The 16” venturi body was basically a three-piece component constructed of 9-Chrome (A335-P91) pipe sections on each end with a 316 stainless steel throat in the center. The P91 pipe was buttered with a deposit of ¼” Inconel 182, and then welded to the 316 throat. The fracture occurred at the edge of the P91 pipe weld, at the interface with the buttering layer, with cracking in the heat affected zone identified as the failure mechanism.
The purpose of this paper is to describe the nature of the failure, the analyses undertaken and their results, the causes and contributing factors, corrective actions taken, and recommendations for preventing such failures in the future. This information is presented with the intent to heighten awareness in the industry about the potential hazards associated with welding dissimilar metals, in particular chrome alloys to stainless steels, and to encourage undertaking preventive measures to identify areas of concern before catastrophic failures can occur.
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