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1060
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Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.homegoods.c0048674
EISBN: 978-1-62708-222-8
... Abstract Fasteners, made in high-production progressive dies from 0.7 mm thick cold-rolled 1060 steel, were used to secure plastic fabric or webbing to the aluminum framework of outdoor furniture. It was found that approximately 30% of the fasteners cracked and fractured as they were compressed...
Abstract
Fasteners, made in high-production progressive dies from 0.7 mm thick cold-rolled 1060 steel, were used to secure plastic fabric or webbing to the aluminum framework of outdoor furniture. It was found that approximately 30% of the fasteners cracked and fractured as they were compressed to clamp onto the framework prior to springback. The heat treatment cycle of the fasteners consisted of austenitizing, quenching, tempering to obtain a tempered martensite microstructure, acid cleaning, zinc electroplating, coating with a clear dichromate and thereafter baking to remove the nascent hydrogen. It was revealed that fasteners treated in this manner were brittle due to hydrogen embrittlement as the baking process was found to not be able to remove all the nascent hydrogen which had induced during acid cleaning and electroplating. The heat treatment cycle was modified to produce a bainitic structure and the method of plating the fastener with zinc was changed from electroplating to a mechanical deposition process to thus avoid hydrogen embrittlement.
Image
in Failure of a Zinc-Electroplated 1060 Steel Fastener
> ASM Failure Analysis Case Histories: Household Products and Consumer Goods
Published: 01 June 2019
Fig. 1 Zinc-electroplated 1060 steel fastener that failed by hydrogen embrittlement. The part was used to secure fabric to lawn-furniture framework. Dimensions given in inches
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Image
Published: 30 August 2021
Fig. 24 Zinc-electroplated 1060 steel fastener that failed by hydrogen embrittlement. The part was used to secure fabric to lawn furniture framework. Dimensions given in inches
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Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.usage.c0048303
EISBN: 978-1-62708-236-5
... were observed. Log stress versus Larson-Miller Parameter (LMP) plots were produced to assess the remaining life of the superheater. It was revealed that the estimated operating temperature of 1060 deg F was higher than the estimated design temperature of 1000 deg F and that the tube wastage had...
Abstract
A tube in a radiant superheater, the boiler of which is coal fired, failed by creep after 17 years of service. The failed tube was specified to be made of ASME SA-213, grade T-22. Measurable swelling of the tube diameter by about 2.4 mm and tube wastage caused by corrosion or erosion were observed. Log stress versus Larson-Miller Parameter (LMP) plots were produced to assess the remaining life of the superheater. It was revealed that the estimated operating temperature of 1060 deg F was higher than the estimated design temperature of 1000 deg F and that the tube wastage had increased the actual operating stress. Tube wastage and high operating temperatures hastened the failure. A better understanding of the material condition of this superheater was recommended to verify all the suspect hot tubes.
Image
in Failure by Stress-Corrosion Cracking of an Ejection Seat Swivel
> ASM Failure Analysis Case Histories: Air and Spacecraft
Published: 01 June 2019
. 1060×
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0006387
EISBN: 978-1-62708-217-4
... of the fixture is at the top. 5×. (c) SEM fractograph of area A from (b). Note slight intergranular appearance of structure. 425×. (d) SEM fractograph of area B from (c) showing intergranular facets on the fracture surface. 1060× Electron optical examination of the fracture at low magnifications revealed...
Abstract
A routine examination on a seat ejection system found that the catapult attachment swivel fabricated from 7075-T651 aluminum alloy plate contained cracks on opposite sides of the part. This swivel, or bath tub, does not experience extreme loads prior to activation of the catapult system. Some loads could be absorbed however, when the aircraft is subjected to G loads. Visual examination of the part revealed that cracks through the wall thickness initiated on the inner walls of the fixture. Scanning electron microscopy (SEM) and electron optical examination revealed that the cracking pattern initiated and progressed by an intergranular failure mechanism. It was concluded that failure of the catapult attachment swivel fixture occurred by SCC. It was recommended that the 7075 aluminum ejection seat fixture be supplied in the T-73 temper to minimize susceptibility to SCC.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003566
EISBN: 978-1-62708-180-1
... is involved in the test.” A similar, if not identical, device also has been used for studies of spalling at Stanley Tools. Velez and Powell ( Ref 5 ) investigated the spalling of 1060 steel using the relatively simple device shown in Fig. 6 . A cylindrical steel projectile, 9.5 mm (0.375 in.) diameter...
