Session: New Developments and Recent Experiences With Nickel, Titanium, Zirconium, and Other High Alloyed Corrosion Resistant Materials
Metallurgical condition a key factor in zirconium tube integrity (C2026-00298)
Tuesday, March 17, 2026
9:00 AM - 9:30 AM Central
Location: 371 AB
Earn .5 PDH
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Zirconium (Zr 702) condenser tubes are widely used in corrosive service environments due to their excellent corrosion resistance. This study presents a metallurgical evaluation and failure analysis of zirconium tubes that leaked shortly after installation, with most leaks occurring near the expanded regions at the tubesheet. The analysis included visual inspection, dye penetrant testing, metallography, hardness measurements, and fractographic evaluation. The investigation identified localized damage consistent with excessive shear stresses during mechanical expansion. Metallographic examination revealed that the tubes were not fully annealed, exhibiting partially recrystallized microstructures and elevated hardness. While factors related to installation quality are known to influence performance, the effect of the initial metallurgical condition prior to expansion is not commonly addressed in industry practice. These findings underscore the importance of verifying the annealed condition of zirconium tubes prior to mechanical expansion to minimize the risk of cracking and leakage. This work provides practical insights to improve fabrication and quality control practices for zirconium heat exchangers.
