Heat exchangers are critical components in nuclear, petrochemical, and energy production, often operating under high pressure and corrosive environments. These demanding conditions frequently necessitate the use of thicker tube sheets to ensure longevity and structural integrity. While thicker tube sheets offer enhanced durability, they present unique challenges during the tube expansion process.

Premature tube failure is a leading cause of downtime in heat exchangers operating in corrosive environments. Stress corrosion cracking is a common tube failure mode in corrosive environments, impacting any number of tubes in a vessel. While stress corrosion can be difficult to identify in the field, there may be ways to reduce the likelihood of occurrence.