Report by: 5 Camber Grove

Metspect Sarel Cilliers Circle

Pinetown
4041
1
13
th
June 2014
Metallurgical Investigation on a Failed Hold-Down Bolt
Submitted by: Stefanutti Stocks Civils, KZN


Photo 1

EXECUTIVE SUMMARY
A failed section of a hold-down bolt and a new bolt were provided for examination. We
were told that the bolt failed during a straightening operation using a hand-held length of
pipe as a lever.
We were requested to do tensile tests, Vickers hardness, chemical analysis and
microstructure on both the failed and the new bolt and to determine the cause of failure of
the failed bolt. The chemical and physical properties of both samples were found to be
within specification with the exception of the hardness, which was found to slightly high in
some sections.
The cause of failure was found to be hydrogen embrittlement.


Report by: 5 Camber Grove
Metspect Sarel Cilliers Circle
Pinetown
4041
2

BACKGROUND
We were told that the bolt failed on a building site in Mocambique. At the time of failure it
had been mounted in a concrete plinth which had been allowed to cure. To align it with the
mating girder it was necessary to straighten the bolt using a hand-held pipe as a lever. It was
during this operation that the bolt snapped.

EXPERIMENTAL
The failed bolt was examined visually and with a stereo microscope. Sections were then
removed for:
a) The fracture face of the failed bolt was examined optically and on a SEM to
determine the failure mode.
b) Longitudinal and transverse sections were removed from both the failed and
the new bolt. These were mounted, polished, etched in 2% nital and
examined on an optical microscope to determine the microstructure. These
samples were then used for Vickers hardness testing
c) Tensile test pieces were machined from both the failed and the new bolt.
Because of the size of the failed sample it was only not possible to obtain a
full 50mm gauge length sample
d) Spectroscopic chemical analysis was done on the sectional remains from the
tensile test pieces.

RESULTS
Visual Examination

Photo 2 Photo 3
Initiation
point
Report by: 5 Camber Grove
Metspect Sarel Cilliers Circle
Pinetown
4041
3
Photo 2 shows the failed bolt and the threaded portion of the new one. It can be seen that
failure occurred on the last, or very near the last, thread. Due to bending moments this
would have been the highest stress section during the straightening operation.
Photo 3 shows the fracture face with the initiation point marked. The fracture is flat faced
with no significant macro deformation, this is indicative of brittle fracture on a macro level.

Microscopic Examination

Photo 4 Photo 5
Photo 4 and 5 show the microstructure of the failed bolt at 200x magnification. Photo 4 is a
transverse section and photo 5 is a longitudinal direction. The samples have been etched in
2% nital to reveal a microstructure of tempered martensite with some grain boundary
bainite.
There is some banding evident in the longitudinal direction. Banding occurs when there is
non-uniform chemical composition across the section. This can cause variations in hardness
between bands.

Photo 6 Photo 7
Photos 6 and 7 show the microstructure of the new bolt at x200 magnification. Photo 6 is a
transverse section and photo 7 is a longitudinal direction. The samples have been etched in
Report by: 5 Camber Grove
Metspect Sarel Cilliers Circle
Pinetown
4041
4
2% nital to reveal a microstructure, which again was tempered martensite with some grain
boundary bainite. Again there is some banding evident in the longitudinal direction.

Scanning Electron Microscope Examination
The fracture face of the broken bolt was examined on a scanning electron microscope (SEM)
to determine the failure mode. Scale bars and magnification are shown on the photos.

Photo 8 Photo 9
Photo 8 was taken at 600x and photo 9 is the same location at 1200x magnification. The
photographs are typical of cleavage failure. Decohesion or cracking can also be seen.
Cleavage is a mechanism of brittle transgranular fracture, resulting in cleaving of the crystals
along their crystallographic planes.

Photo 10 Photo 11
Dimple
rupture
Report by: 5 Camber Grove
Metspect Sarel Cilliers Circle
Pinetown
4041
5

Photo 9 shows more clearly the river patterns associated with brittle cleavage failure. More
than 90% of the fracture face showed a cleavage or quasi-cleavage mode of failure. There
were also small areas of dimple rupture, synonymous with a more ductile failure mode, as
shown in photo 11.

Chemical Analysis and Mechanical Properties
Elements Failed Bolt New Bolt
a
709M40 (En19)
b
PD970-709M40
Carbon 0.38 0.40 0.35-0.45 0.36-0.44
Manganese 0.82 0.87 0.50-0.80 0.70-1.00
Sulphur <=0.005 <=0.011 0.05max 0.04max
Phosphorus <=0.005 <=0.005 0.05max 0.035max
Silicon 0.25 0.21 0.10-0.35 0.10-0.35
Chromium 1.00 1.05 0.90-1.20 0.90-1.20
Molybdenum 0.26 0.30 0.20-0.40 0.15-0.25
Nickel 0.02 <=0.01 - 0.40max
Copper <=0.01 0.04 - 0.40max
Aluminium 0.021 0.035 -
Vanadium <=0.005 0.011 -
Niobium 0.01 0.011 -
Boron <=0.0005 <=0.0005 -
Titanium <=0.005 <=0.005 -
Iron matrix matrix matrix matrix
Table 1: Chemical Analysis
Table 1, above shows the chemical composition of the failed and the new bolt in weight
percent.
a
709M40(En19) was the specification submitted by the customer
b
PD 970:709M40 is a more recent update of 709M40

Both the failed bolt and the new bolt are within the specified standard (709M40), except for
manganese, which is marginally high. This is not a concern because it is well within the
newer specification.




