Microstructural and mechanical characterization of U-bend economizer failures: Integrating experimental testing and CFD simulation
This study provides detailed defect analysis and investigation of the U-bend section in an economizer within a chemical industry heat exchanger, focusing on the implications after 25 years of operation. The analysis integrates experimental techniques such as tensile and flexural testing, hardness me...
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| Format: | Article |
| Language: | English |
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Elsevier
2025-05-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785425009998 |
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| author | Edi Purnomo Ardi Wiranata Deendarlianto Muhammad Akhsin Muflikhun |
| author_facet | Edi Purnomo Ardi Wiranata Deendarlianto Muhammad Akhsin Muflikhun |
| author_sort | Edi Purnomo |
| collection | DOAJ |
| description | This study provides detailed defect analysis and investigation of the U-bend section in an economizer within a chemical industry heat exchanger, focusing on the implications after 25 years of operation. The analysis integrates experimental techniques such as tensile and flexural testing, hardness measurement, metallography, SEM-EDS, and OES, with CFD simulations to identify root causes of failure. Results show a tensile strength of 392.1 MPa and flexural strength of 1325.2 MPa, with uniform hardness across the heat-affected zone (HAZ) and unaffected areas. The SEM-EDS analysis indicates oxidation-related corrosion (FeO, Fe2O3, Fe3O4) due to welding defects. Moreover, CFD simulations highlight increased velocity vectors and wall shear stress around defect sites, leading to erosion. The root causes of failure are identified as welding defects and corrosion, exacerbated by operational stresses. The study emphasizes the importance of high-quality welding practices, routine inspections, and effective maintenance strategies to prevent early failure and enhance heat exchanger reliability and performance. |
| format | Article |
| id | doaj-art-e58a96f2c4244ca394a488a3c1da1cc3 |
| institution | DOAJ |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-e58a96f2c4244ca394a488a3c1da1cc32025-08-20T03:18:18ZengElsevierJournal of Materials Research and Technology2238-78542025-05-01364692470210.1016/j.jmrt.2025.04.178Microstructural and mechanical characterization of U-bend economizer failures: Integrating experimental testing and CFD simulationEdi Purnomo0Ardi Wiranata1 Deendarlianto2Muhammad Akhsin Muflikhun3Mechanical and Industrial Engineering Department, Universitas Gadjah Mada, IndonesiaMechanical and Industrial Engineering Department, Universitas Gadjah Mada, IndonesiaMechanical and Industrial Engineering Department, Universitas Gadjah Mada, Indonesia; Center for Energy Studies, Universitas Gadjah Mada, IndonesiaMechanical and Industrial Engineering Department, Universitas Gadjah Mada, Indonesia; Center for Energy Studies, Universitas Gadjah Mada, Indonesia; Corresponding author. Mechanical and Industrial Engineering Department, Universitas Gadjah Mada, IndonesiaThis study provides detailed defect analysis and investigation of the U-bend section in an economizer within a chemical industry heat exchanger, focusing on the implications after 25 years of operation. The analysis integrates experimental techniques such as tensile and flexural testing, hardness measurement, metallography, SEM-EDS, and OES, with CFD simulations to identify root causes of failure. Results show a tensile strength of 392.1 MPa and flexural strength of 1325.2 MPa, with uniform hardness across the heat-affected zone (HAZ) and unaffected areas. The SEM-EDS analysis indicates oxidation-related corrosion (FeO, Fe2O3, Fe3O4) due to welding defects. Moreover, CFD simulations highlight increased velocity vectors and wall shear stress around defect sites, leading to erosion. The root causes of failure are identified as welding defects and corrosion, exacerbated by operational stresses. The study emphasizes the importance of high-quality welding practices, routine inspections, and effective maintenance strategies to prevent early failure and enhance heat exchanger reliability and performance.http://www.sciencedirect.com/science/article/pii/S2238785425009998U-bendWelding effectFailure analysisHeat exchangerCFD |
| spellingShingle | Edi Purnomo Ardi Wiranata Deendarlianto Muhammad Akhsin Muflikhun Microstructural and mechanical characterization of U-bend economizer failures: Integrating experimental testing and CFD simulation Journal of Materials Research and Technology U-bend Welding effect Failure analysis Heat exchanger CFD |
| title | Microstructural and mechanical characterization of U-bend economizer failures: Integrating experimental testing and CFD simulation |
| title_full | Microstructural and mechanical characterization of U-bend economizer failures: Integrating experimental testing and CFD simulation |
| title_fullStr | Microstructural and mechanical characterization of U-bend economizer failures: Integrating experimental testing and CFD simulation |
| title_full_unstemmed | Microstructural and mechanical characterization of U-bend economizer failures: Integrating experimental testing and CFD simulation |
| title_short | Microstructural and mechanical characterization of U-bend economizer failures: Integrating experimental testing and CFD simulation |
| title_sort | microstructural and mechanical characterization of u bend economizer failures integrating experimental testing and cfd simulation |
| topic | U-bend Welding effect Failure analysis Heat exchanger CFD |
| url | http://www.sciencedirect.com/science/article/pii/S2238785425009998 |
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