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Broken Slide of a Friction Press 摩擦压力机滑块损坏
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001188
F. Naumann, F. Spies
{"title":"Broken Slide of a Friction Press","authors":"F. Naumann, F. Spies","doi":"10.31399/asm.fach.process.c9001188","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c9001188","url":null,"abstract":"\u0000 A short fracture section of a forged and normalized Ck 35 (DIN 17200) steel slide showed three distinct zones: a dark colored crystalline area, an incipient crack propagating into a far advanced, rubbed fracture surface, and a fine crystalline final break. Metallographic examination showed the dark incipient crack was present before the last heat treatment and was oxidized and decarburized prior to the conclusion of the annealing process. The crack ran perpendicular to the fiber, so it was not formed before or during forging. It was a thermal stress crack produced during flame cutting of the middle section of the slide. The initial crack acted as a sharp notch favoring the formation of the fatigue fracture which lead to the failure of the slide.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"82 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":"133014567","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
Stub Axles That Were Rejected Because of Slag Inclusions 因夹渣而被拒绝的短轴
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0047118
{"title":"Stub Axles That Were Rejected Because of Slag Inclusions","authors":"","doi":"10.31399/asm.fach.process.c0047118","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0047118","url":null,"abstract":"\u0000 An automobile manufacturer rejected several 1035 steel stub axles because of what appeared to be short longitudinal cracks in the surfaces of the pins. The cracks were found when six axles were examined for defects by magnetic-particle inspection. However, metallographic examination showed that these lines were not cracks but slag inclusions at and immediately below the surface. Analysis (visual inspection, metallographic examination, and 100x/500x magnetic-particle inspection) supported the conclusions that the inclusions consisted of pieces of fireclay from channel brick that were flushed into the ingot mold. Although no true cracks were present, rejection of the stub axles was nevertheless justified. Slag streaks could reduce the strength of the stub axles and lead to the formation of fatigue fractures during operation. No recommendations were made.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","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":"133270677","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 Welded Shaft 焊接轴的脆性断裂
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001436
{"title":"Brittle Fracture of a Welded Shaft","authors":"","doi":"10.31399/asm.fach.process.c9001436","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c9001436","url":null,"abstract":"\u0000 A 3 in. diam shaft was found to have suffered excessive wear on one of the journals and was built up by welding. While it was in the lathe prior to turning down the built-up region, a crack was discovered in the root of the oil-seal groove and subsequently the end of the shaft was broken off with hammer blows. The fracture surface was duplex in nature, there being an annular region surrounding a central zone, which suggests that the fracture developed in two stages. Microscopic examination confirmed that the fracture was of the brittle type. The shaft material showed a microstructure typical of a medium-carbon steel (carbon approximately 0.4%) in the normalized condition, a material not weldable by ordinary methods. It was concluded that the post-welding crack arose primarily from the thermal contraction which developed in the weld metal on cooling. It is probable that if the built-up zone had extended beyond the oil seal groove, failure in the manner would not have occurred. Experience indicated however, that failure from fatigue cracking would still have been likely to occur.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","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":"126025432","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 Mechanics Analysis of Fatigue Failures in Crankshafts With Drilled Holes and Surface Compression 钻孔和表面压缩曲轴疲劳失效的断裂力学分析
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0046210
