How can overheating lead to boiler failure?

Overheating can lead to boiler failure primarily because it can cause metal fatigue, deformation, or even catastrophic failure due to excessive pressure. When a boiler operates at temperatures beyond its design limits, the materials used in its construction, usually steel, can weaken over time. This weakening can manifest as metal fatigue, which occurs when the material encounters repeated stress and fails to return to its original shape.

Additionally, as the metal heats up, it may undergo structural changes, leading to deformation or warping, which compromises the integrity of the boiler. In extreme cases, if the temperature becomes too high, it can increase the internal pressure beyond what the boiler is rated for, potentially resulting in a catastrophic failure, such as an explosion. Therefore, maintaining proper heating levels is crucial for the safe and efficient operation of a boiler, underscoring the importance of monitoring and controlling temperature to avoid these dangerous outcomes.