In this study, the failure modes of cartwheel and mechanical properties of materials have been analyzed. The results show that rim cracking is always initiated from stringer-type alumina cluster and driven by a combination effect of mechanical and thermal load. The strength, toughness, and ductility are mainly determined by the carbon content of wheel steels. The fatigue crack growth resistance is insensitive to composition and microstructure, while the fatigue crack initiation life increases with the decrease of austenite grain size and pearlite colony size. The dynamic fracture toughness, KID, is obviously lower than static fracture toughness, KIC, and has the same trend as KIC. The ratio of KID/sigma YD is the most reasonable parameter to evaluate the fracture resistance of wheel steels with different composition and yield strength. Decreasing carbon content is beneficial to the performance of cartwheel.

During construction of a revolving sky-tower observatory, a 2.4 m (8 ft) diam cylindrical column developed serious circumferential cracks overnight at the 14 m (46 ft) level where two 12 m (40 ft) sections were joined by a girth weld. The temperatures ranged from 12 deg C (53 deg F) to 7 deg C (45 deg F) that night. The column was shop fabricated in 12 m (40 ft) long sections of 19 mm (3/4 in.) thick steel plate of ASTM A36 steel. Crack initiation was caused by high residual stress during girth welding, and the presence of notches formed by the termination of the incomplete welds. Continuation of the cracks was attributed to the brittle condition of the steel when cooled by the night air. A steel with a much lower ductile-to-brittle transition temperature is essential for this type of structure. Other necessary steps include better control of the girth-welding, choice of a more favorable electrode to avoid porosity, careful termination of all welds to avoid formation of notches, and completion of all welds before other sections of the column are erected.

A 208 cm (82 in.) ID steel aqueduct (ASTM A572, grade 42, type 2 steel) fractured circumferentially at two points 152 m (500 ft) apart in a section above ground. A year later, another fracture occurred in a buried section 6.4 km (4 mi) away. Both pipes fractured during Jan at similar temperatures and pressures. The pipe had a 24 mm wall thickness, and the hydrostatic head was 331 m (1085 ft). The air temperature was approximately -13 deg C (9 deg F), the water temperature approximately 0.6 deg C (33 deg F), and the steel temperature approximately -4 deg C (25 deg F). The pipe had been shop-fabricated in 12 m (40 ft) lengths, then shop welded into 24 m (80 ft) lengths. Field assembly was with bell-and-spigot joints. Investigation (visual inspection and Charpy V-notch testing) supported the conclusion that brittle fracture of the aqueduct pipe was attributed to a combination of stress concentrations at the toes of the fillet welds due to poor welding technique, including shop welds made without preheat, and a brittle condition of the steel at winter temperatures. Recommendations included revised welding techniques, installation of expansion joints, and the use of steel plate rolled from fully killed ingots.

In 1979, during a routine bridge inspection, a fatigue crack was discovered in the top flange plate of one tie girder in a tied arch bridge crossing the Mississippi River. Metallographic analysis indicated a banding or segregation problem in the middle of the plate, where the carbon content was twice what it should have been. Based on this and results of ultrasonic testing, which revealed that the banding occurred in 24-ft lengths, it was decided to close the bridge and replace the defective steel. The steel used in the construction of this bridge was specified as ASTM A441, commonly used in structural applications. Testing showed an increase in hardness and weight percent carbon and manganese in the banded region. Further testing revealed that the area containing the segregation and coarse grain structure had a lower than expected toughness and a transition temperature 90 deg F higher than specified by the ASTM standards. The fatigue crack growth rate through this area was much faster than expected. All of these property changes resulted from increased carbon levels, higher yield strength, and larger than normal grain size.

