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ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions最新文献

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Evaluation of Pitting on a Spur Gear 直齿齿轮点蚀的评价
ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.usage.c9001499
Lester E. Alban
{"title":"Evaluation of Pitting on a Spur Gear","authors":"Lester E. Alban","doi":"10.31399/asm.fach.usage.c9001499","DOIUrl":"https://doi.org/10.31399/asm.fach.usage.c9001499","url":null,"abstract":"\u0000 Three spur gears made from 8622 Ni-Cr-Mo alloy steel formed a straight-line train in a speed reducer on a rail-mounted overslung lumber carrier. The gears were submitted for nondestructive examination and evaluation, with no accompanying information or report. Two teeth on one of the gears were found to be pitted, one low on profile and the adjacent tooth high on profile. The mating gear had a similar characteristic, two adjacent teeth with evidence of pitting and the same difference in profile. It was correctly deduced that the pitting occurred because the gears were in a static position under a reverberating load for an extended period of time.","PeriodicalId":194756,"journal":{"name":"ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions","volume":"23 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116078505","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Problematic Failure Analysis of a Cast Steel Crankshaft 铸钢曲轴故障问题分析
ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.usage.c9001597
D. A. Moore, K. F. Packer, A. Jones, D. Carlson
{"title":"Problematic Failure Analysis of a Cast Steel Crankshaft","authors":"D. A. Moore, K. F. Packer, A. Jones, D. Carlson","doi":"10.31399/asm.fach.usage.c9001597","DOIUrl":"https://doi.org/10.31399/asm.fach.usage.c9001597","url":null,"abstract":"\u0000 This case study involves two continuously cast steel crankshaft failures. Three parties performed their own failure analyses: (1) the engine manufacturer responsible for component design, specification, and application; (2) the steel supplier and forging supplier responsible for making the steel, forging the shape, and preliminary heat treatment; and (3) a supplier that provided induction hardening, finish machining, and inspection. An independent engineering firm was subsequently involved, but because each party had its own agenda, there was no agreement on the metallurgical source of the failure and thus no continued analysis to pin down and eliminate the root cause.","PeriodicalId":194756,"journal":{"name":"ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions","volume":"36 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122111261","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Fatigue Cracking of 4340 Steel Compressor Shafts Because of Cyclic Stresses Induced by Gear-Type Couplings 齿轮式联轴器引起的循环应力导致4340钢压气机轴的疲劳开裂
ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.usage.c0047823
{"title":"Fatigue Cracking of 4340 Steel Compressor Shafts Because of Cyclic Stresses Induced by Gear-Type Couplings","authors":"","doi":"10.31399/asm.fach.usage.c0047823","DOIUrl":"https://doi.org/10.31399/asm.fach.usage.c0047823","url":null,"abstract":"\u0000 High-horsepower electric motors were utilized to drive large compressors (made of 4340 steel shafts and gear-type couplings) required in a manufacturing process. The load was transmitted by two keys 180 deg apart. Six of the eight compressor shafts were found cracked in a keyway and one of them fractured after a few months of operation. Visual examination of fractured shaft revealed that the cracks originated from one of the keyways and propagated circumferentially around the shaft. The shaft and coupling slippage was indicated by the upset keys and this type of fracture. The shaft surface both near and in the keyways indicated fretting which greatly reduced the fatigue limit of the shaft metal and initiated fatigue cracks. Fatigue marks were observed on the fractured key. Repetitive impact loading was responsible for propagation of the cracks. The high cyclic bending stresses were caused by misalignment between the electric motor and compressor and were transmitted to the shaft through the geared coupling. Flexible-disk couplings capable of transmitting the required horsepower were installed on the shafts as a corrective measure.","PeriodicalId":194756,"journal":{"name":"ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions","volume":"41 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"123215952","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Explosion of the Terra Ammonium Nitrate Plant, Port, Neal, Iowa 泰拉硝酸铵工厂爆炸，尼尔港，爱荷华州
ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.usage.c9001584
