Volume 53, Issue 8

The studies outlined show that a large number of errors may occur during the preparatory works and during sample preparation for light microscopic examinations. Another source of error is the choice of the microscopy technique. As is the case for all materialographic examinations, the interpretation of the samples is particularly important. This work wants to help eliminating some of the sources of errors.

We analyze mixtures of magnesium diboride and tetraboride synthesized with magnesium powders of different shapes. To distinguish between magnesium diboride and tetraboride we use the contrast of kelvin probe force microscopy. The microstructural morphology strongly depends on the shape of the magnesium powders used in the reaction between magnesium and magnesium tetraboride to form magnesium diboride. With spherical magnesium powder an equiaxed microstructure of magnesium diboride is formed with residual magnesium tetraboride at the grain boundaries. With plate-like magnesium powders elongated magnesium diboride grains are formed. In this case, residual magnesium tetraboride is found to agglomerate.

A pipe connector of an expansion vessel of a safety heat exchanger was torn off in a test facility's natural gas compressor. From a material point of view, the cause of the damage is a fatigue fracture induced by pulsating bending stress. The fatigue fracture originated from both, the pipe's outer surface as well as from its inner surface, which is consistent with the given stress situation (pulsating bending stress). Material defects or welding-induced flaws were not observed. Corrosion, wear, or thermal overload which may have promoted the damage, were not observed either. The primary cause was a major design error. Cases of dynamic load were obviously not duly taken into account during designing, so that the free-swinging mass of the expansion vessel which was mounted to a pipe of a diameter of only half an inch and, furthermore, installed in an angle of 45° (additional static preload!), could cause the fatigue failure induced by pulsating bending stress in the zone of highest stresses at the transition of the expansion vessel and the the pipe connector due to dynamic operating loads which always occur in plants like these.