Abstract
This article briefly reviews the analysis methods for spalling of striking tools with emphasis on field tests conducted by A.H. Burn and on the laboratory tests of H.O. McIntire and G.K. Manning and of J.W. Lodge. It focuses on the metallography and fractography of spalling. The macrostructure and microstructure of spall cavities are described, along with some aspects of the numerous specifications for striking/struck tools. The article also describes the availability of spall-resistant metals and the safety aspects of striking/struck tools in railway applications.
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001308
EISBN: 978-1-62708-215-0
... by using oil or air, rather than water, as a quenching medium for the rail. Alternatively, a lowercarbon steel, such as 1050 or 1060, or an alloy steel, such as 4130, could have been substituted for the 1080 steel to minimize cracking from water quenching and still have met the hardness requirements...
Abstract
Persistent cracking in a forged 1080 steel turntable rail in a wind tunnel test section was investigated. All cracks were oriented transverse to the axis of the rail, and some had propagated through the flange into the web. Through-flange cracks had been repair welded. A section of the flange containing one through-flange crack was examined using various methods. Results indicated that the cracks had initiated from intergranular quench cracks caused by the use of water as the quenching medium. Brittle propagation of the cracks was promoted by high residual stresses acting in conjunction with applied loads. Repair welding was discontinued to prevent the introduction of additional residual stress., Finite-element analysis was used to show that the rail could tolerate existing cracks. Periodic inspection to monitor the degree of cracking was recommended.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001571
EISBN: 978-1-62708-229-7
...–1060°C for about 30 minutes and E-8 experienced 1075–1100°C for about 30 min. Based on hot-cell work, they concluded that G-8 experienced conditions similar to F-10 and E-6 experienced conditions like E-8. It was concluded that all other specimens experienced temperatures <727°C. Fig. 3 Delta...
Abstract
The accident at Three Mile Island Unit No. 2 on 28 March 1979 was the worst nuclear accident in US history. By Jan 1990, it was possible to electrochemically machine coupons from the lower head using a specially designed tool. The specimens contained the ER308L stainless steel cladding and the A533 Grade B plate material to a depth of about mid-wall. The microstructures of these specimens were compared to that of specimens cut from the Midland, Michigan reactor vessel, made from the same grade and thickness but never placed in service. These specimens were subjected to known thermal treatments between 800 and 1100 deg C for periods of 1 to 100 min. Microstructural parameters in the control specimens and in those from TMI-2 were quantified. Selective etchants were used to better discriminate desired microstructural features, particularly in the cladding. This report is a progress report on the quantification of changes in both the degree of carbide precipitation and delta ferrite content and shape in the cladding as a function of temperature and time to refine the estimates of the maximum temperatures experienced.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001816
EISBN: 978-1-62708-180-1
... 570 °C (1060 °F). For the material in question, the two values were not in agreement; the microstructure, after 16 years of service at 570 °C (1060 °F), should have been fully spheroidized. It was not. Therefore, these calculations of tube metal temperature are estimates—useful to be sure...
