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Metal Waves or Laking on Zinc-Based Diecastings 锌基压铸件上的金属波或缺失
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001199
Gustav R. Perger, P. Robinson
{"title":"Metal Waves or Laking on Zinc-Based Diecastings","authors":"Gustav R. Perger, P. Robinson","doi":"10.31399/asm.fach.process.c9001199","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c9001199","url":null,"abstract":"\u0000 Lakes in zinc die castings are areas encompassed by irregular lines or waves on flat or slightly contoured surfaces which are intended to look uniform. The laked areas have to be removed by polishing before the castings can be plated. This adds considerably to the overall cost of production. Castings examined were of an automobile name-plate holder with two flat sides of approximately 113 sq cm. All castings produced during a trial showed laking defects, the number and position varying from casting to casting. It was found that formation of metal waves and lakes depended primarily on the design of the gate and runner system and operating conditions. High flow efficiencies, with adequate feeding to all sections of the die, and short cavity fill times are desirable.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"26 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":"130568067","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
Investigation of a Case Hardened Sleeve 硬质套管的研究
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001214
F. Naumann, F. Spies
{"title":"Investigation of a Case Hardened Sleeve","authors":"F. Naumann, F. Spies","doi":"10.31399/asm.fach.process.c9001214","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c9001214","url":null,"abstract":"\u0000 A case-hardened sleeve made of C 15 (Material No. 1.0401) was flattened at two opposing sides and had cracked open at these places, the crack initiating at a face plane. The wall of the sleeve was 9 mm thick, but the flat ends were machined down to 5.5 mm from the outside. The customer had specified a 2 mm case depth and a hardness of at least HRC 55 at a depth of 1.5 mm. An etched cross section of the cracked end showed that the case layer had a depth of 2.3 mm, so that the sleeve was almost through-hardened at the flat ends. While the core material with the full wall thickness had the quench structure of low-carbon steel, the structure of the flattened area consisted of coarse acicular martensite with a small amount of pearlite (quench troostite) and ferrite. Therefore the sleeve was overheated and probably quenched directly from case. To prevent damage, it would have been necessary to have a lower case depth, carburize less deeply, and prevent overheating that causes brittleness and leads also to increased case depth, or else use a fine-grained steel of lower hardenability.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"1438 ","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"120875571","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 Failure of an Inlet Header Because of Poor Welding Technique and Unfavorable Weld-Joint Design 由于焊接工艺差和焊缝设计不合理导致的进气集箱疲劳失效
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0089738
{"title":"Fatigue Failure of an Inlet Header Because of Poor Welding Technique and Unfavorable Weld-Joint Design","authors":"","doi":"10.31399/asm.fach.process.c0089738","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0089738","url":null,"abstract":"\u0000 While undergoing vibration testing, a type 347 stainless steel inlet header for a fuel-to-air heat exchanger cracked in the header tube adjacent to the weld bead between the tube and header duct. Investigation (visual inspection and liquid penetrant inspection) supported the conclusion that the crack in the header tube was the result of a stress concentration at the toe of the weld joining a doubler collar to the tube. The stress concentration was caused by undercutting from poor welding technique and an unfavorable joint design that did not permit a good fit-up. Recommendations included manufacturing the doubler collar so that it could be placed in intimate contact with the header duct, and a revised weld procedure was recommended to result in a smaller, controlled, homogeneous weld joint with less distortion.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"50 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":"130627246","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
Steel Socket Pipe Conduit Cracked Next to Weld Seam 钢制承插管在焊缝附近有裂纹
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001257
F. Naumann, F. Spies
