We Take A Closer Look ea) Applied Technical Services METALLURGICAL FAILURE ANALYSIS OF SUPPORT COLUMN C47 ATS JOB # 405953 PURCHASE ORDER # 23006964 Prepared for STEVE JACKSON CAROWINDS 14523 CAROWINDS BOULEVARD CHARLOTTE, NC 28273 Digitally signed by John Miller Date: 2023.08.23 Prepared by. 10:20:57 -04'00" John Miller, P.E., Senior Metallurgist 1 Digitally signed by Ronald J IL. Partington 4 omensllor Date 20230823 103701 Reviewed by. Ronald J. Parrington, P. = FAST, Group Manager ftso 300] Professional Engineors and Sevenists Design + Consulting » Testing and Inspaction bars in AAFS, ACS, ANS, ASM, ASME, ASNT, ASQ, ASTM, AWS, BONA, FSCT, IAAI. WCA, NACE, NCSL, NEPA, SAFS, TAPP (GEORGIA SOCIETY OF PROFESSIONAL ENGINEERS, NATIONAL SOCIETY OF PROFESSIONAApplied Technical Services| +1(888) 287-5227 Contact Steve Jackson Date ‘August 22, 2023 Customer Carowinds Purchase Order 23006964 14523 Carowinds Boulevard Charlotte, NC 28273 Subject Metallurgical Failure Analysis of Support Column C47 Material AISI 1015 Carbon Steel Objective and Background A steel tube support column was submitted to Applied Technical Services (ATS) to determine the cause(s) of failure per ATS Procedure MAT-P-931 Rev. 2. The support column was part of a rollercoaster located outside in the front gate area of the park and experienced temperature ranges from 40-110 °F. The support column was located at turn in the roller coaster and was placed in service In 2015 with an expected service life of 50+ years. The 58,000 Ib. roller coaster train cycled once per minute. Test Procedure and Results Visual inspection AA screenshot of the mated fracture surfaces provided by the customer is shown in Figure 1 indicating the labeling scheme for the samples. Photographs of the as received samples are shown in Figures 2 and 3. The samples were separated into the weld side and tube side sections. Photographs of both the weld side and tube side fracture surface corresponding to the intrados of the track curve are shown in Figure 4 exhibiting ratchet marks. Ratchet marks are ‘macroscopically visible lines or shear ledges on a fatigue fracture surface that run parallel to the overall direction of crack propagation and result from the intersection of fatigue cracks propagating from multiple origins. The fracture at that location was adjacent to the weld joining the 45° support to the vertical support column. As the circumferential ‘weld became more vertical, the fracture began to propagate through the base metal of the vertical support column (Figure 5). & crack branch following the weld which terminated after approximately one inch was observed. The fracture surface as the fracture began to propagate through the base metal of the support column exhibited a chevron pattern indicating the direction of propagation of the fracture. A chevron pattern isa fractographic pattern of radial marks that resemble nested letters “V". Portions of the fracture surface from both sides of the fracture were sectioned and further documented (Figure 7) ‘The fracture surface was examined using an optical microscope capable of magnification up to 100X. The ratchet marked region exhibited beach marks on both the weld side and tube side of the fracture surface (Figure 8). Beach marks are ‘macroscopically visible semi-eliptical or elliptical lines on a fatigue fracture surface that mark successive positions of the advancing crack front. They run perpendicular to the overall direction of crack propagation. Beach marks are created by crack arrests resulting in surface oxide thickness differences on either side of the beach marks or by changes in stress intensity resulting in surface texture differences on either side of the beach marks. Beach marks serve to identify the failure mechanism as fatigue and the shape of beach marks serves to locate the fracture origin(s). The shape of the beach marks as well as the location of the ratchet marks indicated the fracture originated at the outer diameter (OD) of ‘the support column at the toe of the weld. The weld is a notch-like feature that acted as a stress raiser and concentrated local stresses. The fracture surface adjacent to the ratchet marked region exhibited arrest marks (Figure 9) indicating the continued cyclic loading conditions outside of the original fatigue region. ‘ATS 004,07/2021 Page of 20, Ts 405953Applied Technical Services| +1(888) 287-5227 | wwwratslab.com ‘Scanning Electron Micrascopy The fracture surface was examined at higher magnifications using a scanning electron microscope (SEM). The fracture