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The gate valves are part of the petrochemical plant fire protection system. The result of chemical analysis of the received bolts samples, indicates that their composition corresponds to a TWIP steel, having high manganese (16 wt.%) and high chromium (9 wt.%). The microstructural examination of cross sections of bolts, revealed an austenite microstructure with high number density of deformation twinning and slip lines specially at the failure zones, which is typical of the cold deformed TWIP steels. The hardness distribution within the bolt\u2019s head and the head to shank zone was not homogeneous, ranging between 225 HV\n                    <jats:sub>0.1<\/jats:sub>\n                    in the shank central zone and 470 HV\n                    <jats:sub>0.1<\/jats:sub>\n                    at the curved highly stressed zone of the bolt neck. Both the cracked and broken bolts appeared corroded specially at the failure zone of the head to shank neck. The EDS analysis of corrosion products inside cracks indicated high concentration of Cr, Mn, Cu, O and traces of mineral elements of Si, S, Cl, K and Ca. The XRD analysis identified the Chromium Iron Manganese intermetallic Cr\n                    <jats:sub>5<\/jats:sub>\n                    Fe\n                    <jats:sub>6<\/jats:sub>\n                    Mn\n                    <jats:sub>8<\/jats:sub>\n                    and Iron Manganese Carbide Fe\n                    <jats:sub>2.7<\/jats:sub>\n                    Mn\n                    <jats:sub>3<\/jats:sub>\n                    C in the bolt matrix and formation of \u201cSpinel\u201d Copper Chromite CuCr\n                    <jats:sub>2<\/jats:sub>\n                    O\n                    <jats:sub>4<\/jats:sub>\n                    and Iron Manganese Oxide MnFe\n                    <jats:sub>2<\/jats:sub>\n                    O\n                    <jats:sub>4<\/jats:sub>\n                    . The cracks appeared to originate at corrosion pits formed at the crevice between the bolt head and the underneath washer and nut at the head to shank fillet radius and on bolt neck zone, which have high concentration of corrosive species from the humid salty marine atmosphere. The cracks then propagate in perpendicular direction to the tensile stress direction of the bolt torque. The fractography examination of the cracked bolts cross sections and the broken bolts fracture surface depicted mixed ductile\/dimpled mode with areas of quasi-cleavage transgranular and intergranular crack propagation. These observations suggest the failure mechanism to be hydrogen embrittlement\u2013assisted chloride\u2014stress corrosion cracking HE-assisted Cl-SCC.\n                  <\/jats:p>","DOI":"10.1038\/s41598-025-94743-2","type":"journal-article","created":{"date-parts":[[2025,4,23]],"date-time":"2025-04-23T07:19:32Z","timestamp":1745392772000},"update-policy":"https:\/\/doi.org\/10.1007\/springer_crossmark_policy","source":"Crossref","is-referenced-by-count":5,"title":["Failure analysis of bolts in deluge valve bonnet in cooling tower system in petrochemical plant"],"prefix":"10.1038","volume":"15","author":[{"given":"M. A.","family":"El-Zomor","sequence":"first","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"M. H.","family":"Ahmed","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"F. 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