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FAILURE ANALYSIS

CC Technologies performs numerous failure analyses each year in a wide variety of areas. These include coatings, aircraft, pipelines, high-temperature tubular components, and containers for consumer products. We utilize state-of-the-art facilities and equipment for carrying out these failure analysis, including metallographic facilities, optical microscopy, scanning electron microscopy (SEM), transmission electron microscopy (TEM), Fourier Transform Infrared Spectroscopy, as well as surface analytical equipment such as Energy Dispersive Spectroscopy (EDS), Auger Spectroscopy, and X-Ray Photoelectron Spectroscopy (XPS).

A few examples of failure analysis include:

Suction Roll Shell Duplex stainless steels are susceptible to pitting and crevice corrosion in pulp and paper-mill white waters. Pitting on the outside surface of a duplex stainless steel couch roll shell occurred in less than a year of operation. The attack resulted in selective dissolution of the austinetic phase of duplex stainless steel.	Boiler Tubes Five damaged tubes were removed from a waste heat boiler at a methanol plant. It was concluded that the primary cause of failure was corrosion on the internal surfaces. This initial failure resulted in secondary damage and failure of nearby tubes.
Aircraft Two of the main reasons that aluminum aircraft components fail are exfoliation corrosion and fatigue. The CC Technologies staff has con- ducted several investigations to determine the cause of failed aircraft components. Exfoliation corrosion of aluminum alloys can result in significant reduction in strength of structural members. Fatigue cracking can be particularly detrimental to the structural integrity of the aircraft.	Copper Tubing Pitting corrosion 50% through wall beneath scale build-up in copper tubing.
Internal Pipe Corrosion Internal corrosion of oil and gas pipelines is a growing concern to pipeline operators. The "bad" actors for internal corrosion of pipelines are chloride, CO2, H2S, oxygen, and microbiological activity. A recent severe case of internal corrosion caused several failures on a 20-inch (51 cm) oil line after only 2 years of service. The cause of the failure was high CO2 concentrations (9%) in combination with high levels of brine.	Exhaust Manifold Corrosion attack, only a few grains deep, lead to fatigue and failure at the welded joint of a Type 304L stainless steel exhaust manifold of a diesel engine.
Catalyst Tube Excessive casting porosity near the inside surface of a catalyst tube (Nb modified HP alloy) of a reformer furnace caused severe internal oxidation; failure of the tube occurred by local creep damage.	Sterilizer Retort Massive stress-corrosion cracking occurred in 1/4-inch thick walls of a packaged food-sterilizer retort that operated at 180°F with 1 ppm residual chlorine in the spray water.
FBE Coated Pipe Blistering of FBE coatings is a result of a cathodically enhanced osmosis of water thorough the coating, possibly at pre-existing contaminated sites on the steel surface.	Chrysotile Asbestos High magnification view of asbestos microtubes deposited on a carbon grid. Micrograph taken with an analytical transmission electron microscope, original at 200,000X.
Reinforced Rubber Hose This reinforced submersible rubber transfer hose failed in service though the combination of chemical degradation (by gas condensate) and improper loading, resulting in kinking of the hose and eventually delamination and splitting.	Gas Transmission Pipeline Stress corrosion cracking failure of 20-inch diameter transmission natural gas pipeline.

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