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Metallurgical evaluation was performed on a fractured column tube of the reformer furnace in an ammonia plant. The tubes were manufactured from centrifugally cast heat resistant steel HK 40. Optical and scanning electron microscope (SEM) were used for microstructural and fracture analysis. For composition determination of the microconstituents energy dispersive X ray spectroscopy (EDS) was used. To evaluate mechanical properties, hardness and microhardness measurements were performed. Investigations based on the microstructural features with the idea to indicate suitability of weld repair of the column were performed in this study. It was observed that the crack initiation, caused by oxidation/corrosion and thermal stresses induced by temperature gradient, appeared in the inner side of the tube wall and propagation occurred along grain boundaries. The results clearly showed the presence of an irregular microstructure which contributed to crack propagation through the tube wall. An occurrence of precipitated needle-shaped carbides/carbonitrides and brittle σ phase was also identified in the microstructure. Results of the microstructural and fracture analysis clearly indicate that reformer furnace columns made of heat resistant steel HK 40 were unsuitable for weld repair.

Microstructural analysis as the indicator for suitability of weld repairing of the heat resistant Cr - Ni steel