An AISI 9260 steel railroad spike maul failed after a relatively short period of service. The maul head fractured in two pieces when struck against a rail. Visual, fractographic, metallographic, and chemical analyses were conducted on sections taken from the maul head, which was found to have fractured across both sides of the eye. Failure occurred in at least three separate events: formation of two cracks immediately adjacent to the eye, extension of one of the original cracks over a portion of one of the eye sides, and abrupt extension of the original crack across the eye sides, resulting in separation into two halves.

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.