METAL 2006 23-25.5.

2006, Hradec nad Moravicí

THE INFLUENCE OF THE HIGH TEMPERATURE CORROSION DURING GAS

CUTTING ON QUALITY OF ELECTROFILTER’S HAMMERS

Maciej Hajduga, Dariusz Jędrzejczyka

a
Akademia Techniczno-Humanistyczna w Bielsku-Białej, Katedra Podstaw Budowy Maszyn,
Zakład Inżynierii Materiałowej, ul. Willowa 2, 43-309 Bielsko-Biała, Poland

Abstract
In the paper results of structure investigation of hammers broken inside the electrofilter units
are presented. The complex analysis was conducted including: macro and micro observations
(optical and scanning), RTG analysis and chemical composition evaluation, and hardness
measurement. It was stated that the steel structure and chemical composition is adequate to
the steel grade 18G2A. The main reason of hammers destruction is defects (complicated
oxides, structure discontinuity) generated during cutting operation from steel plates

1. INTRODUCTION
Economic aspects and strong competition cause that many producers seek costs
diminution in every element of production stage. It refers also to the formation process. Metal
is frequently formed to its final shape by casting, rolling, forging, welding, pressing,
extrusion, drawing, stamping and other methods. Mentioned methods need additional
equipment and special devices. Considerably cheaper method of formation that frequently
replace forging is cutting the final element from steel plates. Among not contact methods of
metal cutting – oxy-fuel and air-acetylene gas cutting is most commonly used. These methods
are really very cheap, but reveal several disadvantages. It results among other things in heat
changes of metal structure in a „heat-affected zones“ adjacent to the cut (air-acetylene treated
work-pieces are heated up to the 12000C within about 4 min, whereas the temperature inside
the acetylene-oxygen flame reach even 3100 0C). This may degrade some metallurgical
qualities at the cut’s edge, requiring pre-treatment or trimming [1, 2]. Because authors from
many years lead investigation regarding high temperature oxidation process, this kind of
material destruction is well known for them [3-5]. From the other side forging ensures
contoured grain flow yielding greater impact and directional strength and longer tool life.
Using the air-fuel or air-acetylene gas cutting the introduction of air or oxygen stream at
elevated temperature cause rapid combustion reaction between the steel and oxygen. The
resulting molten material or slag should be blown trough the metal by the stream of cutting
gas mixture, providing a relatively smooth and regular end (see Fig. 1).

a b

Fig. 1. Scheme of slag removal during gas cutting (a) and temperature distribution inside the
flame (b)

1
METAL 2006 23-25.5.2006, Hradec nad Moravicí

The aim of presented work is:

1. To verify if oxy-fuel gas cutting method can be used instead of forging without losing
the ready made element quality.
2. Explain reasons of hammers cracking applied inside the electro-filters.

2. THE OWN INVESTIGATIONS

During the investigation hammers wear after exploitation inside the electro-filters unit
were analysed. The reason of hammer destruction was the cracks that appeared near the
hammers fix (see Fig.2) as the effect of striking – shaking down the dust. In the past when
hammers were made by forging there was no problems with tools lifetime.
Analysis was made using samples cut from broken hammers - from places situated
near the fracture. Samples were analysed using optical microscope NEOPHOT 2, additionally
the Vickers hardness was measured.

a b

Fig. 2 The view of hammers being investigated; a – hammer drawing with marked place of
cracking; b – the view of broken hammers

The preparation of material consisted of the following steps:

• mounting,
• grinding of the surface using abrasive papers different gradation on wet – Buller
grinder,
• polishing of the surface using diamond pastes – Buller polisher,
• etching samples with 4%HNO3.

The structure observation and registration of characteristic areas was made using also the
scanning microscope Jeol-J7. Research was mostly concerned on the structure’s homogeneity
estimation and identification of surface defects. During observation the magnification from
1000 up 10000 times was used. To analyse the chemical composition the X-ray microanalyser
JEOL JCXA 733 was used. The intensity of Kα line was measured of such elements like:
wolfram, vanadium and cobalt.

2
METAL 2006 23-25.5.2006, Hradec nad Moravicí

3.RESULTS AND IT’S DISCUSSION

3.1. Metallographic observations

In investigation two phases steel structure was observed – ferritic-pearlitic- typical for
steel 18G2A.
The observed structure is presented at Fig. 3, 4 and 6. Structure presented at Fig.3
shows fundamental defects – discontinuities (length up to 25mm) and great size non-metallic
inclusions situated at depth reaches even 5mm. The structure observed from opposite side of
crack initiation is correct and does not show any defects. Visible is anisotropy structure
character typical for plastic treatment – lines are perpendicular to the outside surface from
where the cracking process started.
Table 1
An example of chemical analysis of hammer steel
Chemical composition, % - results of measurement
C Si Mn S P Cr Ni Al Cu V
0,20 0,38 1,33 0,027 0,022 0,02 0,02 0,03 0,079 0,002
Chemical composition, % - according standard
C Si Mn S P Cr Ni Al Cu V
Max. 0,2- 1,0-1,5 Max. Max. Max. Max. Min. Max. -
0,20 0,55 0,04 0,04 0,3 0,3 0,02 0,3
a b

Fig. 3. The structure of investigated material; etched with- 4%HNO3, mag.x60, a - surface, b
– passing structure from surface side.

