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Fatigue Fracture of a Sand-Cast Steel Axle Housing That Originated at a Hot Tear 热撕裂引起的砂铸钢桥壳疲劳断裂
ASM Failure Analysis Case Histories: Automobiles and Trucks Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.auto.c0089551
{"title":"Fatigue Fracture of a Sand-Cast Steel Axle Housing That Originated at a Hot Tear","authors":"","doi":"10.31399/asm.fach.auto.c0089551","DOIUrl":"https://doi.org/10.31399/asm.fach.auto.c0089551","url":null,"abstract":"\u0000 A sand-cast medium-carbon steel heavy-duty axle housing, which had been quenched and tempered to about 30 HRC, fractured after almost 5000 h of service. Investigation (0.4x magnification) revealed that the fracture had been initiated by a hot tear that formed during solidification of the casting. The mass of a feeder-riser system located near the tear retarded cooling in this region, creating a hot spot. This supported the conclusion that the tear causing the fracture of the axle housing was formed during solidification by hindered contraction and was enlarged in service by fatigue. Recommendations were to change the feeder location to eliminate the hot spot and thus the occurrence of hot tearing.","PeriodicalId":235345,"journal":{"name":"ASM Failure Analysis Case Histories: Automobiles and Trucks","volume":"8 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":"126554337","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
Redesign of a Forged Manual Gear-Shift Lever Mechanism to Overcome Unacceptable Fatigue Failure of Original Forging 为克服原锻件不可接受的疲劳失效，对锻造手动换挡杆机构进行重新设计
ASM Failure Analysis Case Histories: Automobiles and Trucks Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.auto.c0001784
{"title":"Redesign of a Forged Manual Gear-Shift Lever Mechanism to Overcome Unacceptable Fatigue Failure of Original Forging","authors":"","doi":"10.31399/asm.fach.auto.c0001784","DOIUrl":"https://doi.org/10.31399/asm.fach.auto.c0001784","url":null,"abstract":"\u0000 Field fatigue failures occurred in a hand-operated gear shift lever mechanism made of 1049 medium carbon steel hardened to 269 to 285 HB. The failures occurred in the 3.18 mm (0.127 in.) radius. Redesign increased the shift lever's diameter to 25 mm (1 in.) and the radius to 4.75 mm (0.187 in.). Also, instead of the as-forged surface, it was expedient to machine the radius. The as-forged surface at 360 MPa (52 ksi) maximum working stress would not ensure satisfactory life because the recalculated maximum stress was 390 MPa (57 ksi). However, the machined surface with a maximum working stress of 475 MPa (69 ksi) gives a safe margin above the 390 MPa (57 ksi) requirement for design stress. Interpreting these values, the forged surface should have a life expectancy of 1,000,000 cycles of stress. However, because the load cycle was somewhat uncertain, the machined radius was chosen to obtain a greater margin of safety. Redesigning eliminated the failures.","PeriodicalId":235345,"journal":{"name":"ASM Failure Analysis Case Histories: Automobiles and Trucks","volume":"17 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":"127903500","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
Broken Rear Wheel Suspension 后轮悬架破裂
ASM Failure Analysis Case Histories: Automobiles and Trucks Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.auto.c9001157
F. Naumann, F. Spies
{"title":"Broken Rear Wheel Suspension","authors":"F. Naumann, F. Spies","doi":"10.31399/asm.fach.auto.c9001157","DOIUrl":"https://doi.org/10.31399/asm.fach.auto.c9001157","url":null,"abstract":"\u0000 A suspension bushing separated from the disk on the rear wheel suspension of a racing vehicle while under operation on an express highway, causing the wheel to detach from the car. Visual inspection showed fresh turning grooves at four built-up fillet welds on the torus of the outside of the disk. The welding heat and rapid cooling caused the base material of the disk – already with a martensitic structure – to harden throughout the torus, both of which caused cracking in the inner and outer fillets at the transition from bushing to disk. Visual inspection of the other rear wheel showed similar stress cracks in the hardened base material of the transition region as well as the same four welds. Rough finishing and the sharp-edged formation of the cross section transition may have also contributed to the failure. The results of the investigation suggested that machine shops neither execute nor permit repair-welds on highly stressed machine parts and especially vehicle components.","PeriodicalId":235345,"journal":{"name":"ASM Failure Analysis Case Histories: Automobiles and Trucks","volume":"42 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":"115571982","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
Cracking of High Strength Steel Piston Rod During Chrome Plating 高强度钢活塞杆镀铬过程中的裂纹
ASM Failure Analysis Case Histories: Automobiles and Trucks Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.auto.c9001556
A. Das, B. Thippeswamy, J. Prasad
