This study presents a failure analysis in two reformer tubes used for hydrogen production in a petrochemical industry. These tubes (Tube A and Tube B) were made by the centrifugal casting of HP-Nb alloy in such a way that one contained titanium as a micro-element, and the other was free from titanium in its chemical composition. Although the two tubes were subjected to similar creep conditions, Tube A failed after only 46,000 h of operation against the design life of 100,000 h. SEM images showed initiation and growth of creep pores next to chromium carbide particles, as well as the formation of microcracks in Cr23C6 carbides. Pore initiation occurs as a result of grain boundary sliding and is strongly dependent on structural morphology. The tube containing titanium (Tube B) showed higher thermal stability and higher creep resistance than the tube without titanium (Tube A), which was due to the formation of finer and more discrete carbide particles. The final fracture of the tube without titanium (Tube A) occurred due to the coalescence of creep pores and the creation of grain boundary cracks.@en

This paper investigates the synthesis, antibacterial, and photocatalytic properties of silver ion-exchanged natural zeolite/TiO2 photocatalyst nanocomposite. Zeolite is known to have a porous surface structure, making it an ideal substrate and framework in different nanocomposites. Moreover, natural zeolite has a superior thermal and chemical stability, with hardly any reactivity with chemicals. Finding an effective and low-cost method to remove both antibiotics and bacteria from water resources has become a vital global issue due to the worldwide excessive use of chemicals and antibiotics. This research aims to propose a facile method to synthesize Ag-ion-exchanged zeolite/TiO2 catalyst for anti-bacterial purposes and photocatalytic removal of atibiotics from wastewaters. TiO2 particles were deposited on the surface of natural zeolite. Ag ion exchanging was performed via a liquid ion-exchange method using 0.1 M AgNO3 solution. X-ray diffractometry (XRD), scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and Fourier-transform infrared spectroscopy (FTIR) were used to evaluate the structure of synthesized powders. Antibacterial activities of samples were assessed, using Staphylococcus aureus ATCC 25923 and Escherichia coli ATCC 25922 by disc diffusion method. It was shown that Ag-containing nanocomposite samples have an improved antibacterial performance in both cases. Results showed that the synthesized catalyst has promising potentials in wastewater treatment.@en

This paper investigates the photocatalytic characteristics of Ag nanowire (AgNW)/TiO2 and AgNW/TiO2/graphene oxide (GO) nanocomposites. Samples were synthesized by the direct coating of TiO2 particles on the surface of silver nanowires. As-prepared AgNW/TiO2 and AgNW/TiO2/GO nanocomposites were characterized by electron microscopy, X-ray diffraction, UV/visible absorption spectroscopy, and infrared spectroscopy. Transmission electron microscope (TEM) images confirmed the successful deposition of TiO2 nanoparticles on the surface of AgNWs. The photocatalytic activity of synthesized nanocomposites was evaluated using Rhodamine B (RhB) in an aqueous solution as the model organic dye. Results showed that synthesized AgNW/TiO2/GO nanocomposite has superior photocatalytic activities when it comes to the decomposition of RhB.

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This paper investigates the synthesis and characterization of photoactive TiO₂/CuO nanocomposites for the simultaneous antibacterial applications and photocatalytic removal of Amoxicilline from wastewaters. Effective removal of biological and organic contaminants from water resources has become a global challenge due to contaminants' complexity and extensive use. TiO₂/CuO heterojunctions with different CuO loadings were synthesized using a straightforward precipitation method. Electron microscopy, energy-dispersive X-ray spectroscopy (EDS), X-ray diffraction (XRD), Fourier transformed infrared (FTIR), ultraviolet–visible (UV-VIS) analyses were used to characterize synthesized samples. Antibacterial activities of samples were investigated against Staphylococcus aureus. Also, the applicability of synthesized powders in the photocatalytic removal of Amoxicilline from wastewater was methodically investigated. Results showed that the photocatalytic activity of synthesized TiO₂/CuO nanocomposites is highly dependent on the CuO loadings of samples. CuO loading can also increase the light absorption within the visible light region, making TiO₂/CuO samples applicable in the visible light region. Results also showed that CuO loading greatly enhances the antibacterial characteristics of samples.

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This paper aims to investigate the synthesis, structure, and optical properties of SiO2 @YAG:Ce core–shell optical nanoparticles for solid state lighting applications. YAG:Ce phosphor is a key part in white light emitting diodes (LEDs), with its main functionality being the generation of yellow light. Generated yellow light from phosphor will be combined with blue light, emitted from chip, resulting in the generation of white light. Generated light in LEDs will often be scattered by SiO2 nanoparticles. SiO2 nanoparticles are often distributed within the optical window, aiming for a more homogeneous light output. The main idea in this research is to combine these functionalities in one core–shell particle, with its core being SiO2 and its shell being phosphor. In this study core–shell nanoparticles with different Ce3+ concentrations were synthesized by a sol–gel method. Synthesized nanoparticles were characterized by X-ray diffraction (XRD), small angle X-ray scattering (SAXS) analysis, high resolution transmission electron macroscopy (HRTEM), Fourier transform infrared (FTIR), and photoluminescence spectroscopy. Luminescence characteristics of SiO2 @YAG:Ce core–shell particles were compared with that of SiO2 /YAG:Ce mixture composite, which is now used in commercial LEDs. Obtained results showed that core–shell nanoparticles have comparatively much better optical properties, compared to SiO2 /YAG:Ce mixture composite and can therefore be potentially used in LEDs.@en

