Failure analysis on welded joints of 347H austenitic boiler tubes

Microstructural and thermo-mechanical analyses using the finite element method (FEM) were performed on the welded joint of 347H boiler tubes in a coal-fired power plant after 3600 h of operation. The cracks in the failed tube started on the inner surface of the heat-affected zone (HAZ). This area had a high hardness value and volume fraction of strain-induced martensite. The plastic deformation around the crack was concentrated near the grain boundaries. This failure occurred as the stabilizing effect disappeared due to carbide dissolution in the heat-affected zone, and plastic deformation and tensile residual stress were formed at the inner side due to the solidification contraction of the outer bead.