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Iván Uribe Pérez, Tito Luiz da Silveira, Tito Fernando da Silveira, Heloisa Cunha Furtado
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1-6 of 6
Microcracking
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Series: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006916
EISBN: 978-1-62708-395-9
Abstract
This article focuses on manufacturing-related failures of injection-molded plastic parts, although the concepts apply to all plastic manufacturing processes It provides detailed examples of failures due to improper material handling, drying, mixing of additives, and molecular packing and orientation. It also presents examples of failures stemming from material degradation improper use of metal inserts, weak weld lines, insufficient curing of thermosets, and inadequate mixing and impregnation in the case of thermoset composites.
Book Chapter
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001813
EISBN: 978-1-62708-241-9
Abstract
Graphitization, the formation of graphite nodules in carbon and low alloy steels, contributes to many failures in high-temperature environments. Three such failures in power-generating systems were analyzed to demonstrate the unpredictable nature of this failure mechanism and its effect on material properties and structures. In general, the more randomly distributed the nodules, the less effect they have on structural integrity. In the cases examined, the nodules were found to be organized in planar arrays, indicating they might have an effect on material properties. Closer inspection, however, revealed that the magnitude of the effect depends on the relative orientation of the planar arrangement and principle tensile stress. For normal orientation, the effect of embrittlement tends to be most severe. Conversely, when the orientation is parallel, the nodules have little or no effect. The cases examined show that knowledge is incomplete in regard to graphitization, and the prediction of its occurrence is not yet possible.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c9001546
EISBN: 978-1-62708-217-4
Abstract
A longeron assembly constructed of Alclad 2024, some parts being in the T3 condition, others in the T42 condition, failed at a rivet hole. Plastic deformation at the crack site was found, but no plastic deformation was found in similar failed components. It was concluded that the numerous hairline cracks in the Alclad layer adjacent to the main fracture were fatigue cracks. In another case, bonded samples of 2024-T3 sheet were fatigue tested at various stress levels. Failures could be separated into three groups: those that failed in the adhesive bond, those that failed in the base material, and those that exhibited a dual failure. The last category failed in the adhesive bond and also showed a type of pitting on one face of the base material. In a third case, a 2024-T4 extrusion section was found to exhibit blistering after chemical milling. The presence of interconnecting microcracks between adjacent discontinuities supported a hydrogen blistering diagnosis.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0090030
EISBN: 978-1-62708-217-4
Abstract
A DC-10 in transit from Denver to Chicago experienced failure of the center engine. The titanium compressor disk burst and severed the hydraulics of the plane. Investigation supports the conclusion that the cause of the disk rupture was the presence of a large fatigue crack near the bore emanating from a hard alpha (HA) defect. Such defects can result from occasional upsets during the vacuum melting of titanium. These nitrogen-rich alpha titanium anomalies are brittle and often have associated microcracks and microvoids. A probabilistic damage tolerance approach was recommended to address the anomalies, with the objective of enhancing rotor life management practices. The ongoing work involves the use of fracture mechanics and software (called DARWIN.) optimized for damage tolerant design and analysis of metallic structural components.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.homegoods.c0048536
EISBN: 978-1-62708-222-8
Abstract
A brittle-like crack propagation caused failure in a rubber office-chair roller. A crack initiated from the inside of the roller and propagated in a discontinuous brittle-like fashion, as indicated from the evolution of concentric fracture striations. Compressive fatigue was a dominant mode of loading. Nevertheless, the fracture surface of the failure-causing crack suggested a tensile-stress component was involved in driving failure.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c0048845
EISBN: 978-1-62708-229-7
Abstract
The maximum life of base-loaded headers and piping is not possible to be predicted until they develop microcracking. The typical elements of a periodic inspection program after the occurrence of the crack was described extensively. Cracks caused by creep swelling in the stub-to-header welds in the secondary superheater outlet headers (constructed of SA335-P11 material) of a major boiler were described as an example. The OD of the header was measured to detect the amount of swelling and found to have increased 1.6% since its installation. Ligament cracks extending from tube seat to tube seat were revealed by surface inspection. Cracks were found to originate from inside the header, extend axially in the tube penetrations and radially from those holes into the ligaments. Cracks in 94 locations, ranging from small radial cracks to full 360Ý cracks were revealed by dye-penetrant inspection. The unit was operated under reduced-temperature conditions and with less load cycling than previously until a redesigned SA335-P22 header was installed.