This paper investigates the root cause of a failure in gas-turbine blades, made of Nimonic-105 nickel-based superalloy. The failure was reported in two blades in the second stage of a turbine-compressor of a gas turbine in the hot section. Two failed blades were broken from the root and from the airfoil. The failure took place after 20 k h of service exposure in the temperature range 700–850 °C, with the rotating speed being in the range 15,000–16,000 rpm. The microstructures of the failed blades were studied using optical/electron microscopes. Energy dispersive X-ray spectroscopy (EDS) was employed for phase identification. Results showed that failure first initiated from the root. The dominant failure mechanism in the root was concluded to be corrosion-fatigue. The failure scenario was suggested based on the results obtained@en

This paper investigated a failure in a ventilated disc brake in an automobile. The failed brake disc had been in service for approximately 10 years. The observed failure was in the form of radial cracks that appeared to have initiated at the outer edge of the disc brake. The cracks were rather straight with no branching. Optical microscope, scanning electron microscope (SEM), and energy dispersive X-ray spectroscopy (EDS) were used to study the microstructure of the failed disc. Vickers microhardness test was also used to evaluate the hardness of the samples. Results showed that the root cause of crack formation, in this case, was related to the excessive wear in the brake disc. Different wear mechanisms, namely abrasive and adhesive wear, were recognized in the failed specimen. Moreover, the worn surface in some areas was covered with fine oxide particles. These particles appeared to have a significant contribution toward abrasion. To further understand the wear mechanisms, pin-on-disc experiments were also conducted on the samples. Results of the pin-on-disc experiments were compared and correlated to the results obtained from the failed brake disc.@en

This paper investigates the root cause of the formation of surface cracks on hot-rolled C-Mn constructional steel heavy plates. Cracks are rather evenly distributed over the surface in the form of colonies of cracks. Samples were cut from the heavy plate. The microstructure of samples in the as-cast and hot-rolled states were studied using optical and electron microscopes as well as energy dispersive X-ray spectroscopy (EDS). Results show that cracks are heavily oxidized. De-carburized areas are also seen alongside cracks. The crack tip is in the form of a deer-horn, indicating that crack branching has taken place during deformation. The crack initiation sites are V-shaped grooves on the surface of as-cast slabs. Correlations between microstructures, processing parameters, and crack formation are discussed.@en

This paper investigates a severe microbiologically influenced failure in the elbows of a buried amine pipeline in a petrochemical plant. Pipelines can experience di_erent corrosion mechanisms, including microbiologically influenced corrosion (MIC). MIC, a form of biodeterioration initiated by microorganisms, can have a devastating impact on the reliability and lifetime of buried installations. This paper provides a systematic investigation of a severe MIC-related failure in a buried amine pipeline and includes a detailed microstructural analysis, corrosion products/biofilm analyses, and monitoring of the presence of causative microorganisms. Conclusions were drawn based on experimental data, obtained from visual observations, optical/electron microscopy, and Energy-dispersive X-ray spectroscopy (EDS)/X-Ray Di_raction (XRD) analyses. Additionally, monitoring the presence of causative microorganisms, especially sulfate-reducing bacteria which play the main role in corrosion, was performed. The results confirmed that the failure, in this case, is attributable to sulfate-reducing bacteria (SRB), which is a long-known key group of microorganisms when it comes to microbial corrosion.

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This paper investigates a failure in HP-Mod radiant tubes in a petrochemical plant. Tubes fail after 90,000 h of working at 950 °C. Observed failure is in the form of excessive bulging and longitudinal cracking in reformer tubes. Cracks are also largely branched. The microstructure of service-exposed tubes was evaluated using optical and scanning electron microscopes (SEM). Energy-dispersive X-ray spectroscopy (EDS) was used to analyze and characterize different phases in the microstructure. The results of this study showed that carbides are coarsened at both the inner and the outer surface due to the long exposure to a carburizing environment. Metallography examinations also revealed that there are many creep voids that are nucleated on carbide phases and scattered in between dendrites. Cracks appeared to form as a result of creep void coalescence. Failure is therefore attributed to creep due to a long exposure to a high temperature@en

This paper investigates a failure in convection section tubes of a gas heater unit in a petrochemical plant. Tubes are made of AISI 304 stainless steel. The failure is reported after 5 years of service at working temperature 500 °C. The failure is in the form of circumferential cracks in the vicinity of the weld. Various characterization techniques, including optical and electron microscopes as well as energy-dispersive X-ray spectroscopy (EDS), were used to study the failure. Results showed that that the damage has initiated in the heat affected zone (HAZ) area parallel to the weld/base metal interface. Cracks have propagated alongside grain boundaries, resulting in an intergranular fracture. The main cause of failure was concluded to be attributable to the grain boundary sensitization and intergranular grain boundary attack due to improper welding and long time exposure of tubes to high temperature. Possible mitigation strategies to minimize similar failures will be discussed.@en