{"title":"Fracture Mechanics Analysis of Fatigue Failures in Crankshafts With Drilled Holes and Surface Compression","authors":"","doi":"10.31399/asm.fach.process.c0046210","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0046210","url":null,"abstract":"\u0000 Several crankshaft failures occurred in equipment that was being used in logging operations in subzero temperatures. Failure usually initiated at a cracked pin oil hole, and the failure origin was approximately 7.6 mm (0.3 in.) from the shaft surface. The holes were produced by gun drilling, giving rise to surface defects. The fracture surface was characteristic of fatigue in that it was flat, relatively shiny, and exhibited beach marks. The crack surface was at a 45 deg angle to the axis of the shaft, indicating dominant tensile stresses. The material was the French designation AFNOR 38CD4 (similar to AISI type 4140H) and was in the quenched-and-tempered condition, with a yield strength of about 760 MPa (110 ksi). It was treated to have compressive surface stresses, and the prior-austenite grain size was ASTM 8. Analysis (visual inspection, stress analyses, and macrographs) supported the conclusion that failure was caused by fatigue stress caused by surface defects in the oil holes. Recommendation includes drilling the oil holes by a technique that essentially eliminates surface defects.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"45 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":"127195072","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
Plug Weld Defects in Low-Carbon Steel Bomb Fins 低碳钢弹翼塞焊缺陷
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001909
M. Pepi
{"title":"Plug Weld Defects in Low-Carbon Steel Bomb Fins","authors":"M. Pepi","doi":"10.31399/asm.fach.process.c9001909","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c9001909","url":null,"abstract":"\u0000 Welded low-carbon steel bomb fins were rejected because of poor weld practice. Visual and metallographic examination revealed that the resistance plug welds that attach the outer skin to the inner spar displayed inadequate weld penetration. Recommended changes to the resistance welding parameters resulted in acceptable welds.","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":"129920990","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
Corrosion in Pyrotechnic Actuators 烟火执行器的腐蚀
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0049796
{"title":"Corrosion in Pyrotechnic Actuators","authors":"","doi":"10.31399/asm.fach.process.c0049796","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0049796","url":null,"abstract":"\u0000 Problems with materials compatibility were encountered in pyrotechnically driven devices used in a number of ordnance applications requiring rapid mechanical actuation. A fine bridgewire is located in contact with the chemical pyrotechnic, and the charge is ignited by electrical heating of the bridgewire. Evidence of severe corrosion was revealed on examination of the nickel-chromium-iron alloy bridgewire and the nickel-iron alloy pins. Metallic elements in the pin or bridgewire and substantial amounts of chlorine were detected from the x-ray spectra. Morphological changes indicative of decomposition and dissolution were revealed to have occurred in regions of the pyrotechnic that had been in contact with the bridgewire and pin surfaces by examination of the titanium-potassium perchlorate (Ti-K-Cl-O4) pyrotechnic. Substantial amounts of water were revealed to be associated with the surfaces of the titanium particles in the pyrotechnic by nuclear magnetic resonance. It was proposed that the chlorine-containing residue combined with the water from the pyrotechnic to form a thin aqueous film corroding the bridgewire and pins. A new cleaning procedure was implemented for the glass headers to eliminate the chloride contamination and a vacuum drying procedure was instituted for the pyrotechnic.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","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":"129000094","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
Discoloration of a Stainless Steel Tube after Pickling 不锈钢管在酸洗后变色
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001626
S. Suess
{"title":"Discoloration of a Stainless Steel Tube after Pickling","authors":"S. Suess","doi":"10.31399/asm.fach.process.c9001626","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c9001626","url":null,"abstract":"\u0000 A type 17-4PH stainless steel tube exhibited brown discoloration after a pickling operation. EDS analysis of the extracted substance revealed relatively high levels of iron and chromium, along with lower amounts of aluminum, silicon, sulfur, chlorine, calcium, manganese, and nickel. The iron, chromium, and nickel are likely in the form of dissolution products from the pickling solution. FTIR analysis revealed the presence of polypropylene and poly(ethylene:propylene). The EDS results showed that the discoloration of the tube was associated with oxidation products of the tube material, as well as adherent organic residue. Analysis by FTIR of the residue revealed detectable levels of two polymeric substances, which were later determined to be construction materials of the pickling tank. It was recommended that more frequent cleaning and/or replacement of the pickling solution be put into place and another type of tank material be considered.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"24 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":"130662096","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
Embrittlement of Stainless Steel by Liquid Copper From a Welding Fixture 焊接夹具中铜液对不锈钢的脆化
