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Fatigue Fracture of a Shaft for an Amusement Ride Because of Undercuts in Welds 游乐设备轴因焊缝下切引起的疲劳断裂
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0089774
{"title":"Fatigue Fracture of a Shaft for an Amusement Ride Because of Undercuts in Welds","authors":"","doi":"10.31399/asm.fach.process.c0089774","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0089774","url":null,"abstract":"\u0000 An amusement ride failed when a component in the ride parted, permitting it to fly apart. The ride consisted of a central shaft supporting a spider of three arms, each of which was equipped with an AISI 1040 steel secondary shaft about which a circular platform rotated. The main shaft rotated at about 12 rpm and the platforms at a speed of 20 rpm. The accident occurred when one of the secondary shafts on the amusement ride broke. The point of fracture was adjacent to a weld that attached the shaft to a 16 mm thick plate, which in turn bore the platform support arms. Investigation (visual inspection, 0.4x magnification, and stress analysis) supported the conclusion that a likely cause for the fatigue failure was the combination of residual stresses generated in welding and centrifugal service stresses from operation that were accentuated by areas of stress concentration at the undercut locations. Without the excessive residual stress, the shaft dimensions appeared ample for the service load. Recommendations included applying the fillet weld with more care to avoid undercutting. The residual stresses could be minimized by pre-weld and post-weld heat application.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"51 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":"115708884","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
Tinting of Electropolished Copper Parts 电镀抛光铜件着色
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001629
S. Suess
{"title":"Tinting of Electropolished Copper Parts","authors":"S. Suess","doi":"10.31399/asm.fach.process.c9001629","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c9001629","url":null,"abstract":"\u0000 A large number of electropolished copper parts showed evidence of discoloration (tinting) after electropolishing. Because these parts are used in a high-vacuum application, even trace amounts of organic materials would be problematic. Scanning electron microscopy of nondiscolored and discolored areas both showed trace amounts of residue in the form of adherent deposits. EDS, FTIR spectroscopy, XPS, and secondary ion mass spectroscopy (SIMS) analyses indicated that the discoloration to the copper components was due to the development of CuO at localized regions. It was recommended that process changes be made to completely remove residual processing fluids from the part surfaces before electropolishing. The use of more aggressive detergents was suggested, and it was recommended also that a filtering and recirculating system be considered for use in the cleaning and electropolishing tanks.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"13 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":"127152865","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
Overload Failure of a Quench-Cracked AISI 4340 Steel Threaded Rod 淬火裂纹AISI 4340钢螺纹杆的过载失效
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0049797
{"title":"Overload Failure of a Quench-Cracked AISI 4340 Steel Threaded Rod","authors":"","doi":"10.31399/asm.fach.process.c0049797","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0049797","url":null,"abstract":"\u0000 An AISI 4340 threaded steel connecting rod that was part of a connecting linkage used between a parachute and an instrumented drop test assembly fractured under high dynamic loading when the assembly was dropped from an airplane. A large flaw that originated from the root of a machined thread groove was visible on the fracture surface. Heavy oxidation at elevated temperatures was indicated as most of the surface of the flaw was black. Fine secondary cracks aligned transverse to the growth direction was revealed by scanning electron microscopy. It was established that intergranular cracking observed in this alloy was caused during heat treating as the thread root served as an effective stress concentration and induced quench cracking. It was found that fracture in the overload region occurred by a ductile void growth and coalescence process. Premature failure of the threaded rod was thus attributed to the presence of the quench crack flaw caused by an improper machining sequence and heat treatment practice.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","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":"114060874","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 a Steam Pipe Flange 蒸汽管法兰开裂
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001421
{"title":"Cracking of a Steam Pipe Flange","authors":"","doi":"10.31399/asm.fach.process.c9001421","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c9001421","url":null,"abstract":"\u0000 The bottom flange of a vertical pipe coupled to an isolating valve in a steam supply line to a turbine failed. Steam pressure was 1,500 psi and the temperature 416 deg C (780 deg F). Multiple cracking occurred in the bore of the flange. A quarter-segment was cut out and examined. The cracks were located in the part of the flange that formed a continuation of the pipe bore. The majority of them originated at the end of the flange bore and extended axially along the pipe and radially across the flange face. Magnetic crack detection revealed a further number of cracks in the weld deposit. While the fracture in the weld metal was of the ductile type exhibiting a fine fibrous appearance, that in the flange material was of the cleavage type. Microscopic examination revealed that the cracks were blunt-ended fissures of the type characteristic of corrosion-fatigue. It was concluded that cracking was due to corrosion-fatigue, which arose from the combined effect of a fluctuating tensile stress in the presence of a mildly corrosive environment.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"122 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":"114275414","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
Brittle Fracture of a Case-Hardened Component Because of Low Impact Resistance and Grinding Burns 由于低抗冲击性和磨削烧伤导致的表面硬化部件脆性断裂
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0046028
{"title":"Brittle Fracture of a Case-Hardened Component Because of Low Impact Resistance and Grinding Burns","authors":"","doi":"10.31399/asm.fach.process.c0046028","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0046028","url":null,"abstract":"\u0000 The 8620 steel latch tip, carburized and then induction hardened to a minimum surface hardness of 62 HRC, on the main-clutch stop arm on a business machine fractured during normal operation when the latch tip was subjected to intermittent impact loading. Fractographic examination 9x showed a brittle appearance at the fractures. Micrograph examination of an etched section disclosed several small cracks. Fracture of the parts may have occurred through similar cracks. Also observed was a burned layer approximately 0.075 mm (0.003 in.) deep on the latch surface, and hardness at a depth of 0.025 mm (0.001 in.) in this layer was 52 HRC (a minimum of 55 HRC was specified). Thus, the failure was caused by brittle fracture in the hardness-transition zone as the result of excessive impact loading. The burned layer indicated that the cracks had been caused by improper grinding after hardening. Redesign was recommended to include reinforcing the backing web of the tip, increasing the radius at the relief step to 1.5 x 0.5 mm (0.06 x 0.02 in.), the use of proper grinding techniques, and a requirement that the hardened zone extend a minimum of 1.5 mm (0.06 in.) beyond the step.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"32 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":"129472887","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