surface exhibited mechanical damage and oxidation product which obscured any fine fractographic features (Figure 10}. ‘Attempts to clean the fracture surface did not significantly remove the corrosion product or reveal any fine fractographic features. Metallography ‘Alongitudinal section through fracture origin region in the ratchet marked area of the fracture surface was prepared per [ASTM £3-14(2017], Standard Practice for Preparation of Metallographic Specimens. The fracture surface was perpendicular to the axis of the support column indicating a brittle fracture mechanism (Figure 11). The fracture originated at the toe of the weld in the hest affected zone (HAZ). Figure 12 shows a higher magnification of the fracture origin atthe toe of the weld. Secandary cracks were observed adjacent to the fracture origin in the HAZ (Figure 13) Secondary cracks are indications of multiple fatigue origins. The microstructure of the weld consisted of acicular ferrite (Figure 14, top). The microstructure of the HAZ consisted of acicular ferrite and pearlite (Figure 14, bottom). The ‘microstructure of the support column base metal consisted of pearlte and ferrite (Figure 15). No microstructural abnormalities were observed that would have contributed to the failure. Mechanical Testing The tensile strength of the tube adjacent to the fracture was tested per ASTM A370-22, Standard Test Methods and Definitions for Mechanical Testing of Steel Products. The tensile results are shown in Table | ‘The impact strength of the tube was measured per ASTM A370-22 at -12'C. The results are shown in Table lI. The tube met the minimum value of 27 J specified by the customer. ‘A microindentation hardness traverse was performed from the center of the weld into the base metal of the support column per ASTM E92-23, Standard Test Method for Vickers Hardness and Knoop Hardness of Metallic Materials. The results are shown in Table Ill. The weld and HAZ were slightly harder than the base metal. This is considered god practice with a weld as it provides higher fatigue resistance at the weld area. Chemical Analysis The chemical composition of the tube was analyzed using ASTM £415-21, Standard Test Method for Analysis of Carbon and Low-Alloy Steel by Spork Atomic Emission Spectrometry, as a guide. The tube was consistent with AIS! 1015 carbon steel. Detailed results of the analysis are shown in Table IV. ‘ATS 084, 07/2023, Page 2of 20 ATS # 405953Applied Technical Services| +1(888) 287-5227 | voww.atslab.com Discussion and Conclusions The presence of macro features such as ratchet marks and beach marks as well as secondary crack microfeatures indicate the fracture in the support column was the result of unidirectional bending fatigue (Ie, fracture under cyclic loading). The fracture originated at the toe of the weld and propagated around the circumference of the support column Until the remaining cross-sectional area was no longer able to support the applied stresses leading to the final fracture of the support column. Fatigue occurs at loads typically below the yield strength of a material and can be accelerated by the presence of stress concentrators, a geometric or mechanical notch that intensifies local stresses. The fracture occurred at the toe of the weld which acted as a rapid change in radius of the support column. The rapid change in radius was a stress raiser that accelerated the formation and propagation of the fatigue fracture. The support column was consistent with AIS! 1015 carbon steel with a tensile and yield strength of 67,500 psi and 46,500 psi, respectively. The average impact strength of the support column was 174 J (128 ft.lb.) at -12°C. The hardness of the weld was higher than the base metal. The microstructure of the weld consisted of acicular ferrite. The microstructure of the HAZ consisted of acicular ferrite and pearlite. The microstructure of the base metal consisted of pearlite and ferrite ats 044, 07/2021, Page of 20 A738 405953TS 08¢, 07/2021 Applied Technical Services| +2(888) 287-5227 | www.atslab.com Table I: Tensile Results Property Tube Tensile Strength | 67,500 psi Yield Strength | 46,500 psi % Elongation | 36% Table Il: Charpy Impact Results Sample _| Impact Energy | Lateral Expansion (mil) | % Shear 1 [i743 (128 feb) 30 100% 2 [174 (128 fb) Bt 100% 3472) (227 feb) 82 1.00% Average | 174 J (128 ft.lb.) 84 100% Table Ill: Microindentation Hardness (HV) Location | Distance from Weld Center | Hardness Center 203 Weld 0.013" 203 0.023" 186 0.039" 176 0.052" 163 baie 0.065" 151 0.078" 164 0.091" 