{"title":"Steel Socket Pipe Conduit Cracked Next to Weld Seam","authors":"F. Naumann, F. Spies","doi":"10.31399/asm.fach.process.c9001257","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c9001257","url":null,"abstract":"\u0000 A steel socket pipe conduit NW 150 cracked open during pressure testing next to the weld seam almost along the entire circumference. The crack occurred in part in the penetration notch and in part immediately adjacent to it. While the uncracked pipe showed the light etch shading of a low-carbon steel in which the zone heated during welding was delineated only slightly next to the seam, the other pipe was etched much darker, i.e., higher in carbon, and the heated zone appeared to stand out darkly against the basic material. The overlapping weld was defect-free and dense. The uncracked pipe consisted of soft steel that obviously was made for this purpose, while the cracked pipe consisted of a strongly-hardenable steel which contained not only more carbon and manganese than customary but also a considerable amount of chromium. Therefore, the damage was caused by a mix-up of materials that allowed an unsuitable steel to be used for the weldment.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","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":"133922227","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
Plating Adherence Problems in Electronic Components 电子元件镀层附着问题
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001492
Arun Kumar
{"title":"Plating Adherence Problems in Electronic Components","authors":"Arun Kumar","doi":"10.31399/asm.fach.process.c9001492","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c9001492","url":null,"abstract":"\u0000 Electroless nickel plating separation from copper alloy CDA175 retaining clips used on printed circuit boards was caused by a copper oxide layer that reduced adhesion of the nickel plating on the clips. Stresses that developed during module insertion caused flaking to occur at the oxidized copper surface. Electroless nickel plating separation from OFHC copper leads was caused by improper handling rather than a plating anomaly per se. Tin plating separation from copper underplating on a hybrid package lid occurred because of a four-week delay between the copper plating and tin plating steps. It was recommended that tin plating should follow the copper underplating within 24 h and a cleaning step of bright dipping after copper plating be performed.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"1997 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":"132490928","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 a Type 347 Stainless Steel Pressure-Probe Housing Originating at Voids in a Brazed Joint 347型不锈钢压力探头壳体在钎焊接头空隙处引起的疲劳断裂
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0047753
{"title":"Fatigue Fracture of a Type 347 Stainless Steel Pressure-Probe Housing Originating at Voids in a Brazed Joint","authors":"","doi":"10.31399/asm.fach.process.c0047753","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0047753","url":null,"abstract":"\u0000 A pressure probe assembly comprised of type 347 stainless steel housing, brazed with AMS 4772D filler metal to the pressure probe, failed due to detachment of a rectangular segment from the housing. The presence of a large brazing metal devoid region in the pressure probe-housing joint was revealed by visual examination. Fatigue marks, emanating from multiple crack origins on the inside surface of the housing at the brazed joint were revealed by further study of the fracture. A poor metallurgical bond was confirmed by the presence of large irregular voids, flux trapped braze metal and separation between braze and housing.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"259 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":"132504754","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
Ultrasonic Inspection of a 1.7 m (68 in.) Diam 8822 Steel Billet and the Ring Into Which It Was Rolled 1.7 m (68 in.)直径的超声检查直径8822钢坯及其轧成的环
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0059924
{"title":"Ultrasonic Inspection of a 1.7 m (68 in.) Diam 8822 Steel Billet and the Ring Into Which It Was Rolled","authors":"","doi":"10.31399/asm.fach.process.c0059924","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0059924","url":null,"abstract":"\u0000 The large steel ring produced for a nuclear application from a billet of 8822 steel was inspected. The large billet was first forged into a doughnut preform in a large press, and then formed into the ring by ring rolling. A straight-beam ultrasonic inspection was instituted and calibrated using the back-surface-reflection method to determine whether adequate ultrasonic penetration was available. Areas of indications were noted at approximately midheight and adjacent to the bore area. An axial angle-beam inspection from the outside was performed, mainly in the area of indications to reveal detectable indications. The indications were not considered serious enough to reject the forgings. A few small indications in the areas tested were revealed by magnetic particle inspection. The area was conditioned by grinding and polishing to obtain an additional inspection at a greater depth from the inside surface. A much more severe condition was revealed after the test. The indications were classified as areas of chemical segregation and nonmetallic inclusions. The ring was considered unsatisfactory for the application and replacement of the defective ring from an acceptable billet was the most economical solution.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"90 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":"116832269","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 that Originated on the Ground Surface of a Medium- Carbon Steel Forging with a Notch-Sensitive Band Structure 一种缺口敏感带结构中碳钢锻件的表面疲劳断裂