In TAKR 300 (Bob Hope) Class transport ships, the builder observed cracking of steel cloverleaf vehicle tie-down deck sockets following installation. Sockets were made from AH36 steel plate by flame cutting and cold coining, then submerged-arc welded to the shop deck. Cracks initiated from the tip of the cloverleaf pattern in >300 cases aboard several cargo vessels in various stages of construction. Consultants who analyzed the situation concluded that the problem may have been corrosion and hydrogen embrittlement. Three possible mechanisms of failure were considered: overload failure; fatigue fracture; and, environmentally-assisted cracking. Testing indicated overload failure was the cause. Remedial actions were taken to improve the fracture properties of the deck socket. A modified manufacturing process was developed involving milling and cutting instead of coining to round the comers of the flame-cut cloverleaf lobe. This new manufacturing process solved the problem.

A forged alloy steel arm of a lifting fork with an approximate cross section of 150 x 240 mm (5.92 x 9.45 in.) fractured after only a short service life on a lift truck. The fracture surface had the appearance of a fracture originating from a surface crack. Analysis (visual inspection, 200x micrographs, chemical analysis, and metallographic examination) supported the conclusion that the primary cause of the failure was the brittleness (lack of impact toughness) of the steel. The coarse bainitic microstructure was inadequate for the service application. The microstructure resulted from either improper heat treatment or no heat treatment after the forging operation. The surface cracks in the lifting-fork arm acted as starter notches (stress raisers), assisting in the initiation of fracture. No recommendations were made.

A metallurgical failure analysis was performed on pieces of the cracked vent header pipe from the Edwin I. Hatch Unit 2 Nuclear power plant. The analysis consisted of optical microscopy, chemical analysis, mechanical Charpy impact testing, and fractography. It was found that the material of the vent header met the mechanical and chemical properties of ASTM A516 Grade 70 carbon-manganese steel material and microstructures were consistent with this material. Fracture faces of the cracked pipe were predominantly brittle in appearance with no evidence of fatigue contribution. The NDTT (Nil ductility Transition Temperature) for this material was approximately -51 deg C (-60 deg F). The fact that the material's NDTT was significantly out of the normal operating range of the pipe suggested an impingement of low temperature nitrogen (caused by a faulty torus inerting system) induced a thermal shock in the pipe which, when cooled below its NDTT, cracked in a brittle manner.

A support arm on a front-end loader failed in a brittle manner while lifting a load. The arm had a cross section of 50 x 200 mm (2 x 8 in.). Material used for the arm was hot-rolled ASTM A572, grade 42 (type 1), steel, which exhibited poor impact properties in the as-rolled condition and had a ductile-to-brittle transition temperature exceeding 93 deg C (200 deg F). This transition temperature was much too high for the application. It was recommended that a modified ASTM A572, grade 42 (0.15% C max), type 1 or 2, steel be used (type 1, which contains niobium, may be needed to meet strength requirements). The steel should be specified to be killed, fine-grained, and normalized, with Charpy V-notch impact-energy values of 20 J (15 ft·lbf) at -46 deg C (-50 deg F) in the longitudinal direction and 20 J (15 ft·lbf) at -29 deg C (-20 deg F) in the transverse direction.

A riveted 0.25% carbon steel oil-storage tank in Oklahoma was dismantled and reassembled in Minnesota by welding to form a storage tank for soybean oil. An opening was cut in the side of the tank to admit a front-end loader. A frame of heavy angle iron was welded to the tank and drilled for bolting on a heavy steel plate. The tank was filled to a record height. In mid-Jan the temperature dropped to -31 deg C (-23 deg F), with high winds. The tank split open and collapsed. The welding used the shielded metal arc process with E6010 electrodes, which could lead to weld porosity, hydrogen embrittlement, or both. At subzero temperatures, the steel was below its ductile-to-brittle transition temperature. These circumstances suggest a brittle condition. Steps to avoid this type of failure: For cold conditions, the steel plate should have a low carbon content and a high manganese-to-sulfur ratio and be in a normalized condition, low-hydrogen electrodes and welding practices should be used, all corners should be generously radiused, the welds should be inspected and ground or dressed to minimize stress concentrations, postweld heating is advisable, and radiographic and penetrant inspection tests should be performed.

