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doi: 10.14355/me.2014.0302.02
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Introduction
Instances of very short service lives are very common
experiences in using many consumer items in Nigeria
in recent years. Plumbing fittings have been found to
fail and had to be replaced within months. Service
lives of electric bulbs have been found to average less
than four weeks. Wall electrical outlets commonly heat
up under household amperage, melt and burn the
plastic housing. Electric stoves, water heaters, pressing
iron, rechargeable lamps, ceiling lamp holders and IT
products, often pack up in few months of use. The list
is longer and there have been officially statements
about the trend (Agboola, 2011). Since many of these
items were imported into the country, such
experiences can be expected in many parts of the globe.
For this work, plumbing parts that have been found to
fail in service after remarkably short service lives were
focused. Shower sprinklers and drainers (sieves in
kitchen sink hole) produced to appear like stainless
steel have been found to rust to dirty brown within
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Designation
F1
F2
F3
F4
Exhibits
FIGURE 1 INSTANCES OF TAP1 AS FOUND IN SERVICE SHOWING DETERIORATION LEVELS AND EMBOSSED PRODUCTION
STAMP SHOWING SUPPOSED STANDARD SPECIFICATION KEPT.
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(c)
(a)
(b)
FIGURE 2 TAP SAMPLES AS OBTAINED FROM THE PLUMBING SHOP
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TABLE 2 ELEMENTAL COMPOSITION (%) OF ALLOYS USED IN THE DRAINER (D), THE CONTROL RODS (R) AND HOUSING (H) OF THE SAMPLE FAUCETS, AND
THE STANDARD SPECIFICATIONS OF SUCH PARTS.
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R1
R2
R3
H1
H2
H3
H4
ST
SD
Al
0.023
0.149
0.003
0.0088
0.245
0.087
83.3
0.1-0.8
0.031
0.100
As
0.034
0.032
0.016
0.014
0.014
--
0.193
0.244
0.195
--
--
--
--
0.142
0.080
Cr
0.532
0.313
0.0042
0.0068
0.02
0.069
0.070
0.084
20.000
Cu
0.037
0.04
0.0033
58.2
67.5
54.2
1.86
58-63
0.081
Fe
97.7
97.35
99.3
0.74
0.95
0.7
0.5
0.7
99.2
68.995
Mn
0.79
1.02
0.369
0.009
0.005
0.003
1.18
0.5
0.108
2.000
Ni
0.009
0.015
0.021
0.306
0.281
0.281
--
0.053
8.000
0.036
0.037
0.047
0.0079
0.005
0.005
--
0.02
0.045
0.045
Pb
0.003
0.001
0.002
2.61
5.63
6.22
0.05
0.5 - 2.5
0.024
0.03
0.020
0.0061
0.011
0.007
--
--
0.048
0.750
Si
0.58
0.71
0.021
0.013
0.066
0.14
1.3
0.05
0.188
0.030
Sn
0.026
0.027
0.0012
0.81
2.44
1.6
0.146
0.0043
Zn
--
--
0.013
37.17
22.68
36.65
11.40
30.43 38.13
0.01
--
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acceptable.
The bulk body alloy used in F4 housing found to be of
aluminum alloy is a good alternative to the brass
alloys. The composition shows an Al-Zn alloy that can
come under the BS 1475:7000 series. Aluminum is
known for its tenacious thin surface oxide which
makes aluminum alloys naturally corrosion resistant
(Snodgrass, 2003). The surface of this faucet was also
treated to a tenacious coating, and the material can be
considered acceptable.
Microstructures of Component Alloys
The housings of the various faucets generally show
different as cast microstructures. Since the housings
actually did not give any problem in service or in the
corrosion test, the micrographs are inconsequential in
further analysis of the performance problem. Figures
4a and b, micrographs obtained for H1 and H3, were
therefore shown only as representative micrographs of
the brass housings.
FIGURE 4 OPTICAL MICROGRAPH OF THE BRASS HOUSING OF (A: LEFT) TAP1, SHOWING A GRANULAR AS-CAST +
STRUCTURE (EXPECTED AT 37 % Zn, X 400), AND (B: RIGHT) H3, SHOWING A PREDOMINANTLY -BRASS MATRIX (AT 22 % Zn, X 200)
WITH EQUIAXED AS CAST STRUCTURE.
FIGURE 5 OPTICAL MICROGRAPHS OF THE VALVE CONTROL RODS OF (A: LEFT) TAP1 SHOWING AS-ROLLED DIRECTIONAL
GRAIN (X 400) AND (B: RIGHT) TAP2 SHOWING RECRYSTALLISED GRAINS POSSIBLY FROM FULL ANNEAL (X 400).
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FIGURE 6 OPTICAL MICROGRAPHS OF (A: LEFT) THE VALVE CONTROL ROD OF TAP3 SHOWING THE AS ROLLED STRUCTURE
LARGELY RELIEVED, THOUGH LITTLE FLOW IS STILL RESIDUAL (X 400), AND (B: RIGHT) THE DRAINER SIEVE WITH CLEARLY
FLOWED PEARLITE MORPHOLOGY IN A FERRITE MAIN MATRIX (X 400).
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R1-Static
R1-Dynamic
R2-Static
R2-Dynamic
R3-Static
R3-Dynamic
12
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10
8
6
4
2
Time (days)
0
0
10
20
30
40
FIGURE 7 CUMULATIVE MASS LOSS PER UNIT AREA UNDER STATIC AND DYNAMIC EXPOSURES OF CONTROL RODS IN F1, F2
AND F3, DENOTED AS R1, R2 AND R3 RESPECTIVELY.
6
5
4
3
2
1
0
0
10
20
30
Time (days)
40
FIGURE 8 CUMULATIVE MASS LOSS PER UNIT AREA OVER TIME OF EXPOSURE OF THE DRAINER SIEVE TO ORDINARY WATER
UNDER DYNAMIC CONDITION, WITH VIEWS OF THE CORRODED TEST SAMPLE INSET.
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Elements
Chromium (Cr)
Copper (Cu)
Iron (Fe)
Lead (Pb)
Manganese(Mn)
Nickel (Ni)
Zinc (Zn)
Tested Water
Sample (mg/L)
0.074
0.186
130.8
1.039
0.027
28.833
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Architectural
Services
Department.
General
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http://minerals.usgs.gov/minerals/pubs/commodity/recycle/r
ecymyb01.pdf Accessed July 2013.
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Iyiola Olatunji OTUNNIYI is a
Metallurgical Engineering academic.
He studied at Obafemi Awolowo
University
Ile-Ife,
Nigeria
and
University of Pretoria, South Africa.
He holds a PhD degree and has more
than ten years of teaching and research
experiences in Universities and Institutes.
Oluwayimika O OLUOKUN is a notably bright upcoming
Metallurgical Engineer. He studied at Federal University of
Technology, Akure and took interest in materials quality and
integrity in service, metallurgical plant and process design.
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