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0047602
{"title":"Embrittlement of Stainless Steel by Liquid Copper From a Welding Fixture","authors":"","doi":"10.31399/asm.fach.process.c0047602","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0047602","url":null,"abstract":"\u0000 Parts of 21Cr-6Ni-9Mn stainless steel that had been forged at about 815 deg C (1500 deg F) were gas tungsten arc welded. During postweld inspection, cracks were found in the HAZs of the welds. Welding had been done using a copper fixture that contacted the steel in the area of the HAZ on each side of the weld but did not extend under the tungsten arc. In SEM examination, the cracks appeared to be intergranular and extended to a depth of approximately 1.3 mm (0.05 in.). The crack appearance suggested that the surface temperature of the HAZ could have melted a film of copper on the fixture surface and that this could have penetrated the stainless steel in the presence of tensile thermal-contraction stresses. The cracks in the weldments were a form of liquid-metal embrittlement caused by contact with superficially melted copper from the fixture and subsequent grain-boundary attack of the stainless steel in an area under residual tensile stress. The copper for the fixtures was replaced by aluminum. No further cracking was encountered.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"8 3 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":"126669692","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 Pressure Vessel During Autofrettage Because of Scale Worked Into Forging Laps and Seams 压力容器在自强化过程中因锻造圈和接缝处的水垢而开裂
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0047144
{"title":"Cracking of a Pressure Vessel During Autofrettage Because of Scale Worked Into Forging Laps and Seams","authors":"","doi":"10.31399/asm.fach.process.c0047144","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0047144","url":null,"abstract":"\u0000 During autofrettage of a thick-wall steel pressure vessel, a crack developed through the wall of the component. Certain forged pressure vessels are subjected to autofrettage during their manufacture to induce residual compressive stresses at locations where fatigue cracks may initiate. The results of the autofrettage process, which creates a state of plastic strain in the material, is an increase in the fatigue life of the component. Analysis (visual inspection, 50x/500x unetched micrographs, and electron microprobe analysis) supports the conclusion that the fracture toughness of the steel was exceeded, and failure through the wall occurred because of the following reason: the high level of iron oxide found is highly abnormal in vacuum-degassed steels. Included matter of this nature (exogenous) most likely resulted from scale worked into the surface during forging. Therefore, it is understandable that failure occurred during autofrettage when the section containing these defects was subjected to plastic strains. Because the inclusions were sizable, hard, and extremely irregular, this region would effect substantial stress concentration. No recommendations were made.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","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":"121587687","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
Fatigue Fracture of a Highway Tractor-Trailer Steel Drawbar 公路拖拉机-挂车钢牵引杆疲劳断裂
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0046233
{"title":"Fatigue Fracture of a Highway Tractor-Trailer Steel Drawbar","authors":"","doi":"10.31399/asm.fach.process.c0046233","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0046233","url":null,"abstract":"\u0000 A drawbar connecting two tank-type trailers of a highway gasoline rig broke while the rig was on an exit ramp of an interstate highway. The drawbar was a weldment of steel plates, tubes, and castings. Light fractography showed no discernable causes for the failure, but a TEM fractograph at 20,000x revealed fatigue striations and corrosion products on the fracture surface, indicating that this area was probably the site of fracture origin and that it had cracked before the accident happened. The casting on the right side of the drawbar contained large voids and a significant amount of porosity. Electron fractography established that the cast connection on the left side failed by brittle fracture. Metallographic examination showed poor weld quality in the casting-to-tube joint. Evidence found supports the conclusions that the drawbar fractured in fatigue, which originated in the weld joining the cast connector to the right side of the drawbar assembly. The crack initiated in a region of poor weld quality. A contributing factor to fracture of both connectors was the presence of voids and porosity in the castings. Recommendations included revising the welding procedures and instituting receiving inspection of the connection castings.","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":"125291396","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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