The splined shaft (1040 steel, heat treated to a hardness of 44 to 46 HRC and a tensile strength of approximately 1448 MPa, or 210 ksi) from a front-end loader used in a salt-handling area broke after being in service approximately two weeks while operating at temperatures near -18 deg C (0 deg F). During the summer, similar shafts had a service life of 5 to eight months. Examination of the fracture surface showed brittle fatigue cracks, and visual examination of the splines disclosed heavy chatter marks at the root of the spline, with burrs and tears at the fillet area. Evidence found supports the conclusion that the shaft failed as the result of stress in the sharp fillets and rough surfaces at the root of the splines. Cold weather failure occurred sooner than in hot weather because ductile-to-brittle transition temperature of the 1040 steel shaft was too high. Recommendations include redesign of the fillet radius to a minimum of 1.6 mm (0.06 in.) and a maximum surface finish in the spline area of 0.8 microns. Material for the shafts should be modified to a nickel alloy steel, heat treated to a hardness of 28 to 32 HRC before machining.

The 8620 steel latch tip, carburized and then induction hardened to a minimum surface hardness of 62 HRC, on the main-clutch stop arm on a business machine fractured during normal operation when the latch tip was subjected to intermittent impact loading. Fractographic examination 9x showed a brittle appearance at the fractures. Micrograph examination of an etched section disclosed several small cracks. Fracture of the parts may have occurred through similar cracks. Also observed was a burned layer approximately 0.075 mm (0.003 in.) deep on the latch surface, and hardness at a depth of 0.025 mm (0.001 in.) in this layer was 52 HRC (a minimum of 55 HRC was specified). Thus, the failure was caused by brittle fracture in the hardness-transition zone as the result of excessive impact loading. The burned layer indicated that the cracks had been caused by improper grinding after hardening. Redesign was recommended to include reinforcing the backing web of the tip, increasing the radius at the relief step to 1.5 x 0.5 mm (0.06 x 0.02 in.), the use of proper grinding techniques, and a requirement that the hardened zone extend a minimum of 1.5 mm (0.06 in.) beyond the step.

After a quick-release fitting of an ejection seat broke, an investigation was performed to determine the manner and cause of crack propagation. Most fractography-based investigations aim to characterize only qualitative characteristics, such as the fracture orientation and origin position, topology, and details of interactions with microstructural features. The aim of this investigation was to use quantitative fractography as a tool to extract information, including striation spacing and size of the stretched zone, in order to make a direct correlation with fracture mechanic concepts. As the crack propagated, striations were created on the fracture surface as a result of service-induced load changes. The size of the striations were measured to estimate crack propagation rate. Remaining lifetime estimates were also made. The dimensions of plastically stretched zones found at the tips of the cracks were evaluated using electron micrograph stereo image pairs to characterize local fracture toughness. To complete the failure analysis, nondestructive evaluation, metallographic examination, and chemical investigations were carried out. No secondary cracks could be found. Most of the broken parts showed that the microstructure, the hardness, and the chemical composition of the Al-alloy were within the specification, but some of the cracked parts were manufactured using a different material than that specified.

Optimized modeling of fracture-critical structural components and connections requires the application of elastic-plastic fracture mechanics. Such applications, however, can require sophisticated analytical techniques such as crack tip opening displacement (CTOD), failure assessment diagram (FAD), and deformation plasticity failure assessment diagram (DPFAD). This article presents the origin and description of FAD and addresses R6 FAD using J-integral. It details the fracture criteria of BS 7910. The factors to be considered during the use of FAD and the applications of FAD are also reviewed.

The article commences with an overview of short-term and long-term mechanical properties of polymeric materials. It discusses plasticization, solvation, and swelling in rubber products. The article further describes environmental stress cracking and degradation of polymers. It illustrates how surface degradation of a plain strain tension specimen alters the ductile brittle transition in polyethylene creep rupture. The article concludes with information on the effects of temperature on polymer performance.