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0089459
{"title":"Fatigue Fracture that Originated on the Ground Surface of a Medium- Carbon Steel Forging with a Notch-Sensitive Band Structure","authors":"","doi":"10.31399/asm.fach.process.c0089459","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0089459","url":null,"abstract":"\u0000 The connecting end of two forged medium-carbon steel rods used in an application in which they were subjected to severe low-frequency loading failed in service. The fractures extended completely through the connecting end. The surface hardness of the rods was found to be lower than specifications. The fractures were revealed to be in areas of the transition regions that had been rough ground to remove flash along the parting line. The presence of beach marks, indicating fatigue failure, was revealed by examination. The fracture origin was confirmed by the location and curvature of beach marks to be the rough ground surface. An incipient crack 9.5 mm along with several other cracks on one of the fractured rods was revealed by liquid penetration examination. Metallographic examination of the fractured rods indicated a banded structure consisting of zones of ferrite and pearlite. It was established that the incipient cracks found in liquid-penetrant inspection had originated at the surface in the banded region, in areas of ferrite where this constituent had been visibly deformed by grinding. Closer control on the microstructure, hardness of the forgings and smooth finish in critical area was recommended.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"77 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":"114593371","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 Failure of Malleable Iron Diesel-Engine Rocker Levers Originating at Spiking Defects 柴油机可锻铸铁摇杆杆的疲劳失效
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0089651
{"title":"Fatigue Failure of Malleable Iron Diesel-Engine Rocker Levers Originating at Spiking Defects","authors":"","doi":"10.31399/asm.fach.process.c0089651","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0089651","url":null,"abstract":"\u0000 Several diesel-engine rocker levers (malleable iron similar to ASTM A 602, grade M7002) failed at low hours in overspeed, over-fuel, highly loaded developmental engine tests. Identical rocker levers had performed acceptably in normal engine tests. The rocker levers were failing through the radius of an adjusting screw arm. The typical fracture face exhibited two distinct modes of crack propagation: the upper portion indicated overload at final fracture, whereas the majority of the fracture suggested a fatigue fracture. Investigation (visual inspection, 1.5x/30x/60x magnification, and nital etched 300x magnification) supported the conclusion that the rocker levers failed in fatigue, with casting defects, or spiking, acting as stress raisers to initiate failures in highly loaded engine tests. Recommendations included shot peening of the levers as an interim measure to reduce the possibility of failure and redesign to increase the cross-sectional area of the levers.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"77 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":"128398312","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
Seizing of a Spool-Type Hydraulic Valve 阀芯型液压阀的卡扣
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0092148
{"title":"Seizing of a Spool-Type Hydraulic Valve","authors":"","doi":"10.31399/asm.fach.process.c0092148","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0092148","url":null,"abstract":"\u0000 Occasional failures were experienced in spool-type valves used in a hydraulic system. When a valve would fail, the close-fitting rotary valve would seize, causing loss of flow control of the hydraulic oil. The rotating spool in the valve was made of 8620 steel and was gas carburized. The cylinder in which the spool fitted was made of 1117 steel, also gas carburized. Investigation (visual inspection, low magnification images, 400x images, metallographic exam, and hardness testing) supported the conclusion that momentary sliding contact between the spool and the cylinder wall caused unstable retained austenite in the failed cylinder to transform to martensite. The increase in volume resulted in sufficient size distortion to cause interference between the cylinder and the spool, seizing, and loss of flow control. The failed parts had been carburized in a process in which the carbon potential was too high, which resulted in a microstructure having excessive retained austenite after heat treatment. Recommendations included modifying the composition of the carburizing atmosphere to yield carburized parts that did not retain significant amounts of austenite when they were heat treated.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"35 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":"134511599","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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