Abstract
This article explains the main types and characteristic causes of failures in boilers and other equipment in stationary and marine power plants that use steam as the working fluid with examples. It focuses on the distinctive features of each type that enable the failure analyst to determine the cause and suggest corrective action. The causes of failures include tube rupture, corrosion or scaling, fatigue, erosion, and stress-corrosion cracking. The article also describes the procedures for conducting a failure analysis.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001812
EISBN: 978-1-62708-180-1
Abstract
This article discusses different types of mechanical fasteners, including threaded fasteners, rivets, blind fasteners, pin fasteners, special-purpose fasteners, and fasteners used with composite materials. It describes the origins and causes of fastener failures and with illustrative examples. Fatigue fracture in threaded fasteners and fretting in bolted machine parts are also discussed. The article provides a description of the different types of corrosion, such as atmospheric corrosion and liquid-immersion corrosion, in threaded fasteners. It also provides information on stress-corrosion cracking, hydrogen embrittlement, and liquid-metal embrittlement of bolts and nuts. The article explains the most commonly used protective metal coatings for ferrous metal fasteners. Zinc, cadmium, and aluminum are commonly used for such coatings. The article also illustrates the performance of the fasteners at elevated temperatures and concludes with a discussion on fastener failures in composites.
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006805
EISBN: 978-1-62708-329-4
Abstract
This article first provides an overview of the types of mechanical fasteners. This is followed by sections providing information on fastener quality and counterfeit fasteners, as well as fastener loads. Then, the article discusses common causes of fastener failures, namely environmental effects, manufacturing discrepancies, improper use, or incorrect installation. Next, it describes fastener failure origins and fretting. Types of corrosion in threaded fasteners and their preventive measures are then covered. The performance of fasteners at elevated temperatures is addressed. Further, the article discusses the types of rivet, blind fastener, and pin fastener failures. Finally, it provides information on the mechanism of fastener failures in composites.
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006825
EISBN: 978-1-62708-329-4
... hydroxide). Below 570 °C (1060 °F), the main constituent of the scale formed on carbon and low-alloy steel is magnetite (Fe 3 O 4 ), whereas above 570 °C (1060 °F), it is wustite (FeO). The scale formed on T91 steel, which has special significance as a tube material for supercritical boilers, is somewhat...
Abstract
Failures in boilers and other equipment taking place in power plants that use steam as the working fluid are discussed in this article. The discussion is mainly concerned with failures in Rankine cycle systems that use fossil fuels as the primary heat source. The general procedure and techniques followed in failure investigation of boilers and related equipment are discussed. The article is framed with an objective to provide systematic information on various damage mechanisms leading to the failure of boiler tubes, headers, and drums, supplemented by representative case studies for a greater understanding of the respective damage mechanism.
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006820
EISBN: 978-1-62708-329-4
...-stressed gears, SAE 1040, 1050, and 1060 are in common usage. For more demanding and larger applications, low alloys such as SAE 4140 and 4340 are used, because the constituents result in greater depth of hardness and increased toughness. Most of the alloys have an “H” suffix, such as SAE 4140H or 4340H...
Abstract
This article first reviews variations within the most common types of gears, namely spur, helical, worm, and straight and spiral bevel. It then provides information on gear tooth contact and gear metallurgy. This is followed by sections describing the important points of gear lubrication, the measurement of the backlash, and the necessary factors for starting the failure analysis. Next, the article explains various gear failure causes, including wear, scuffing, Hertzian fatigue, cracking, fracture, and bending fatigue, and finally presents examples of gear and reducer failure analysis.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003510
EISBN: 978-1-62708-180-1
Abstract
This article provides an overview of the effects of various material- and process-related parameters on residual stress, distortion control, cracking, and microstructure/property relationships as they relate to various types of failure. It discusses phase transformations that occur during heat treating and describes the metallurgical sources of stress and distortion during heating and cooling. The article summarizes the effect of materials and the quench-process design on distortion and cracking and details the effect of cooling characteristics on residual stress and distortion. It also provides information on the methods of minimizing distortion and tempering. The article concludes with a discussion on the effect of heat treatment processes on microstructure/property-related failures.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001815
EISBN: 978-1-62708-180-1
... widely used gear materials. Consequently, steel gears receive primary consideration in this article. Among the through-hardening steels in wide use are 1040, 1060, 4140, and 4340. These steels can also be effectively case hardened by induction heating. Among the carburizing steels used in gears...