150 Base 0.1047 143 Metal 0.117" 147 0.130" 139 Page 4of 20 ATS # 405953Applied Technical Services| +1(888) 287-5227 | wunw.atslab.com Table IV: Chemical Composition (Wt. %) Element c | mn | P s si | wi | cr | Mo} wf] a | v | fe Requirements | 0.12 | 930 | 0040] ooso] _ | _ | _ | _ (a) 0.18 | 0.60 | max | max ee ats#1 | 0.13 | 0.48 | 0.014 | 0.006 | 0.18 | 0.02 | <0.01 | 0.01 | <0.01 | 0.06 | <0.01 | Matrix (a) ASM Metals Handbook, Vol. 1, 10th edition, 1015 Carbon Steel ats044, 07/2021 Page of 20, Ts 405953‘75 084, 07/2021 Applied Technical Services| +1(888) 287-5227 | wwwatslab.com Intrados of track 4 | turn q Figure 1: Screenshot of the mated fracture surfaces from the support column. Page 6 of 20, ATS # 405953Applied Technical Services| +1(888) 287-5227 | www.atslab.com Figure 2: Photographs of the weld side of the fractured support column. The arrows indicate the location of the weld attaching the two columns at a 45° angle. ‘ats 0a4, 07/2021 Page 7 of20 ATS 405953Applied Technical Services| #1(888) 287-5227 | w Figure 3: Photographs of tube side of the fractured support column. ‘ATS 004, 07/2021 Page 8of 20 ATS #405953Applied Technical Services| +1(888) 287-5227 | www.atslab.com ‘Watetals Testing | Engineering / NDT Calibrations 170.423.1400, Figure 4: Photographs of the fracture surface at the intrados side of the support column ‘on the weld side (top) and corresponding fracture surface on the tube side (bottam). Both fracture surfaces exhibit ratchet marks indicating multiple-origin fatigue. ats 044, 07/2021 Page 9 of 20 ATS 405953Applied Technical Services| +1(888) 287-5227 | www.atslab.com mT i Testing / Engineering | NOT /albretens ree 70.423.1400 jaisiab.com pep Figure 5: Photograph of the weld side fracture where the fracture (black arrow} no longer follows the weld (bracket). A crack branch (red arrow) does follow the weld before terminating, TS 04a, 07/2021 Page 100f 20 ATS 405953Applied Technical Services| +1(888) 287-5227 | Figure 6: Photograph of the tube side fracture surface away from the ratchet marked region exhibiting chevrons (red arrows) indicating the direction of propagation (white arrow). {ATS 048, 07/2021 Page 11 of 20 ATS # 4059Applied Technical Services| +1(888) 287-5227 | www.atslab.com Figure 7: Photographs of the sectioned portions from the weld side (rop) and tube side (bottom) fractures at the center of the ratchet marked region. ‘ATS 044, 07/2021, Page 120f 20 ATS #408953Applied Technical Services| +1(888) 287-5227 | wwrw.atslab.com Figure 8: Macrographs of the center of the ratchet marked region of the weld side (top) and tube side (bottom) fracture surfaces exhibiting ratchet marks (black arrows) and beach marks (dashed lines). aTs048, 07/2021, Page 13 of 20 ATS 405953Applied Technical Services| +1(888) 287-5227 | www.atslab.com Figure 9: Macrograph of the fracture surface adjacent to the ratchet marked region exhibiting subtle arrest marks or beach marks (arrows). ‘ATS 044, 07/2021 Page 14of 20 ‘ATS # 405953Figure 10: SEM image of the ratchet marked region of the weld side fracture surface exhibiting oxidation and mechanical damage obscuring any fine fractographic features aTs044, 07/2021, Page 15 0f 20 ATS #405953Applied Technical Services| +1(888) 287-5227 | wwwaatslab.com Tube side Fracture Surface Weld side Etchant: Nital Figure 11: Micrograph of the longitudinal section through the fracture surface showing the origin (white arrows) at the toe of the weld. ATS 004, 07/2021 Page 16020 ATS # 405953Applied Technical Services| +1(888) 287-5227 | www.atstab.com racture Surface Etchant: Nital Figure 12: Micrographs in the as polished (top) and etched (bottom) conditions of the weld side fracture origin (arrows) showing the fracture origin at the weld toe. ‘nts 044, 07/2021 Page 17 of 20 TS 4 405953Applied Technical Services| +1(888) 287-5227 | www.atslab.com etchant: Nital Figure 13: Micrographs in the as polished (top) and etched conditions (bottom) of the origin white arrows) on the tube side ofthe fracture surface exhibiting secondary cracks (black arrows). T5044, 07/2021 Page 18 of 20 ATS 405953Applied Technical Services| +1(888) 287-5227 | www.atslab.com Figure 14: Micrographs of the typical weld (tap) and HAZ (bottom) microstructures. The weld microstructure consists of acicular ferrite grains. The HAZ microstructure consists of acicular ferrite (light) and pearlite (dark) ‘ATS.044, 07/2021, Page 19 of 20 ats 405983wwww.atslab.com Applied Technical Services| +1(888) 287-5227 | ferrite (light) and pearlite (dark). ATS #405953, Page 200f 20