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    Pipe Defects

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    Hansel Francis
    The document discusses various defects that can be introduced into metals during fabrication processes like forging and extrusion, such as cracks, laps, seams, forging bursts, and speed cracks. It provides examples of how processes like closed-die forging and direct extrusion can result in defects and describes defects like flash cracks, surface scaling, and incomplete mold filling.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Pipe Defects

    Uploaded by

    Hansel Francis
    206 views2 pages
    The document discusses various defects that can be introduced into metals during fabrication processes like forging and extrusion, such as cracks, laps, seams, forging bursts, and speed cracks. It provides examples of how processes like closed-die forging and direct extrusion can result in defects and describes defects like flash cracks, surface scaling, and incomplete mold filling.

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    Pipe defects during manufacturing

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    The document discusses various defects that can be introduced into metals during fabrication processes like forging and extrusion, such as cracks, laps, seams, forging bursts, and speed cracks. It provides examples of how processes like closed-die forging and direct extrusion can result in defects and describes defects like flash cracks, surface scaling, and incomplete mold filling.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    206 views2 pages

    Pipe Defects

    Uploaded by

    Hansel Francis
    The document discusses various defects that can be introduced into metals during fabrication processes like forging and extrusion, such as cracks, laps, seams, forging bursts, and speed cracks. It provides examples of how processes like closed-die forging and direct extrusion can result in defects and describes defects like flash cracks, surface scaling, and incomplete mold filling.

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    MATERIALS SCIENCE AND ENGINEERING Vol. III Defects Introduced into Metals During Fabrication and Service A.J.

    J.Wilby and D.P. Neale

    defects can be introduced by the forming process, typically restricted to cracks, and
    surface shape and size related defects.
    2.2.1. Cracks, Laps and Seams

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    Closed-die forging produces a sliver of material which is forced out between the dies.
    This is known as flash. The flash is removed after forging, but if the strain
    experienced during extrusion of the flash is excessive, the flash may crack.
    Occasionally the cracks can run into the forging and remain when the flash has been
    removed. The resultant defect is known as a flash crack.

    Figure 2: Forging bursts and flash cracks

    During the reduction of thick section forgings, high levels of triaxial stress can be set up
    deep within the sections. If the stress exceeds the tensile strength of the material,
    fissures can form. These are referred to as forging bursts. Bursts can be surface
    breaking, but are more often wholly embedded and therefore difficult to detect.
    Metals that are quite malleable at room temperature such as aluminum, copper and lead,
    can be formed either without any additional heat, or with only a modest amount. On the
    other hand, metals or alloys that have high temperature strength need to be heated to a
    point where they can be forged. This can then lead to oxidation and surface scaling,
    which in itself is not necessarily detrimental, but can lead to secondary problems. More
    specifically, the surface scale can become folded and rolled into the surface in deep
    channels. This then forms a line of weakness if not removed during subsequent
    manufacturing operations. These defects are known as laps or seams.

    Encyclopedia of Life Support Systems (EOLSS)

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    MATERIALS SCIENCE AND ENGINEERING Vol. III Defects Introduced into Metals During Fabrication and Service A.J.Wilby and D.P. Neale

    Figure 3: Composite Sketch of Typical Rolling Defects

    During direct extrusion, as the billet is forced out through the die, the center sections of
    the ingot are extruded first, the outer surface moving to the center as the extrusion
    progresses. Being a hot process, the outer surface will be oxidized and during the latter
    stages, this oxide is extruded with the metal and enters the extrusion. This effect is
    eliminated in indirect extrusion. High speed or high temperature extrusion can also
    result in defects when lubrication becomes difficult. Friction between the product and
    the dies can result in sticking of the product to the die. As the extrusion breaks away,
    fissures known as speed cracks are formed.
    When forging close to the finished product shape, it is clearly important to ensure that
    the blank is of adequate size and shape to fill the mold to produce the desired
    component. If the mold is incompletely filled, then some part of the finished product
    will be missing. Although this may be obvious during even the simplest of quality
    control checks, many mass produced products are only sample checked at manufacture
    and rejectable products may not be detected.

    Encyclopedia of Life Support Systems (EOLSS)

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