissolution
Cm - NaOH Electrolytic Etched MacroDf - Longitudinal Section
Macrography transverse to the circunferential weld, longitudinal to the piping, presenting the location, a little far from the welded joint margin, where the through wall cracking is positioned.
160
VIEW
ML00002 / Jan.2018
Preferential Dissolution and Cracks in SDSS
M - Super Duplex Stainless SteelP - Fabrication WeldAp - PipingCd - Preferential Dissolution
Cm - NaOH Electrolytic Etched MicroDf - Through Wall Cracking
Longitudinal section micrography at the cracked position, close to the external surface of the flange, showing cracks transverse to the thickness, associated to the microstructure.
147
VIEW
ML00002 / Jan.2018
Preferential Dissolution and Cracks in SDSS
M - Super Duplex Stainless SteelP - Fabrication WeldAp - PipingCd - Preferential Dissolution
Cm - NaOH Electrolytic Etched MicroDf - Cracks Transverse to the Surface

+11 more from this case →