{"title":"Explosion of the Terra Ammonium Nitrate Plant, Port, Neal, Iowa","authors":"","doi":"10.31399/asm.fach.usage.c9001584","DOIUrl":"https://doi.org/10.31399/asm.fach.usage.c9001584","url":null,"abstract":"\u0000 On 13 Dec 1994, two massive detonations leveled portions of an ammonium nitrate plant near Sioux City, IA. The primary explosion allegedly occurred in defectively-designed titanium sparger piping inside the neutralizer vessel. Investigation however, revealed the explosion occurred because of unsafe plant operations and poor maintenance procedures. Specifically, the ammonium nitrate within the 18,000 gal capacity neutralizer vessel had become contaminated and made highly acidic. The operators then injected superheated steam directly into the ammonium nitrate in the neutralizer vessel.","PeriodicalId":194756,"journal":{"name":"ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions","volume":"52 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"126456675","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Shear Band Failures in Threaded Titanium Alloy Fasteners 螺纹钛合金紧固件剪切带失效
ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.usage.c9001660
G. Hopple
{"title":"Shear Band Failures in Threaded Titanium Alloy Fasteners","authors":"G. Hopple","doi":"10.31399/asm.fach.usage.c9001660","DOIUrl":"https://doi.org/10.31399/asm.fach.usage.c9001660","url":null,"abstract":"\u0000 Failure analysis was performed on threaded Ti-6Al-4V fasteners that had fractured in the threads during installation. Scanning electron microscopy (SEM) and optical metallography revealed that the fractures initiated in circumferential shear bands present at the thread roots. The fractures propagated by microvoid coalescence typical of that observed in notched tensile specimen fractures of the same material. For comparison, Ti-6Al-4V fasteners from various commercial sources were tested to failure in uniaxial tension and examined in the SEM. In all cases, the fracture appearances were similar to that exhibited by the fasteners that failed during installation. In addition, results of optical microscopy indicated that the geometry and extent of the shear bands appeared to depend on the fabrication process employed by the individual manufacturers. Causes of shear band formation are discussed along with potential methods to eliminate these microstructural in homogeneities.","PeriodicalId":194756,"journal":{"name":"ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions","volume":"10 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129998174","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Failure of a Repair Weld on a Crankshaft Because of Inclusions and Porosity 曲轴修补焊缝因夹杂物和气孔而失效
ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.usage.c0047545
{"title":"Failure of a Repair Weld on a Crankshaft Because of Inclusions and Porosity","authors":"","doi":"10.31399/asm.fach.usage.c0047545","DOIUrl":"https://doi.org/10.31399/asm.fach.usage.c0047545","url":null,"abstract":"The AISI 1080 steel crankshaft of a large-capacity double-action stamping press broke in service and was repair welded. Shortly after the crankshaft was returned to service, the repair weld fractured. The repair-weld fracture was examined ultrasonically which revealed many internal reflectors, indicating the presence of slag inclusions and porosity. A low-carbon steel flux-cored filler metal was used in repair welding the crankshaft, without any preweld or postweld heating. This resulted in the formation of martensite in the HAZ. The repair weld failed by brittle fracture, which was attributed to the combination of weld porosity, many slag inclusions and the formation of brittle martensite in the HAZ. A new repair weld was made using an E312 stainless steel electrode, which provides a weld deposit that contains considerable ferrite to prevent hot cracking. Before welding, the crankshaft was preheated to a temperature above which martensite would form. After completion, the weld was covered with an asbestos blanket, and heating was continued for 24 h. During the next 24 h, the temperature was slowly lowered. The result was a crack-free weld.","PeriodicalId":194756,"journal":{"name":"ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128207260","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Fatigue Failures of Shafts Repaired by Welding 焊接修复轴的疲劳失效
ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.usage.c9001430
{"title":"Fatigue Failures of Shafts Repaired by Welding","authors":"","doi":"10.31399/asm.fach.usage.c9001430","DOIUrl":"https://doi.org/10.31399/asm.fach.usage.c9001430","url":null,"abstract":"\u0000 An intermediate shaft (3 in. diam), part of a camshaft drive on a large diesel engine, broke after two weeks of service. Failure occurred at the end of the taper portion adjacent to the screwed thread. The irregular saw-tooth form of fracture was characteristic of failure from torsional fatigue. A second shaft carried as spare gear was fitted and failure took place in a similar manner in about the same period of time. Examination revealed that the tapered portion of the Fe-0.6C carbon steel shaft had been built up by welding prior to final machining. A detailed check by the engine-builder established that the manufacture of these two shafts had been subcontracted. It was ascertained that the taper portions had been machined to an incorrect angle and then subsequently built-up and remachined to the correct taper. The reduction in fatigue endurance following welding was due to heat-affected zone cracking, residual stresses, the lower fatigue strength of the weld deposited metal, and weld defects.","PeriodicalId":194756,"journal":{"name":"ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions","volume":"12 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125395229","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Creep Failure of a 2.25Cr-1Mo Steel Superheater Tube 2.25Cr-1Mo钢过热器管蠕变失效
ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.usage.c0048303
{"title":"Creep Failure of a 2.25Cr-1Mo Steel Superheater Tube","authors":"","doi":"10.31399/asm.fach.usage.c0048303","DOIUrl":"https://doi.org/10.31399/asm.fach.usage.c0048303","url":null,"abstract":"\u0000 A tube in a radiant superheater, the boiler of which is coal fired, failed by creep after 17 years of service. The failed tube was specified to be made of ASME SA-213, grade T-22. Measurable swelling of the tube diameter by about 2.4 mm and tube wastage caused by corrosion or erosion were observed. Log stress versus Larson-Miller Parameter (LMP) plots were produced to assess the remaining life of the superheater. It was revealed that the estimated operating temperature of 1060 deg F was higher than the estimated design temperature of 1000 deg F and that the tube wastage had increased the actual operating stress. Tube wastage and high operating temperatures hastened the failure. A better understanding of the material condition of this superheater was recommended to verify all the suspect hot tubes.","PeriodicalId":194756,"journal":{"name":"ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions","volume":"66 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134138153","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Failure of Propeller Attachment Bolts 螺旋桨连接螺栓失效
ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.usage.c9001728
C. Craft
{"title":"Failure of Propeller Attachment Bolts","authors":"C. Craft","doi":"10.31399/asm.fach.usage.c9001728","DOIUrl":"https://doi.org/10.31399/asm.fach.usage.c9001728","url":null,"abstract":"\u0000 The propeller from a small private airplane came off in flight. The head ends of all six attachment bolts remained in the propeller hub when it was found. Two threaded shanks with nuts remained with the engine, while the remaining four shank ends with their nuts were missing. Parts available for examination, in addition to the hub and attachment bolts, were the two propeller blades and the engine crankshaft. The purpose of this examination was to determine the nature and probable cause of failure in the six attachment bolts. Indications of fatigue failure and wear were the major findings in visual and low power microscopic examination. Fracture surfaces indicated failure was initiated in the threads in four bolts and in the shanks in two. The group of four bolts failed primarily due to tensile loads, while the other two bolts failed primarily due to bending loads. It was concluded that failure was due to improper installation torqueing of the bolts.","PeriodicalId":194756,"journal":{"name":"ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129049823","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Scoring Damage Caused by Chipping of Chromium Plating on a Cylinder 钢瓶镀铬剥落造成的划痕损伤
ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.usage.c0046366
{"title":"Scoring Damage Caused by Chipping of Chromium Plating on a Cylinder","authors":"","doi":"10.31399/asm.fach.usage.c0046366","DOIUrl":"https://doi.org/10.31399/asm.fach.usage.c0046366","url":null,"abstract":"\u0000 Several large chromium-plated 4340 steel cylinders were removed from service because of deep longitudinal score marks in the plating. One of the damaged cylinders and a mating cast aluminum alloy B850-T5 bearing adapter that also exhibited deep longitudinal score marks were submitted for examination. Analysis (visual inspection, manual testing of the hardness and adherence of the chromium plating, 100x microscopic examination, and hardness testing) supported the conclusions that high localized loads on the cylinder had resulted in chipping of the chromium plating, particles of which became embedded in the aluminum alloy adapter. The sliding action of the adapter with embedded hard particles resulted in scoring of both the cylinder and the adapter. If the cylinder alone had been available for examination, it might have been concluded that the scoring had been caused by entrapped sand or debris from an external source. No recommendations were made.","PeriodicalId":194756,"journal":{"name":"ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions","volume":"15 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134055073","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
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