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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001203
EISBN: 978-1-62708-235-8
.... Bearing boxes Overheating Welded joints Welded steel Joining-related failures (Other, general, or unspecified) fracture Three bearing bosses from the cover of scrap shears were sent in for examination. They had torn off the base plate to which they had been welded by fillet welds all around. Two...
Abstract
Three bearing bosses from the cover of scrap shears were sent in for examination. They had torn off the base plate to which they had been welded by fillet welds all around. Two of these were examined. They showed entirely the same symptoms. The bosses had broken away on three sides along the welds. The cleaved fractures in the burned notches propagated partially above and partially below several incipient cracks which may have been fatigue fractures. Metallographic sections showed that the fractures had occurred either at the burned notches near the transition from the weld to the sheet, or else they ran in the sheet material next to the weld. The quality of the welds could not be judged because the opposite fracture pieces to which they adhered had not been sent in. It was concluded that the breakaway of these bosses was at least favored by overheating and hardening.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c0047939
EISBN: 978-1-62708-225-9
... surfaces of the bearing. As a remedial action, the bearing was insulated for protection from stray currents by grounding of the motor and the moisture was kept out by sealing both bearings in the assembly. Electrolytic etching Gear boxes Grounding (electrical) Roller bearings 8620 UNS G86200...
Abstract
Rough operation of the roller bearing mounted in an electric motor/gearbox assembly was observed. The bearing components made of low-alloy steel (4620 or 8620) and the cup, cone and rollers were carburized, hardened and tempered. The contact surfaces of these components (cup, cone and roller) were revealed to be uniformly electrolytically etched by visual examination. The action similar to anodic etching was believed to have occurred as a result of stray currents in the electric motor (not properly grounded) and the presence of an electrolyte (moisture) between the cup and roller surfaces of the bearing. As a remedial action, the bearing was insulated for protection from stray currents by grounding of the motor and the moisture was kept out by sealing both bearings in the assembly.
Image
in Failure Analysis of High-Speed Pinion Gear Shaft
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 11 Shaft surface exposed after removal of bearing ring; ( a ) adhered material (unetched) and ( b ) boxed region in (a) showing severely deformed grains
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.machtools.c0047964
EISBN: 978-1-62708-223-5
... Abstract Drastic reduction in the service life of a production gearbox was observed. Within the gearbox, the axial load on a bevel gear (8620 steel, OD 9.2 cm) was taken by a thrust-type roller bearing (3.8 cm ID, 5.6 cm OD) in which a ground surface on the back of the bevel gear served...
Abstract
Drastic reduction in the service life of a production gearbox was observed. Within the gearbox, the axial load on a bevel gear (8620 steel, OD 9.2 cm) was taken by a thrust-type roller bearing (3.8 cm ID, 5.6 cm OD) in which a ground surface on the back of the bevel gear served as a raceway. Spalling damage on the ground bearing raceway at five equally spaced zones was disclosed by inspection of the bevel gear. The bearing raceway was checked for runout by mounting the gear on an arbor. It was found that the raceway undulated to the extent of 0.008 mm total indicator reading and a spalled area was observed at each high point. The presence of numerous cracks that resembled grinding cracks was revealed both by magnetic-particle inspection and microscopic examination. Spalling was produced by nonuniform loading in conjunction with grinding cracks. As corrective measures, the spindle of the grinding machine was reconditioned to eliminate the undulations and retained austenite was minimized by careful heat treatment.
Image
in Evaluating Component Failures: The Cure Can Be Worse Than the Illness
> ASM Failure Analysis Case Histories: Improper Maintenance, Repair, and Operating Conditions
Published: 01 June 2019
Fig. 1 The presence of secondary, branching intergranular stress-corrosion cracking (arrows) in a type 440C stainless bearing caused the analyst to overlook the real culprit — a mechanically initiated, primary transgranular crack that propagated through the steel's hard chromium carbide (box
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.conag.c9001466
EISBN: 978-1-62708-221-1
... of fracture indicated that bending stresses were primarily responsible, the alignment of the assembly was checked and it was found that the level of the inboard feet of the gear-box was 0.060 in. below that of the out-board feet and the bearing pedestal which carried the other end of the shaft, as indicated...
Abstract
A shaft, which carried both a worm wheel and hoist barrel, fractured at a reduction in diameter adjacent to a mating gearbox. The appearance of the fracture was characteristic of a fatigue failure of a rotating shaft resulting from excessive bending stresses. Cracks of the fatigue type broke out all around the circumference at the change of section and progressed inwards. Microscopic examination of the material showed it to be an alloy steel in the hardened and tempered condition, with no abnormal features. It was considered that the bending stresses due to the deflection of the shaft arising from misalignment were responsible for the fatigue failure, which occurred in a region of stress concentration where insignificant fillet radius had been provided.
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001799
EISBN: 978-1-62708-241-9
... crack in the transverse direction is shown in Fig. 13 . Crack propagation was by both transgranular and inter-granular processes. Fig. 11 Shaft surface exposed after removal of bearing ring; ( a ) adhered material (unetched) and ( b ) boxed region in (a) showing severely deformed grains...