{"title":"Cracking of High Strength Steel Piston Rod During Chrome Plating","authors":"A. Das, B. Thippeswamy, J. Prasad","doi":"10.31399/asm.fach.auto.c9001556","DOIUrl":"https://doi.org/10.31399/asm.fach.auto.c9001556","url":null,"abstract":"\u0000 A few Cr-Mo steel piston rods from different production batches were found identically cracked in the eye end near the radius after chrome plating and baking treatment. Two of them cracked in the plating stage itself instantly broke on slight tapping. Cracking initiated from the outer base surface of the forked eye end. The 40 mm diam forged piston rods were subjected to plating after heavy machining on the part without any stress-relieving treatment. Also, time lapses between plating and baking were varied from 3 to 11 h. The brittle cracking along forked eye-end radius portion was attributed to hydrogen embrittlement that occurred during chrome plating.","PeriodicalId":235345,"journal":{"name":"ASM Failure Analysis Case Histories: Automobiles and Trucks","volume":"37 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":"127175556","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
Forming Process Anomalies in Diesel Fuel Injection Control Sleeve 柴油机燃油喷射控制套成形过程异常
ASM Failure Analysis Case Histories: Automobiles and Trucks Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.auto.c0089258
{"title":"Forming Process Anomalies in Diesel Fuel Injection Control Sleeve","authors":"","doi":"10.31399/asm.fach.auto.c0089258","DOIUrl":"https://doi.org/10.31399/asm.fach.auto.c0089258","url":null,"abstract":"\u0000 The cold start advance solenoid sleeve was found leaking through the wall during troubleshooting complain of a diesel engine that failed to start in cold weather. The component was revealed to be a tubular product with a “bulb” section at one end and threads on the other. The manufacturing method used to create the bulb shape was hydroforming, using a 300 series stainless steel tube in the full-hard condition. The leak was attributed to a crack in the sleeve in the radius between the bulb area and the cylindrical portion of the sleeve. Fatigue cracks initiated at multiple sites near the OD of the sleeve were revealed by scanning electron microscopy of the broken-open crack. It was revealed by analysis that during the hydroforming process, heavy biaxial strains were imparted to the sleeve wall. It was interpreted that when combined with the heavy strains inherently present in the full-hard 300 series stainless steel, the hydroforming strains in the radius caused the microcracking. The root cause for this failure was identified to be omission of an intermediate stress relief or annealing treatment prior to hydroforming to the final shape.","PeriodicalId":235345,"journal":{"name":"ASM Failure Analysis Case Histories: Automobiles and Trucks","volume":"20 2 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":"131489923","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
An Example of Incidence of Non-Metallic Inclusions in an Alloy Steel 一种合金钢中非金属夹杂物发生率的例子
ASM Failure Analysis Case Histories: Automobiles and Trucks Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.auto.c9001256
P. Chatterjee
{"title":"An Example of Incidence of Non-Metallic Inclusions in an Alloy Steel","authors":"P. Chatterjee","doi":"10.31399/asm.fach.auto.c9001256","DOIUrl":"https://doi.org/10.31399/asm.fach.auto.c9001256","url":null,"abstract":"\u0000 There was a large incidence of surface defects on the crank pins and journals and other areas of crank shafts of a high power automotive engine. The steel used was a Cr-Mo type of nitriding steel. Metallographic observations conclusively proved that the defective areas were entrapment of foreign bodies, resulting from steel making/deoxidizing/teeming stages. The occasionally globular nature of the foreign particles suggested these were formed at the liquid condition of the steel. The ratio of Mn-Si as seen on electron probe microanalysis also suggested the globules high in Mn content might have resulted in deoxidizing stage. Particularly the absence of Fe in some areas in the inclusion was indicative of precipitation deoxidation by ferromanganese/ferrosilicon. The defects apparently did not have time to coalesce and rise up to the top.","PeriodicalId":235345,"journal":{"name":"ASM Failure Analysis Case Histories: Automobiles and Trucks","volume":"31 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":"128857073","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 an Automobile Transmission Stick-Shift 汽车变速箱手动换档故障
ASM Failure Analysis Case Histories: Automobiles and Trucks Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.auto.c0048535
{"title":"Failure of an Automobile Transmission Stick-Shift","authors":"","doi":"10.31399/asm.fach.auto.c0048535","DOIUrl":"https://doi.org/10.31399/asm.fach.auto.c0048535","url":null,"abstract":"\u0000 A stick-shift from an automobile transmission failed in service. Failure occurred by stable fatigue crack propagation at locations R and L. Plausibly, the crack initiated at location R due to maximum tensile stress, which was perhaps further concentrated by a surface imperfection. As the crack progressed, the service load shifted to the section marked L. This overload on location L appears to have caused another fatigue crack that propagated first over the smooth-banded region. Catastrophic failure occurred when the component became unstable under the applied load.","PeriodicalId":235345,"journal":{"name":"ASM Failure Analysis Case Histories: Automobiles and Trucks","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":"115568895","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 Fracture of an 8640 Steel Shaft From a Fuel-Injection-Pump Governor Because of Insufficient Fatigue Strength 喷油泵调速器8640钢轴疲劳断裂原因分析