Abstract
Gears can fail in many different ways, and except for an increase in noise level and vibration, there is often no indication of difficulty until total failure occurs. This article reviews the major types of gears and the basic principles of gear-tooth contact. It discusses the loading conditions and stresses that effect gear strength and durability. The article provides information on different gear materials, the common types and causes of gear failures, and the procedures employed to analyze them. Finally, it presents a chosen few examples to illustrate a systematic approach to the failure examination.
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006816
EISBN: 978-1-62708-329-4
Abstract
This article introduces some of the general sources of heat treating problems with particular emphasis on problems caused by the actual heat treating process and the significant thermal and transformation stresses within a heat treated part. It addresses the design and material factors that cause a part to fail during heat treatment. The article discusses the problems associated with heating and furnaces, quenching media, quenching stresses, hardenability, tempering, carburizing, carbonitriding, and nitriding as well as potential stainless steel problems and problems associated with nonferrous heat treatments. The processes involved in cold working of certain ferrous and nonferrous alloys are also covered.
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006830
EISBN: 978-1-62708-329-4
... from high-carbon steels, typically grade 1060 or higher in carbon. The descriptions of the different steels have a long history and, rated from lowest strength to highest strength, are traction steel, plowed steel, improved plowed steel, extra-improved plowed steel, and extra-extra-improved plowed...
Abstract
The types of metal components used in lifting equipment include gears, shafts, drums and sheaves, brakes, brake wheels, couplings, bearings, wheels, electrical switchgear, chains, wire rope, and hooks. This article primarily deals with many of these metal components of lifting equipment in three categories: cranes and bridges, attachments used for direct lifting, and built-in members of lifting equipment. It first reviews the mechanisms, origins, and investigation of failures. Then the article describes the materials used for lifting equipment, followed by a section explaining the failure analysis of wire ropes and the failure of wire ropes due to corrosion, a common cause of wire-rope failure. Further, it reviews the characteristics of shock loading, abrasive wear, and stress-corrosion cracking of a wire rope. Then, the article provides information on the failure analysis of chains, hooks, shafts, and cranes and related members.
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006834
EISBN: 978-1-62708-329-4
... bearings). It also allows more uniform hardness distribution over the thickness of the part. For thin-section bearings made of punched materials (i.e., thrust plates, axial plates, needle bushes, or bearing shells), one may also make advantageous use of low-carbon steels such as AISI 1060 (Ck67 or WN...
Abstract
This article is dedicated to the fields of mechanical engineering and machine design. It also intends to give a nonexhaustive view of the preventive side of the failure analysis of rolling-element bearings (REBs) and of some of the developments in terms of materials and surface engineering. The article presents the nomenclature, numbering systems, and worldwide market of REBs as well as provides description of REBs as high-tech machine components. It discusses heat treatments, performance, and properties of bearing materials. The processes involved in the examination of failed bearings are also explained. Finally, the article discusses in detail the characteristics and prevention of the various types of failures of REBs: wear, fretting, corrosion, plastic flow, rolling-contact fatigue, and damage. The article includes an Appendix, which lists REB-related abbreviations, association websites, and ISO standards.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006829
EISBN: 978-1-62708-295-2
Abstract
Fretting is a wear phenomenon that occurs between two mating surfaces; initially, it is adhesive in nature, and vibration or small-amplitude oscillation is an essential causative factor. Fretting generates wear debris, which oxidizes, leading to a corrosion-like morphology. This article focuses on fretting wear related to debris formation and ejection. It reviews the general characteristics of fretting wear, with an emphasis on steel. The review covers fretting wear in mechanical components, various parameters that affect fretting; quantification of wear induced by fretting; and the experimental results, map approach, measurement, mechanism, and prevention of fretting wear. This review is followed by several examples of failures related to fretting wear.