How to Handle Failure: Learn from the Experts at ASM Seminar

G2MT is pleased to be among the many great presenters at this years ASM Houston Failure Analysis seminar. The meeting was held February 2, 2016, at the Kingwood Country Club, where we specifically discussed two topics that we have seen lead to many failures: (1) microstructure in specifications and (2) the importance of the oxide for corrosion protection.2016 ASM Failure Analysis Seminar

 

Microstructure in Specifications: When steel is purchased for industrial uses, the requirements of the steel (e.g. ingredients, strength, corrosion resistance) are typically specified by ASTM or other similar groups. Many companies have additional requirements beyond the manufacturer’s specification based on their own needs and previous experiences. Recently, we see more and more companies including microstructure analysis as part of their specification. This makes great sense as the variety and quality of steel and other metals changes dramatically depending on how they are made. The chemistry and tensile properties may be acceptable but the ultimate performance is still sub-par in some cases. Microstructure analysis is the of the best ways to ensure your metal is really what you think it is.

The Importance of the Oxide: Oxides are the thin layer of metal mixed with oxygen that are the key to corrosion resistance and performance of titanium, aluminum, stainless steel, and other alloys. So long as the oxide is in place, these metals will corrode very slowly; but take the oxide away and run-away corrosion can occur. Unfortunately, many times materials are tested and used in a way that only evaluates the passive state (when the oxide is in tact) but neglects to evaluate what happens when the oxide is broken (the active state). In the real world, there are many different processes that can break the oxide and this leads to the case where materials corrode and/or fail very prematurely.

 

 

Replacing and Maintaing the Global Infrastructure

Over $60 Trillion Needed to Combat Corrosion of Global Infrastructure

A staggering new estimate of the cost of corrosion over the next 15 years says we will need to spend at least $60 trillion globally just to upgrade and maintain the existing infrastructure. This includes the cost of replacing and upgrading bridges, railroads, highways, power generation, telecommunications, and water facilities around the world. However, the recommendations suggested by this study to mitigate the problems are:

“McKinsey recommends improving:

  • Strategic sourcing
  • Demand consolidation
  • Contractor development
  • Lean execution
  • Project organization/governance planning optimization
  • Increasing infrastructure construction productivity
  • Getting more from existing capacity”

That misses the point: we need to attack corrosion at its source by understanding the likely causes of failures and preventing them. This requires a combination of efforts:

  1. Appropriate materials selection, design, and maintenance.
  2. Integrity management programs provide an effective means to predict and prevent corrosion.
  3. Just as importantly, proper design and selection can prevent many failures from occurring.
  4. Advances in the development of new steel and other metal alloys, inspection technologies, and quality assurance are all likely to provide better management and prevention of corrosion.

Metallurgists at G2MT Labs and other companies are working hard on all of these topics. What approaches do you find are most effective against corrosion?

 

Surface corrosion of drill pipes during storage

Drill pipe failure analysis

With drilling expanding in virtually every corner of the US, including the Bakken, Eagle Ford, Permian, Marcellus, Anadarko, Niobrara, and Granite Wash plays, failure analysis is increasingly important to keep up with the rapid expansion of oil and gas drilling operations.

Drill pipe and casing failures are one of the most common types we receive for failure analysis. G2MT has performed numerous failure analysis on drill pipe and joint sections from drill strings around the US and abroad. Improper processing and/or storage resulted in early corrosion and failures in several of these cases. The improper processing was demonstrated by metallography and microscopy of the drill pipe steels and can result in cracking, corrosion, and early failures if not found before use.  In other cases, improper use of pipe in overly aggressive conditions or spinning the pipe without lubrication were the root causes of failure.

Surface corrosion of drill pipes during storageAt G2MT we provide more than just guesswork about failures,  we focus on the root cause and provide effective recommendations to solve the problem.

Metallurgical Failure Analysis Services Include:

 

Please contact us now at 888-308-9084 to learn more or:

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To learn more about G2MT Labs, please check out:

– Our facilities

– See some of our high-quality metallographic testing,

– More about our failure analysis services, and

– Cutting-edge hydrogen assessment capabilities.

 

G2MT is awarded a Phase I SBIR for Residual Stress Characterization in Pipelines

G2MT recently was began work on a DOT PHMSA (Department of Transportation Pipeline and Hazardous Materials Safety Administration) SBIR Phase I Project. The objective of the project is to characterize the residual stresses in pipeline dents and damaged regions. The nondestructive electromagnetic testing technology being developed for this project provides a leap forward for pipeline inspection by providing through-thickness testing of the residual stress without removal of coatings.

G2MT is working with several partner companies and collaborators to obtain and testing dented and damaged pipeline specimens and to perform in-situ testing of pipelines. Read more about our project on the official DOT PRIMIS website. If you want to learn more or contribute to this project, please contact us today!