ASM Failure Analysis Case Histories: Automobiles and Trucks Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.auto.c0047846
{"title":"Fatigue Fracture of an 8640 Steel Shaft From a Fuel-Injection-Pump Governor Because of Insufficient Fatigue Strength","authors":"","doi":"10.31399/asm.fach.auto.c0047846","DOIUrl":"https://doi.org/10.31399/asm.fach.auto.c0047846","url":null,"abstract":"\u0000 An 8640 steel shaft installed in a fuel-injection-pump governor that controlled the speed of a diesel engine used in trucks and tractors broke after few days of operation. The mechanism that drove the shaft was designed to include a slip clutch to protect the governor shaft from shock loading. It was revealed by visual examination that the fracture had initiated in the sharp corner at the bottom of a longitudinal hole which was part of a force feed lubricating system. Beach marks were observed on the fracture surfaces. It was revealed by further examination that the slip clutch was removed in an effort to reduce cost and hence the shaft was subjected to increased vibration and shock loading. Insufficient fatigue limit of the shaft was revealed by fatigue testing of the shafts taken from stock in a rotating-beam machine. As a corrective measure, the fatigue limit of shafts was increased to 760 MPA by nitriding for 10 h at 515 deg C.","PeriodicalId":235345,"journal":{"name":"ASM Failure Analysis Case Histories: Automobiles and Trucks","volume":"114 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":"132010695","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
Fracture of a Steering Damper 转向阻尼器断裂
ASM Failure Analysis Case Histories: Automobiles and Trucks Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.auto.c9001156
{"title":"Fracture of a Steering Damper","authors":"","doi":"10.31399/asm.fach.auto.c9001156","DOIUrl":"https://doi.org/10.31399/asm.fach.auto.c9001156","url":null,"abstract":"\u0000 The piston rod of a steering damper on a single decker bus fractured after 100,000 miles of service in the fully-extended left full-lock position. The steering damper, which is similar in shape and operation to a telescopic shock absorber, was secured by ball joints locked with slotted nuts. The steel piston rod fractured at the axle end leaving approximately 5 mm of rod welded to a securing ferrule. The failure was caused by a fatigue mechanism. Small surface cracks formed during welding in the heat-affected zone close to an unradiused shoulder in the piston. Under alternating stresses in normal service these cracks propagated through the piston rod made less tough by the extended weld heat-affected zone.","PeriodicalId":235345,"journal":{"name":"ASM Failure Analysis Case Histories: Automobiles and Trucks","volume":"47 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":"121944857","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
Use of XRD to Assess Residual Stresses in Steel Springs 用XRD测定钢弹簧残余应力
ASM Failure Analysis Case Histories: Automobiles and Trucks Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.auto.c0090626
{"title":"Use of XRD to Assess Residual Stresses in Steel Springs","authors":"","doi":"10.31399/asm.fach.auto.c0090626","DOIUrl":"https://doi.org/10.31399/asm.fach.auto.c0090626","url":null,"abstract":"\u0000 A steel spring used in an automotive application suddenly began to fail in the field, although “nothing had changed” in the fabrication process. Fatigue tests using springs fabricated prior to field failures lasted 500,000 cycles to failure, whereas fatigue tests performed on springs fabricated after field failures lasted only 50,000 cycles to failure. It was discovered that the percent coverage of shot peening prior and subsequent to the increase in failure incidence was much less than 100%, with a shot peening time of 12 min. The residual-stress state of “as fabricated” springs in three conditions were evaluated using XRD: springs manufactured prior to failure incidence increase, 12 min peen; springs manufactured following failure incidence increase, 12 min peen; and 60 min peen. The conclusion was that the failure occurred because low peening time significantly decreased the compressive residual-stress levels in the springs. Recommendation was made to increase the time the spring was shot peened from 12 to 60 min.","PeriodicalId":235345,"journal":{"name":"ASM Failure Analysis Case Histories: Automobiles and Trucks","volume":"71 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":"127591667","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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