Also the grain increase at subsurface zone is visual (Fig, 2b) as the effect of burner
overheating influence. The chemical composition of steel 18G2A presented in Table 1 shows
that there is no disagreement between specification and results of measurement.
The chemical composition evaluated in micro-areas (Table 2) by RTG micro-analyser
allows for inclusions identification - complex Fe oxides, that are composed besides Si and Mn
also such elements, like: S, Cl, K, Ca.
So, generally the conclusion could be formulated that the short hammers lifetime
follows from defects occurring at the cross section created as the result of not proper cutting
procedure. Localized defects cause tension accumulation (calculated by MES method tension
reaches about 170 MPa in non defected area) in investigated area and crack propagation along
the anisotropy steel structure (fatigue fracture).

3
METAL 2006 23-25.5.2006, Hradec nad Moravicí

a b

Fig. 4. Microstructure observed under scanning microscope inside the investigated hammers,
not etched, with marked points of chemical composition analysis; a, c – inclusion view, b –
subsurface layer.

a b

Fig. 5. The EDS diagram obtained for precipitation visual at fig. 4; a- point 2; b – point 5 (see
also Table 2).

4
METAL 2006 23-25.5.2006, Hradec nad Moravicí

a b

Fig. 6. The fragment of analysed defect - a, with marked sector along which the analysis of
linear changes of oxygen, silicon, manganese and iron was made – b
Table 2
Examples of quantity chemical composition analysis inside the micro areas of investigated
samples
Point Chemical composition, %
designation Al Si S Cl Ca Mn Fe Ni Cu
Inclusion 1 - 0,42 - - - 0,88 98,17 - 0,13
Fig.4 0,08Cr
2 0,12 2,89 2,54 0,22 1,01 5,70 51,81 0,03 0,22
0,36Mg 31,86O2
3 - 8,27 - - - - 39,89 0,03 0,12
0,17Cr 32,28O2
5 0,33 27,22 - - - 23,82 4,90 0,03 0,08
2,37Na 0,05Cr 41,21O2
6 0,05 9,76 0,08 - - 13,83 44,59 - -
0,08Cr 34,52O2
7 - 0,24 - - - 0,32 98,68 0,08 0,21
Structure Al Si S Cl Ca Mn Fe Ni Cu
under 1 0,10 0,54 0,00 - - 0,68 97,78 0,20 -
oxides 0,26Cr
3 0,04 0,38 0,02 - - 0,67 98,35 - -
0,05Cr
4 - 0,38 0,06 - - 0,61 98,71 0,07 -
0,06Cr
5 0,16 0,49 - - - 0,99 98,88 0,11 0,19
6 - 0,35 - - - 1.04 97,90 - -
7 0,03 0,50 0,08 - - 1,13 97,15 - 0,21
Structure Al Si S Cl Ca Mn Fe Ni Cu
in the core 1 0,02 0,36 0,12 - - 1,57 97,15 - 0,30
0,09Cr
2 0,14 0,41 0,10 - - 1,31 96,97 0,32 0,55
3 0,04 0,43 - - - 1,60 96,90 - 0,50

5
METAL 2006 23-25.5.2006, Hradec nad Moravicí

4.CONCLUSIONS

1. The destruction of investigated materials – hammers was the consequence of local

weakness of cross section.
2. In the place of crack initiation the zone of material was find out that shows different
mechanical properties (hardness, structure) from these, that was measured inside the
hammers core was find out at the cross section.
3. The external zone (thickness about 5mm) where the hardness is considerable higher
contains great amount of non-metallic inclusion – mainly complex Fe oxides, that are
composed besides Si and Mn also such elements, like: S, Cl, K, Ca (see EDS diagram
– fig. 5.
4. The observed structure change is probably the result of local too high over-heating
during gas cutting. The chemical composition of external zone reveals small
differences in comparison to the sample core (manganese content inside the core is
about. 0,5% higher, other elements are at similar level .
5. Additional disadvantageous factor that negative influence on the crack propagation
inside the sample is manner of steel plate plastic treatment – the plastic treatment lines
are directed perpendicular to the outside surface from where the crack is being
initiated.
6. From the opposite side of investigated cross sections there was no such structure
differentiation and defects like from the cracks initiation side.

BIBLIOGRAPHY

[1] KLIMPEL A.: Welding, soudage and metal cutting, Warszawa, WNT, 1999.
[2] WASIUNYK K.: Matrix forging, Ed. 3, Warszawa, WNT, 1987
[3] HAJDUGA M., JEDRZEJCZYK D.: The influence of high-temperature oxidation on
decarburization, hardness and on fatigue limit in Fe-C-Cr-Mn-Si steels. KSCS 2000. 3rd
Kurt Schwabe Corrosion Symposium. August 30 – September 2, 2000. Zakopane.
[4] HAJDUGA M., JEDRZEJCZYK D.: „The metallographic investigation of oxides
occuring in the scale layer of steels after the high temperature oxidation”, Acta
Metallurgica Slovaca, 10, 2004, p. 428-432.
[5] HAJDUGA M., JEDRZEJCZYK D.: „The analysis of high temperature oxidation process
of some high alloyed steels”, Acta Metallurgica Slovaca, 10, 2004, p. 422-427.