Cracked Pipe Elbow of a Hydraulic Installation 液压装置的管弯头开裂
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001227
F. Naumann, F. Spies
{"title":"Cracked Pipe Elbow of a Hydraulic Installation","authors":"F. Naumann, F. Spies","doi":"10.31399/asm.fach.process.c9001227","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c9001227","url":null,"abstract":"\u0000 An elbow of 70 mm OD and 10 mm wall thickness made from St 35.29, and exposed to 315 atmospheres internal pressure in an oil hydraulic shear installation, cracked lengthwise after a short operating period. Because the stress was not sufficient to explain the fracture of this elbow under this pressure, an investigation was conducted to establish whether material or processing errors had occurred. Microscopic examination showed that a ferritic-pearlitic structure in select locations was very fine-grained. Other signs of fast cooling as compared to normally formed structure of the core zone were noted. It was also possible that the pipe was resting on a cold plate during bending or that it came in touch with a cold tool. This apparently caused the strains at the transition to the cross-sectional part that had been cooled more slowly. The location of the crack at just this point gave rise to the conclusion that it was formed either by the sole or contributive effect of these stresses.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"210 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":"114222863","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 1055 Steel Crane-Bridge Wheel 1055钢吊桥车轮断裂
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0048099
{"title":"Fracture of a 1055 Steel Crane-Bridge Wheel","authors":"","doi":"10.31399/asm.fach.process.c0048099","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0048099","url":null,"abstract":"\u0000 A bridge wheel on a crane, forged from 1055 steel, fractured after one year of service. The wheel fractured in the web between the hub and the rim. A small area containing beach marks that originated in a heavily burned area on the web surface was revealed by visual examination of the fracture surface. Surface burning to a depth of approximately 0.8 mm was disclosed by metallographic examination of a section taken through the region that contained the beach marks. A forging defect was indicated by the degree of decarburization and oxide dispersion that were visible. The failure was concluded to have been caused by surface burning during the forging operation. As a preventive measure more closely controlled heating practice during forging to eliminate surface burning was recommended. The burnt region was suggested to be removed in case burning occurs.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"32 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":"128106463","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
Decarburization 脱碳
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001241
F. Naumann, F. Spies
{"title":"Decarburization","authors":"F. Naumann, F. Spies","doi":"10.31399/asm.fach.process.c9001241","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c9001241","url":null,"abstract":"\u0000 Decarburization of steel may occur as skin decarburization by gases either wet or containing oxygen, and as a deep ongoing destruction of the material by hydrogen under high pressure. Guidelines are given for recognizing decarburization and determining at what point cracks occurred. How decarburization changes workpiece properties and the case of hydrogen decarburization are addressed through examples.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"446 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":"115512366","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: 1
Failure of a Steam Accumulator Due to Lack of Complete Weld Penetration 由于焊缝未完全渗透造成的蒸汽蓄能器失效
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0048782
{"title":"Failure of a Steam Accumulator Due to Lack of Complete Weld Penetration","authors":"","doi":"10.31399/asm.fach.process.c0048782","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0048782","url":null,"abstract":"\u0000 A steam accumulator, constructed with 10.3 mm thick SA515-70 steel heads and an 8 mm thick SA455A steel shell, ruptured after about three years of service. The accumulator was used in plastic molding operations. An extensive lack of weld penetration in this the head-to-shell girth weld was revealed by laboratory examination. Some misalignment of the head to the shell because of radial displacement of the shell and head centerlines was observed which was found to result in excessive clearances between the two parts and a slight difference in the thicknesses of the parts. Transgranular fracture with occasional secondary branching was revealed. It was interpreted by stress analysis that a small amount of misalignment added to lack of penetration increased the stresses to near the tensile strength of the material. The failure was judged to be a short-cycle high-stress notch-fatigue failure.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"262 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":"114838954","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 Alloy Steel Valve Springs Because of Pipe 管道引起的合金钢气门弹簧疲劳断裂
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0048117
{"title":"Fatigue Fracture of Alloy Steel Valve Springs Because of Pipe","authors":"","doi":"10.31399/asm.fach.process.c0048117","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0048117","url":null,"abstract":"\u0000 Two outer valve springs made from air-melted 6150 pretempered steel wire broke during production engine testing. The springs were 50 mm in OD and 64 mm in free length, had five coils and squared-and-ground ends, and were made of 5.5 mm diam wire. It was revealed that fracture was nucleated by an apparent longitudinal subsurface defect. The defect was revealed by microscopic examination to be a large pocket of nonmetallic inclusions (alumina and silicate particles) at the origin of the fracture. Partial decarburization of the steel was observed at the periphery of the pocket of inclusions. Torsional fracture was indicated by the presence of beach marks at a 45 deg angle to the wire axis. It was established that the spring fractured by fatigue nucleated at the subsurface defect.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"4 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":"116914457","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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