The ASTM A178 boiler tube is a crucial component in the steam and power generation industry. Manufactured under the standards set by ASTM (formerly known as the American Society for Testing and Materials), ASTM A178 boiler tubes are designed to withstand high pressures and temperatures, ensuring the efficiency and safety of steam boilers. This article will delve into the specifics of ASTM A178 boiler tubes, their applications, material composition, manufacturing process.
ASTM A 178 And ASTM A 178Grade A
This specification covers minimum-wall-thickness, electric-resistance-welded tubes made of carbon steel and carbon-manganese steel intended for use as boiler tubes, boiler flues, superheater flues, and safe ends. The ASTM SA 178 tube sizes and thicknesses usually furnished to this specification are 1/2 to 5 in. [12.7 to 127 mm] in outside diameter and 0.035 to 0.320 in. [0.9 to 9.1 mm], inclusive, in minimum wall thickness. Tubing having other dimensions may be furnished, provided such tubes comply with all other requirements of this specification. Mechanical property requirements do not apply to tubing smaller than 1/8 in. [3.2 mm] in inside diameter or 0.015 in. [0.4 mm] in thickness.
SA178A / ASTM A178 Grade A. SA178 A is an
ERW (electric resistance welded) low carbon steel boiler tube used in super heaters, water wall panels, heat exchangers, condensers, marine application, refineries, paper pulping, petrochemical applications, pressure vessels, and general engineering applications.
What is ASTM A178 Boiler Tube?
The ASTM A178 boiler tube is a specification for seamless steel tubes intended for use in low and medium-pressure steam boilers. The tubes are designed to handle pressures not exceeding 350 psi (2.4 MPa) and are made of carbon steel. ASTM A178 covers seamless steel tubes for the water-tube and fire-tube boilers found in many industrial applications such as power plants, chemical plants, and manufacturing facilities.
These tubes must meet strict requirements regarding material composition, mechanical properties, and testing methods. ASTM A178 provides the framework for these properties to ensure the tubes perform reliably under demanding conditions.
ASTM A178 Tube Grades and Chemical Composition
ASTM A178 covers several grades, including A, C, and D. Each grade has different chemical compositions to meet varying mechanical and thermal performance needs.
Grade A: Low-carbon steel, offering good weldability and moderate strength.
Grade C: Higher carbon content, providing increased strength but slightly reduced ductility.
Grade D: Carbon-manganese steel, enhancing strength and toughness for demanding applications.
|
Grade
|
Carbon (C) %
|
Manganese (Mn) %
|
Phosphorus (P) %
|
Sulfur (S) %
|
|
A
|
0.06–0.18
|
0.27–0.63
|
≤ 0.035
|
≤ 0.035
|
|
C
|
0.35 max
|
0.80 max
|
≤ 0.035
|
≤ 0.035
|
|
D
|
0.27 max
|
1.00–1.50
|
≤ 0.030
|
≤ 0.015
|
Mechanical Properties of ASTM A178 Boiler Tubes
Mechanical properties determine the tube’s performance under high temperatures and pressures.
|
Grade
|
Tensile Strength (MPa)
|
Yield Strength (MPa)
|
Elongation (%)
|
|
A
|
325 min
|
180 min
|
35 min
|
|
C
|
485 min
|
275 min
|
30 min
|
|
D
|
415 min
|
255 min
|
30 min
|
Chemical Composition:
|
Element
|
Grade A
|
Grade C
|
Grade D
|
|
|
Low carbon steel
|
Medium carbon steel
|
Manganess steel
|
|
C%
|
0.06-0.18
|
0.35Max
|
0.27Max
|
|
Mn%
|
0.27-0.63
|
0.80Max
|
1.00-1.50
|
|
P%
|
0.035
|
0.035
|
0.03
|
|
S%
|
0.035
|
0.035
|
0.015
|
|
Si%
|
.....
|
.....
|
0.10Min
|
|
|
|
|
|
Mechanical Propertise:
|
|
Grade C
|
Grade D
|
|
|
Grade A
|
|
|
Tensile Strength loading Ksi (Mpa)
|
=47(325)
|
60(415)
|
70(485)
|
|
Yield Strength Loading Ksi(Mpa)
|
=26(180)
|
37(255)
|
40(275)
|
|
Elongation (50mm)%
|
35
|
30
|
30
|
Manufacturing Process of ASTM A178 Boiler Tubes
Carbon Steel SA 178 Boiler Tubes are plain carbon steel supplied in regular condition. This alloy is processed by tempering, regularizing and annealing processes. These boilers are characterized by moderate strength and impact toughness. These boilers are used where high temperature services are required. These boilers are formed at a temperature of 900 – 1200 degrees Celsius. The saturation time should be kept low to prevent scaling. Also, time and temperature should be controlled.These boilers have very good machinability, which reduces their machining cost. This alloy is corrosion resistant in mild conditions. Moreover, they are resistant to pitting, crevice corrosion and stress corrosion cracking. They have the best performance at high temperatures.
The production of ASTM A178 boiler tubes involves several key steps to ensure the final product meets the required standards.
1. Steel Selection
High-quality carbon steel is selected for the production of ASTM A178 boiler tubes. The steel is tested for chemical composition and mechanical properties.
2. Tube Formation
The steel is extruded into seamless tubes through a process called rotary piercing. This method ensures the tubes have no welded seams, which enhances their strength.
3. Heat Treatment
After extrusion, the tubes undergo heat treatment, typically through normalizing. This process improves the tubes' tensile strength and overall properties.
4. Testing and Inspection
The tubes are rigorously tested for dimensions, tensile strength, and other properties. Non-destructive testing, such as ultrasonic testing, is also performed to ensure there are no internal defects.
5. Finishing
Once the tubes pass all tests, they are cut to length and may undergo additional treatments, such as polishing or coating, to further enhance their resistance to corrosion and wear.
Applications of ASTM A178 Boiler Tubes
ASTM A178 boiler tubes are primarily used in industries that rely on steam boilers to generate power or heat. These include:
1. Power Plants
In power plants, steam boilers generate steam, which drives turbines for electricity production. ASTM A178 tubes are found in both water-tube and fire-tube boilers in these settings.
2. Chemical and Petrochemical Industries
These industries use steam boilers for heating and chemical processing. ASTM A178 boiler tubes help ensure the system operates safely under high-pressure conditions.
3. Manufacturing Facilities
Manufacturing plants often use steam boilers for heating and sterilizing. ASTM A178 tubes provide the durability needed for these demanding tasks.
4. Food Processing
Boilers are used in food plants for cooking and sterilization. ASTM A178 boiler tubes help keep these operations running efficiently and safely.
ASTM A178 Boiler Tube Manufacturers
BAOWI Steel is a trusted manufacturer, supplier, and trader of Carbon Steel SA178 Boiler Tubes, offering a variety of specifications, dimensions, and shapes with customization options. These boilers are made from high-quality materials and processed using advanced machinery for precise dimensions and surface finish. All products comply with national and international standards, with experienced professionals overseeing the fabrication process to ensure top quality.
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