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Brittle Fracture of a Clapper Weldment for a Disk Valve Due to Improper Filler Metal 由于填充金属不当导致阀瓣瓣焊件脆性断裂
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0048767
{"title":"Brittle Fracture of a Clapper Weldment for a Disk Valve Due to Improper Filler Metal","authors":"","doi":"10.31399/asm.fach.process.c0048767","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0048767","url":null,"abstract":"\u0000 The clapper in a 250 mm diam disk valve (made from ASTM A36 steel, stress relieved and cadmium plated) fractured at the welded joint between the clapper and a 20 mm diam support rod (also made of same material). The valve contained a stream of gas consisting of 55% H2S, 39% CO2, 5% H2, and 1% hydrocarbons at 40 deg C and 55 kPa during operation. Voids on the fracture surface and evidence of incomplete weld penetration were revealed by examination. Brittle fracture was indicated by the overall appearance through some fatigue beach marks were observed. Very narrow bands of high hardness were revealed at the edges of the weld metal. It was revealed by chemical analysis of this band that a stainless steel filler metal had been used which produced mixed composition at the weld boundaries. The plating material was revealed to be nickel by chemical analysis. It was concluded that clapper failed by fatigue and brittle fracture because it was welded with an incorrect filler metal. A clapper assembly was welded with a low-carbon steel filler metal, then cadmium plated.","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":"129514679","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 Non-Magnetic Rotor Banding Wire From Stress-Corrosion 非磁性转子带线应力腐蚀失效研究
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001397
{"title":"Failure of Non-Magnetic Rotor Banding Wire From Stress-Corrosion","authors":"","doi":"10.31399/asm.fach.process.c9001397","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c9001397","url":null,"abstract":"\u0000 Banding wires of the rotor of an 1800 hp motor were renewed following replacement of the banding rings. After about six months of service, a breakdown occurred due to bursting of the banding wires in several places. The 0.064 in. diam wire was nonmagnetic and of the 18/8 Cr-Ni type of austenitic stainless steel. The fractures were short and partially crystalline, with no evidence of slowly developing cracks of the fatigue type. Microscopical examination of sections taken through the fractures showed the cracking to be of the multiple branching type. Because the material was in the heavily cold-worked condition, it was not possible to determine with certainty if the cracks were of the inter- or trans-granular type. It was concluded that failure was due to stress-corrosion cracking in a chloride environment. Failure of the wires was likely due to the use of a chloride-containing flux during the soldering operation.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"56 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":"128508589","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
Primary Grain Boundary Cracks in Cast Ingots and Flaky Crankshafts 铸锭和片状曲轴的初生晶界裂纹
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001253
F. Naumann, F. Spies
{"title":"Primary Grain Boundary Cracks in Cast Ingots and Flaky Crankshafts","authors":"F. Naumann, F. Spies","doi":"10.31399/asm.fach.process.c9001253","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c9001253","url":null,"abstract":"\u0000 Octagonal cast ingots weighing 6.5 tons and made of unalloyed heat treated steel CK 45 according to DIN 17200, and crankshafts forged from these ingots showed internal separations during ultrasonic testing. To determine the cause of defect, an ingot slice and a crank arm were examined metallographically. Investigation showed this was a case where flaky forgings were made from cast ingots with primary grain boundary cracks. This parallelity supports the often expressed opinion that both occurrences have the same origin, i.e. that hydrogen precipitation was the driving force in the formation of primary grain boundary cracks in cast ingots.","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":"124286602","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 Electron Fractography to Diagnose Cracking in a 7075-T6 Aluminum Forging 利用电子断口学诊断7075-T6铝合金锻件裂纹
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001541
J. A. Scott
{"title":"Use of Electron Fractography to Diagnose Cracking in a 7075-T6 Aluminum Forging","authors":"J. A. Scott","doi":"10.31399/asm.fach.process.c9001541","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c9001541","url":null,"abstract":"\u0000 A forging of 7075-T6 aluminum alloy, which formed a support for the cylinder of a cargo door, cracked at an attachment hole. Fluorescent penetrant inspection showed the crack ran above and below the hole out onto the machined flat surface of the flange. A 6500x electron fractograph proved the crack to be a forging defect called a cold shut. Because defects of this type are usually detected when the raw forging is inspected, this occurrence was considered to be an isolated instance.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"25 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":"123342367","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 Zinc Layer on a Hot-Galvanised Hook 热镀锌钩上的脆锌层
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001215
Egon Kauczor
{"title":"Brittle Zinc Layer on a Hot-Galvanised Hook","authors":"Egon Kauczor","doi":"10.31399/asm.fach.process.c9001215","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c9001215","url":null,"abstract":"\u0000 The surface of a hook did not possess the smooth and shiny zinc bloom surface normally observed on hot galvanized steel parts but was matte and rough. Large cracks were observed in the zinc layer. The hook was made of silicon-killed alloy steel 41Cr4. A silicon content of 0.27% was established analytically. Silicon accelerates the reaction between iron and zinc, which should have been taken into account in the present case by reducing the dip time or a small addition of aluminum (0.1 to 0.2%) to the galvanizing bath to retard the extremely rapid growth of the zinc layer and the strong alloy formation. Even in the case of steel parts with lower silicon contents the reaction between iron and zinc can continue until the pure zinc layer has been consumed entirely if the work piece is not cooled sufficiently after withdrawal.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"28 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":"131759841","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 Clamp-Strap Assembly 夹带组件的脆性断裂
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0045988
