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Fracture Failure Analysis of a High-Pressure Bypass Valve Stem

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Abstract

The high-pressure bypass valve stem of an ultra-supercritical unit has undergone a fatal fracture after running for more than 10,000 h. We analyzed the causes and types of the fracture by applying a series of tests: macroscopic and metallographic observation, chemical analysis, scanning electron microscopy (SEM), microhardness, and high-temperature tensile tests. The results show that the leading reasons for fracture are inadequate chemical composition of the material, unreasonable structural design, insufficient high-temperature strength, vibration, and corrosion. Furthermore, the two ends of the dowel hole represent the crack source, and crack propagation and transient fracture zones could be observed. Based on these characteristics, it is concluded that the fracture of the valve stem belongs to fatigue fracture.

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Acknowledgments

This work was financially supported by the Science and Technology Project HNKJ19-H25 (Research and application of the Key technologies of controlled spalling and pre-separation of oxide peel in online detection of super (ultra) critical unit) of the China Huaneng Group. The authors are grateful for this support.

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Authors and Affiliations

  1. Xi’an Thermal Power Research Institute Co., Ltd., Xi’an, 710054, China

    Chen Long Zhou, Ai Jun Yan, Xuan Wei & Zhi Dong Fan

  2. Mianchi Power Plant of Huaneng Co., Ltd., Sanmenxia, 472400, Henan, China

    Lei Zhu

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  1. Chen Long Zhou
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  2. Ai Jun Yan
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  3. Xuan Wei
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  4. Zhi Dong Fan
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Correspondence to Chen Long Zhou.

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Zhou, C.L., Yan, A.J., Wei, X. et al. Fracture Failure Analysis of a High-Pressure Bypass Valve Stem. J Fail. Anal. and Preven. 23, 1038–1045 (2023). https://doi.org/10.1007/s11668-023-01647-2

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  • DOI: https://doi.org/10.1007/s11668-023-01647-2

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