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A 25 mm (1 in.) diam carrier shaft failed suddenly during operation. The shaft failed near the toe of the 4.8 mm (316 in.) frame-to-shaft 60 deg and 120 deg submerged metal arc (SMA) tack welds after an unknown time in service. Material specifications called for the shaft to be made from SAE 1018 cold-rolled carbon steel. Carrier assembly components were made from type 300 stainless steel, and all nuts, spacers, and washers were to be SMA tack welded to the stainless steel frame. Chemical analyses (OES, SEM/EDS) showed the shaft to actually be made from SAE 1050 high-carbon...

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