Report by: 5 Camber Grove
Metspect Sarel Cilliers Circle
Pinetown
4041
6
Sample
Diameter
mm
Area
mm
2
Gauge
Length
mm
0.2%
Proof
Load
kN
Max
Load
kN
Extension
mm
0.2%
Proof
Stress
MPa
Elongation
%
RA
%
UTS
MPa
Failed Bolt 10.21 81.87
a
36.26 66.44 78.49 7.07 812 19.5 54.1 959
New Bolt 9.92 77.29 51.14 62.80 78.19 6.85 813 13.4 51.3 1012
Specification
665
min
13
min

850-
1000
Table 2: Tensile test data.
Note that because of the size of the available sample it was not possible to get a standard
tensile test piece on the failed bolt. The reduced gauge length could be expected to affect
the % elongation result, causing it to be slightly high.
Distance from surface(mm) 0.25 0.5 1.0 2.0 3.0 4.0 5.0
Failed Bolt 322 304 310 317 317 322 303
New Bolt 347 331 325 321 322 336 307
Table 3: Vickers hardness readings (HV)
Table 3 is a plot of Vickers hardness readings, using a 5kg load, against the distance from
the surface of the bolt. It shows that there is variation in hardness across the section, due to
banding. In fact when separate readings were taken in the light and dark bands variation
between 288HV and 331Hv were found on the failed bolt. Similar readings on the new bolt
varied between 307HV and 345 HV

DISCUSSION
Hydrogen Embrittlement
Hydrogen Embrittlement (HE) is a form of embrittlement caused by the absorption of
hydrogen ions (H
+
) into the structure of susceptible steels. The presence of hydrogen in
concentrations of only a few parts per million (ppm) is sufficient to cause disastrous brittle
failure.
The susceptibility of a steel to hydrogen embrittlement is a function of its strength, not its
chemical composition. Usually only steels with an Ultimate Tensile Strength (UTS) greater
than 1000MPa are susceptible.
The mode of failure with hydrogen embrittlement can be cleavage, quasi-cleavage, micro-
void coalescence or intergranular, depending on the crack tip stress, temperature, the
hydrogen concentration and its effects on its plasticity (reference: Professor M.N. James,
University of Plymouth, England)
Report by: 5 Camber Grove
Metspect Sarel Cilliers Circle
Pinetown
4041
7
Hydrogen embrittlement is known to occur during the acid pickling process commonly used
to clean components prior to hot-dip galvanizing.
ASTM A143 (Standard Practice for Safeguarding against Embrittlement of Hot-Dip
Galvanized Structural Steel Products)
Section 3.2 "Hydrogen embrittlement may also occur due to the possibility of atomic hydrogen being
absorbed by the steel. The susceptibility to hydrogen embrittlement is influenced by the type of steel;
it's previous heat treatment, and degree of previous cold work. In the case of galvanized steel, the acid
pickling reaction prior to galvanizing presents a potential source of hydrogen. In practice hydrogen
embrittlement of galvanized steel is usually of concern only if the steel exceeds approximately 150 ksi
(1000 MPa) in ultimate tensile strength, approximately 310 HV

CONCLUSIONS
Although the bolts were found to be nominally to specification, the failed bolt failed in a
brittle manner, both macroscopically (minimal distortion) and on a microstructural level
(cleavage). The bolts were found to have a banded structure resulting in areas having a
hardness of up to 347HV, equivalent to a UTS of 1100 MPa. There was evidence of
decohesion present, (photos 8 & 9), which is common with hydrogen embrittlement.
From these results our conclusion is that this bolt failed as a result of hydrogen
embrittlement.

RECOMMENDATIONS
1) Those bolts presently mounted in concrete could be tested by affixing a
mounting plate and tightening the bolts up to the correct torque and leaving
them for 48hours. Hydrogen embrittlement is often a delayed failure but, in
our experience, if they are going to fail they will usually do so within 48 hours.

2) All future bolts might be mechanically cleaned, rather than acid pickled, prior
to hot-dip galvanizing. Alternatively a hydrogen relieving heat treatment
process might be instituted after galvanising.



Signed:

_____________________ ______________________ __12/06/2014_____
Alan Blundell Dr. Clinton Bemont (Pr Eng) Date