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Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001416
EISBN: 978-1-62708-235-8
Abstract
Hydraulic cylinders on three identical presses failed in a similar manner after approximately ten years' service life. The cylinder was a steel casting having a carbon content of the order of 0.3 to 0.4%. During machining of the internal surfaces, a sharp corner had been left at the junction of the head with the shell. From this stress raiser a fatigue crack had developed around the entire circumference of the cylinder to give a smooth crack of annular form. The use of a flat end to the cylinder, therefore, resulted in excessive stresses being introduced at the junction of the end with the cylinder.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.usage.c0047545
EISBN: 978-1-62708-236-5
Abstract
The AISI 1080 steel crankshaft of a large-capacity double-action stamping press broke in service and was repair welded. Shortly after the crankshaft was returned to service, the repair weld fractured. The repair-weld fracture was examined ultrasonically which revealed many internal reflectors, indicating the presence of slag inclusions and porosity. A low-carbon steel flux-cored filler metal was used in repair welding the crankshaft, without any preweld or postweld heating. This resulted in the formation of martensite in the HAZ. The repair weld failed by brittle fracture, which was attributed to the combination of weld porosity, many slag inclusions and the formation of brittle martensite in the HAZ. A new repair weld was made using an E312 stainless steel electrode, which provides a weld deposit that contains considerable ferrite to prevent hot cracking. Before welding, the crankshaft was preheated to a temperature above which martensite would form. After completion, the weld was covered with an asbestos blanket, and heating was continued for 24 h. During the next 24 h, the temperature was slowly lowered. The result was a crack-free weld.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.usage.c9001016
EISBN: 978-1-62708-236-5
Abstract
An automatic press for making burlap bags had been used for several years. The press failed after being shipped by truck for a distance of about 400 mi. The objective was to determine whether failure occurred during or before shipment. The large piece which broke off the press included a section of the ways and a heavy adjustable mechanism which normally rides on these ways. The weight of the broken section was estimated at several hundred pounds. There was no support for the broken piece beyond the point of breakage. The material was a commercial cast iron, and the largest proportion of the fracture area was fresh and bright. It was concluded that this was a fresh fracture which occurred during shipment, and the crack itself was not present prior to shipment. The fact that a material defect of some sort was present and probably determined the location of the crack was apparently not significant as far as its usage was concerned. The failure could have been avoided by providing support underneath the overhanging member.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001188
EISBN: 978-1-62708-235-8
Abstract
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.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.machtools.c0045903
EISBN: 978-1-62708-223-5
Abstract
A 230 mm (9 in.) thick casing, fabricated from ASTM 235-55 low-carbon steel, of a 450 Mg (500 ton) extrusion press failed after 27 years of service. Initial visual examination revealed an area that exhibited multiple origins and classic beach marks radiating out approximately 75 mm (3 in.) from the origin along the wall of a hydraulic-oil bleed hole. Investigation with a SEM showed corrosion pits along the bleed hole wall, but oxidation and corrosion prevented review of microfractographic details. Vacuum epoxy encapsulation, sectioning of the bleed hole, and metallographic examination revealed a basic microstructure of pearlite and ferrite with bands of slightly finer pearlite, with a large concentration of inclusion stringers in the area of the fracture origin. Further investigation using an energy-dispersive x-ray analyzer showed high concentrations of sulfur and manganese. Thus, the failure appeared to have resulted from corrosion-assisted fatigue, and the inclusion concentration in the fracture-initiated area indicated that the chemical-composition limits for sulfur and manganese would have greatly exceeded material specifications. A higher quality steel was recommended for the replacement unit to lessen the possibility of such gross inclusion segregation and to improve the fracture toughness of the cylinder.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.machtools.c9001154
EISBN: 978-1-62708-223-5
Abstract
The cause of fracture of two piston rods of hammers of a drop forge was determined. The first rod of 180 mm diam consisted of an unalloyed steel with 0.37% C and 0.67% Mn and had a strength of 56 kp/sq mm at 26% elongation. Fatigue fractures propagated from several points which could be recognized as flaky cracks already in the fracture, and which later were united. No material defects could be detected in the cross section parallel to the fracture plane except for these very short cracks. These comparatively insignificant defects were sufficient to cause the fracture during high impact fatigue stresses in the drop forge. The second piston rod of 120 mm diam consisted of a steel with 0.25% C and 1.00% Mn. It allegedly had 57 kp/sq mm tensile strength and 26% elongation. The basic structure of the 120 mm piston rod was ferritic-pearlitic and hardness of 155 Brinell was accordingly low, corresponding to approximately 53 kp/sq mm tensile strength. The incipient fractures had no connection with the material defects in this shaft and therefore the fracture could not have been caused by them. Probably the low strength of the piston rod was insufficient for the high stresses.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.machtools.c9001183
EISBN: 978-1-62708-223-5
Abstract
In a continuously cast aluminum press stud, two small foreign metal slivers were found that had caused difficulties with the cable sheathing press. Spectroscopic examination revealed the slivers consisted of a chromium-molybdenum-vanadium steel with minor (unintentional) additions of copper, nickel, and cobalt. A steel of similar composition, X38Cr-MoV5 1 (W-No. 2343) was used for hot working tools. The sliver originated from a damaged press tool.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.machtools.c9001413
EISBN: 978-1-62708-223-5
Abstract
The fractured end of a piston rod of a hydraulic press failed in line with the leading face of the piston retaining nut. Although the nut apparently had been seated uniformly, the face was polished, indicating that relative movement between it and the piston had taken place. Failure resulted from the culmination of two principal fatigue cracks which developed on approximately parallel planes from the roots of adjacent threads. A longitudinal section through the screw thread on the piston rod showed it had been carburized but not hardened, and that subsequent surface de-carburization to a depth of approximately 0.001 in. had occurred. It was concluded that insufficient tightening, as evidenced by the polish markings, was the main reason for failure, the portion of the rod therefore being subjected to a greater variation of cyclic stress during operation. The presence of the de-carburized layer lowered its resistance to the initiation of a fatigue crack to that of iron, considerably less than the resistance of the mild steel from which the rod was made and well below that shown by the carburized layer.
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001288
EISBN: 978-1-62708-215-0
Abstract
The side supporting flange of the bottom platen of an 800 ton hydraulic press fractured after 9 x 10's cycles under a maximum load of 530 tons. The platen material specified in the design was cast steel 52. Metallographic examination of the fracture surface indicated that the platen had failed in fatigue as a result of a high stress concentration in a sharp 0.6 mm (0.02 in.) radius fillet. Stress analysis and fracture mechanics predictions revealed that there was also danger of fatigue failure for platens with the design radius of 10 mm (0. 4 in.) if the press operates at 800 tons. It was recommended that the remaining life of similar presses be assessed periodically controlling the cracks, their dimensions, and their propagation rates. An increase in the radius of the fillet was also recommended.