This article commences with a discussion on the characteristics of stress-corrosion cracking (SCC) and describes crack initiation and propagation during SCC. It reviews the various mechanisms of SCC and addresses electrochemical and stress-sorption theories. The article explains the SCC, which occurs due to welding, metalworking process, and stress concentration, including options for investigation and corrective measures. It describes the sources of stresses in service and the effect of composition and metal structure on the susceptibility of SCC. The article provides information on specific ions and substances, service environments, and preservice environments responsible for SCC. It details the analysis of SCC failures, which include on-site examination, sampling, observation of fracture surface characteristics, macroscopic examination, microscopic examination, chemical analysis, metallographic analysis, and simulated-service tests. It provides case studies for the analysis of SCC service failures and their occurrence in steels, stainless steels, and commercial alloys of aluminum, copper, magnesium, and titanium.

This article describes the underlying fundamentals, applications, the relevance and necessity of performing proper stress analysis in conducting a failure analysis. It presents an introduction to the stress analysis of bodies containing crack-like imperfections and the topic of fracture mechanics. The fracture mechanics approach is an important part of stress analysis at the tips of sharp cracks or discontinuities. The article reviews fracture mechanics concepts, including linear elastic fracture mechanics, elastic-plastic fracture mechanics, and subcritical fracture mechanics. It also provides information on the applications of fracture mechanics in failure analysis.

This article reviews the mechanical behavior and fracture characteristics that discriminate structural polymers from metals. It provides information on deformation, fracture, and crack propagation as well as the fractography involving the examination and interpretation of fracture surfaces, to determine the cause of failure. The fracture modes such as ductile fractures and brittle fractures are reviewed. The article also presents a detailed account of various fracture surface features. It concludes with several cases of field failure in various polymers that illustrate the applicability of available analytical tools in conjunction with an understanding of failure mechanisms.

Fractography is the means and methods for characterizing a fractured specimen or component. This includes the examination of fracture-exposed surfaces and the interpretation of the fracture markings as well as the examination and interpretation of crack patterns. This article describes the former of these two parts of fractography. It presents the techniques of fractography and explains fracture markings using glass and ceramic examples. The article also discusses the fracture modes in ceramics and provides examples of fracture origins.

A 22 m (72 ft) diameter filled grain storage bin made from a 0.2% carbon steel collapsed at a temperature of −1 to 4 deg C (30 to 40 deg F). Failure analysis indicated that fracture occurred in a two-step process: first downward, by ductile failure of small ligament from a bolt hole near the bottom of the tank to create a crack 25 mm (1 in.) long, and then upward, by brittle fracture through successive 1.2 m (4ft) wide sheets of ASTM A446 material. Site investigation showed that the concrete base pad was not level. Chemical analysis indicated that the material had a high nitrogen content (0.020%). The allowable stress based on yield was estimated using four different design criteria. Correlation among those results was poor. The different criteria indicated that the material was loaded from the maximum allowable to approximately 30% less than allowable. Nevertheless, at this stress level, fracture mechanics indicated that the 25 mm (1 in.) starter crack exceeded or was very near the critical crack length for the material. Additional factors not taken into account in the design equations included cold work from a hole punching operation, thread imprinting in bolt holes, and an additional hoop stress created by forcing an incorrectly formed panel to fit the pad base radius. These factors increased the nominal design stress to a sufficiently large value to cause the critical crack length to be exceeded.

The repeated failure of a welded ASTM A283 grade D pipe that was part of a 6 km (4 mi) line drawing and conducting river water to a water treatment plant was investigated. Failure analysis was conducted on sections of pipe from the third failure. Visual, macrofractographic, SEM fractographic, metallographic, chemical, and mechanical property (tension and impact toughness) analyses were conducted. On the basis of the tests and observations, it was concluded that the failure was the combined result of poor notch toughness (impact) properties of the steel, high stresses in the joint area, a possible stress raiser at the intersection of the spiral weld and girth weld, and sudden impact loading, probably due to water hammer. Use of a semi- or fully killed steel with a minimum Charpy V-notch impact value of 20 J (15 ft·lbf) at 0 deg C (32 deg F) was recommended for future water lines. Certified test results from the steel mill, procedure qualification tests of the welding, and design changes to reduce water hammer were also recommended.