{"title":"Brittle Fracture of a Clamp-Strap Assembly","authors":"","doi":"10.31399/asm.fach.process.c0045988","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0045988","url":null,"abstract":"\u0000 During installation, a clamp-strap assembly, specified to be type 410 stainless steel-austenitized at 955 to 1010 deg C (1750 to 1850 deg F), oil quenched, and tempered at 565 deg C (1050 deg F) for 2 h to achieve a hardness of 30 to 35 HRC, and used for securing the caging mechanism on a star-tracking telescope, fractured transversely across two rivet holes closest to one edge of the pin retainer in a completely brittle manner. Comparison with a non-failed strap using microscopic examination, spectrographic analysis, and slow-bend tests showed that both fit the 410 stainless steel specs, but hardness and grain size were different. Reheat treatment of full-width specimens showed that coarse grain size (ASTM 2 to 3) was responsible for the brittle fracture, and excessively high temperature during austenitizing caused the large grain size in the failed strap. The fact that the hardness of the strap that failed was lower than the specified hardness of 30 to 35 HRC had no effect on the failure because that of the non-failed strap was even lower. Recommendation was that the strap should be heat treated as specified to maintain the required ductility and grain size.","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":"122649181","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
True Brinelling of Ball-Bearing Raceways During Ultrasonic Cleaning 超声清洗过程中滚珠轴承滚道的真正布林化
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0047956
{"title":"True Brinelling of Ball-Bearing Raceways During Ultrasonic Cleaning","authors":"","doi":"10.31399/asm.fach.process.c0047956","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0047956","url":null,"abstract":"\u0000 Randomly selected dictating-machine drive mechanisms, which contained small ball bearings, were found to exhibit unacceptable fluctuations in drive output during the early stages of production. It was indicated that the bearing raceways were being true brinelled before or during installation of the bearings. The preinstallation practices and the procedures for installing the bearings were carefully studied. It was revealed that during one preinstallation step, the lubricant applied by the bearing manufacturer was removed and the bearing was relubricated with another type of lubricant prior to which the bearings were ultrasonically cleaned in trichloroethylene to ensure extreme cleanness. Equally spaced indentations resembling true brinelling were revealed by careful examination of the bearing raceways. It was concluded that the ultrasonic energy transmitted to the balls brinelled the raceways enough to cause fluctuations in machine output. Solvent-vapor cleaning was employed as a corrective technique for removing bearing lubricant.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"16 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":"129640884","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
Assessing the Durability of Aluminum Castings 铝铸件耐久性评估
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001640
D. Aliya
{"title":"Assessing the Durability of Aluminum Castings","authors":"D. Aliya","doi":"10.31399/asm.fach.process.c9001640","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c9001640","url":null,"abstract":"\u0000 A new supplier for aluminum die castings was being evaluated, and the castings failed to meet the durability test requirements. Specifically, the fatigue life of the castings was low. Initial inspection of the fatigue fracture surfaces revealed large-scale porosity visible to the naked eye. New castings with reduced porosity also failed the durability tests. The fatigue fracture surfaces of additional casting fragments were very rough and contained multiple ratchet marks along the inner fillet. These observations indicated the fatigue process was heavily influenced by the presence of surface imperfections. Improving the surface finish or choosing a stronger alloy, were more likely to improve part durability than reducing the porosity.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","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":"126582926","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 Clamp Because of Burning During Forging 锻造过程中因燃烧造成的夹钳脆性断裂
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0047176
{"title":"Brittle Fracture of a Clamp Because of Burning During Forging","authors":"","doi":"10.31399/asm.fach.process.c0047176","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0047176","url":null,"abstract":"\u0000 A ring clamp (8740 (AMS 6322), steel forged and cadmium plated) used for attaching ducts to an aircraft engine became loose after three hours of service. When the clamp was removed from the engine, the hinge tabs on one clamp half were found to be broken. Analysis (visual inspection and microscopic and metallographic examination) supported the conclusion that both hinge tabs on the clamp half fractured in a brittle manner as the result of gross overheating, or burning, during forging. The mechanical properties of the metal, especially toughness and ductility, were greatly reduced by burning. Evidence that burning was confined to the hinge end of the clamp indicated that the metal was overheated before or during the upset forging operation. Recommendations included notifying the supplier of the burned condition on the end of the clamp. The clamps should be macroetched before cadmium plating to detect overheating. The clamps in stock should be inspected to ensure that the metal had not been weakened by overheating during the upset forging operation.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"27 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":"128120598","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
Printed Circuit Board Failures at Plated Through Holes 印刷电路板镀通孔故障
ASM Failure Analysis Case Histories: Processing Errors and Defects Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001493
{"title":"Printed Circuit Board Failures at Plated Through Holes","authors":"","doi":"10.31399/asm.fach.process.c9001493","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c9001493","url":null,"abstract":"\u0000 An open electrical circuit was found between plated through-holes in a six-layer printed circuit board after thermal cycling. The copper plating was very thin in the failure area but did make an electrical contact during initial testing. During thermal cycling, differential z-expansion between the epoxy board and copper caused the thin plating to crack. During electrical testing of a four-layer circuit board, an open electrical circuit was found between the plated through-holes. Plating discontinuity was caused by poor drilling using a dull drill with improper speed (rpm) and/or feed rate as was observed by nonuniform plating and nodule formation in the plated layer. In a third example, an open electrical circuit was found in a six-layer board between two adjacent plated through-holes. A plating void was on one side of the conductor joining the two holes. Continuity was found when tested from one side of the board but lost when tested from the other. In a fourth case, an open circuit found between a plated through-hole and contact pad on a six-layer printed circuit board was caused by an etching defect.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","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":"128469954","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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