Search Results for weld failure

A new design and welding process may extend the life of furnace rolls in hot-dip coating lines, which often fail in less than one year. This article is a case study of analysis of a failed furnace roll that led to a proposed improved design to extend component life.

Typical vehicles contain more than 3000 spot welds, and failure parameters for these welds must be accurately predicted in crash simulations. A testing protocol developed at EWI for the purpose of creating spot weld failure parameters has been used since 2010 to establish these parameters for automotive manufacturers for a range of steel and aluminum stack-ups. Crash simulations in full-vehicle models show that the failure parameters created by this method are accurate for predicting the initiation of spot weld failure by comparing results with experimental data.

Through a series of case studies, the benefits of micro x-ray fluorescence (XRF) over traditional XRF are demonstrated in the power generation industry for informing weld procedures, identifying root cause, and providing materials or component specifications.

Advanced instrumentation combined with effective test procedures gives manufacturers an edge in measuring and analyzing welds.

This article describes how shielding gas composition, either argon or nitrogen, affects the hardness, tensile strength, and toughness of high-power, high-brightness laser welds made on various base materials, including A508 forging steel, 316L stainless steel, Inconel 690, and solution-annealed IN718.

Compared to traditional power plant materials, creep strength enhanced ferritic steels require new approaches to nondestructive examination and weld repair. The metallurgical complexity of these steels prompted EPRI to conduct research to define and/or improve the detection limits of ultrasonic testing techniques, explore novel electromagnetic techniques, evaluate the sensitivity and applicability of acoustic emission testing, and conduct studies on improved weld repair procedures.

Two case studies highlight the strengths and weaknesses between traditional metallurgical techniques and 3D micro-computed tomography, as well as the interplay between the two.

This article describes the investigation conducted by the National Transportation Safety Board following an explosion triggered by a natural gas pipeline rupture. In addition to determining the likely cause of the rupture, the NTSB issued safety recommendations calling for hydrostatic pressure testing of similar gas lines and making them more amenable to inline inspection methods.

In this brief case study, finite element analysis and linear elastic fracture mechanics are used to evaluate new weld designs for large marine engines.

Compared with traditional fatigue testing, the ultrasonic method achieves much speedier results along with the ability to run extremely high test cycles in a reasonable time frame.

A new solid-state joining process for medical guidewire applications increases joint strength, provides superior bending properties, and does not require tertiary metals or ferrules. This process may be a superior method to create joints between dissimilar metals such as stainless steel and Nitinol.

This article presents highlights from a panel session held at International Materials, Applications & Technologies (IMAT) 2023. Experts from ASM affiliate societies shared insights on the impact of new materials and manufacturing technologies in their respective fields. The panel was moderated by David Furrer, Pratt & Whitney. The panelists were Thomas Ackerson, Blue Origin LLC (representing the Failure Analysis Society); Arvind Agarwal, College of Engineering and Computing, Florida International University (Thermal Spray Society); Marvin Barnes, NASA (Heat Treating Society); Jay Demarest, IBM (Electronic Device Failure Analysis Society); and Laura Moyer, Lehigh University (International Metallographic Society).

Samuel Leslie Hoyt was one of the earliest metallurgists to receive his advanced training in Europe. He was involved in many of the key metallurgical developments in the middle part of the 20th century and also wrote about the achievements of his peers in the book Men of Metals.

Self-pierce riveting is a candidate for joining magnesium alloy sheet, extrusions, and castings in automotive applications. This article evaluates the fatigue performance of magnesium lap joints held together by laser-assisted self-piercing rivets (SPR) with and without the addition of adhesives.

Automobile performance and passenger safety both rely on sound spot welds in advanced high-strength steels. A new, high-frequency ultrasonic matrix phased array probe performs nondestructive inspection of these welds, saving time and cost.

Advanced materials engineering is being used to solve component life cycle improvement challenges in extremely harsh working conditions. This article discusses examples from various industries where new materials and surface modifications are used to extend the useful life of engineering components and equipment.

News about ASM members, chapters, events, awards, conferences, affiliates, and other society activities. Topics include: ASM Board nominees for 2019-2022 announced; ASM partnerships with Intelligent Manufacturing Systems and its World Manufacturing Forum (IMS/WMF) and with the Materials Research Society (MRS); ASM Materials Camp celebrates 20 years.

Stress corrosion cracking is an insidious form of damage that can occur when a susceptible metal is subjected to a tensile stress in a specific environment. To relieve tensile stresses at welded joints, postweld heat treatment can be helpful in reducing the susceptibility of carbon steel fabrications to SCC. When planning to use stainless steels in chloride-containing environments, it is advisable to select alloys that have been specifically developed to resist stress chloride cracking such as ferritic-austenitic (duplex) alloys, low-carbon ferritic alloys, and 6% Mo austenitic alloys or to select high-nickel alloys.

News about ASM members, chapters, events, awards, conferences, affiliates, and other society activities. Topics include: ASM Nominating Committee announces the officer nominations for 2021; update and revision of the ASM Constitution; column from ASM President Diana Essock regarding the principles of a stronger community; outlook for new energy storage professionals by Pralav P. Shetty; professional profile for Yan Li; contributor profile for Brett A. Miller.

This case study measures residual stress on a truck axle housing as it goes through the manufacturing process.