Abstract
A high-speed pinion gear shaft, part of a system that compresses natural gas, was analyzed to determine why it failed. An abnormal wear pattern was observed on the shaft surface beneath the inner race of the support bearings. Material from the shaft had transferred to the bearing races, creating an imbalance (enough to cause noise and fumes) that operators noted two days before the failure. Macrofeatures of the fracture surface resembled those of fatigue, but electron microscopy revealed brittle, mostly intergranular fracture. Classic fatigue features such as striations were not found. To resolve the discrepancy, investigators created and tested uniaxial fatigue samples, and the microfeatures were nearly identical to those found on the failed shaft. The root cause of failure was determined to be fatigue, and it was concluded that cracks on the pinion shaft beneath the bearings led to the transfer of material.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.usage.c9001545
EISBN: 978-1-62708-236-5
... Abstract The presence of secondary, branching intergranular stress-corrosion cracking in a type 440C stainless bearing caused the analyst to overlook the real culprit, which was a mechanically-initiated, primary transgranular crack that propagated through the steel's hard chromium carbide...
Abstract
The presence of secondary, branching intergranular stress-corrosion cracking in a type 440C stainless bearing caused the analyst to overlook the real culprit, which was a mechanically-initiated, primary transgranular crack that propagated through the steel's hard chromium carbide. Failure was actually caused by overload. Had the original conclusion been accepted, a relatively exotic alloy would have been specified. In another case, brass heat exchanger tube failure was automatically attributed to attack by an acidic cleaner, and a decision was made to stop using the solution. A more thorough analysis showed failure was caused by tube vibration. In a third case, a type 304 stainless steel bellows in a test loop was thought to have failed because of chloride stress corrosion. The report concluded with a recommendation that carbon steel be used as an alternative bellows material. Caustic, not chloride, stress corrosion was the culprit. Had material substitutions been made on the original premise of countering chloride stress corrosion, most of the loop's highly stressed components would have eventually failed.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001822
EISBN: 978-1-62708-180-1
... 3 , 4 ). The 1947 paper ( Ref 3 ) discusses twist-off failures due to overheated bearings. This failure mode is referred to as a hot-box in railroad terminology. Almost all axle-journal failures were claimed to be attributed to intergranular embrittlement of the steel by molten brass or copper...
Abstract
This article provides a background of friction-bearing failures due to overheating. The failures of locomotive axles caused by overheated traction-motor support bearings are discussed. The article also describes liquid-metal embrittlement (LME) in steel. It examines the results of various axle studies, with illustrations and concludes with information on the simulation of the LME mechanism.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.rail.c9001665
EISBN: 978-1-62708-231-0
... is a simplified drawing of one end of the casting prepared from the original engineering drawings. It gives a general idea of the shape of the casting as seen from a direction perpendicular to the axis of the freight car. The journal box, within which one of the wheel-bearing axles rotated, is shown on the left...
Abstract
Following a freight train derailment, part of a fractured side frame was retained for study because a portion of its fracture surface exhibited a rock candy appearance and black scale. It was suspected of having failed, thereby precipitating the derailment. Metallography, scanning electron microscopy, EDXA, and x-ray mapping were used to study the steel in the vicinity of this part of the fracture surface. It was found to be contaminated with copper. Debye-Scherrer x-ray diffraction patterns obtained from the scale showed that it consisted of magnetite and hematite. It was concluded that some copper was accidentally left in the mold when the casting was poured. Liquid copper, carrying with it oxygen in solution, penetrated the austenite grain boundaries as the steel cooled. The oxygen reacted with the steel producing a network of scale outlining the austenite grain structure. When the casting fractured as a result of the derailment, the fracture followed the scale in the contaminated region thus creating the “rock candy” fracture.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.rail.c9001719
EISBN: 978-1-62708-231-0
... , Feb 1954 5. Laudig J.J. , Hot-Box Research Results..in the Iron-Back Journal Bearing , Rail. Age , Vol 134 ( No. 12 ), March 1953 , p 65 – 69 6. Vander Voort G. F. , Failure of Locomotive Axles , ASM Handbook , Vol 11 , 9th Edition , 1986 7. ASM Metals...
Abstract
Metallography is an important component of failure analysis. In the case of a liquid metal embrittlement (LME) failure it is usually conclusive if a third phase constituent can be formed inside of the cracks after failure. In the case where it is necessary to characterize the third phase material, one can use various x-ray spectrographic techniques in conjunction with a scanning electron microscope (SEM). This study describes those metallographic and SEM analysis techniques for determining the mode of failure for a locomotive traction motor by LME.
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001754
EISBN: 978-1-62708-241-9
... Abstract The case study presented in this article details the failure investigation of an M50 alloy steel bearing used in a jet engine gearbox drive assembly. It discusses the investigative steps and analytic tools used to determine the root cause, highlighting the importance of continuous...
Abstract
The case study presented in this article details the failure investigation of an M50 alloy steel bearing used in a jet engine gearbox drive assembly. It discusses the investigative steps and analytic tools used to determine the root cause, highlighting the importance of continuous, thorough questioning by the investigating activity. The combined analyses demonstrated that the bearing failed by a single event overload as evidenced by bulk deformation and traces of foreign material on the rolling elements. The anomalous transferred metal found on the rolling elements subsequently led to the discovery of overlooked debris in an engine chip detector, and thus resulted in a review of several maintenance practices.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c9001152
EISBN: 978-1-62708-234-1
... worn out bearing or fits, and a broken rear axle tube of a bus are described. Crankshafts Thermal Stresses Tubes Welded joints St 37-2 40Mn4 Fatigue fracture Thermal and transformation stresses, resulting from welding, adding up with operational stresses can result in failure...
Abstract
Thermal and transformation stresses, resulting from welding, adding up with operational stresses can result in failure. Examples involving the crankshaft of a shaft-drive to produce artificial waves in a swimming pool, the joint bar of a dredger cast out of a running non-alloyed steel with 39 kg/sq mm tensile strength, which had been strengthened by welding plate strips on both sides had fractured in service; an axle tube out of 40 Mn 4 after DIN 17 200 from a paper fabrication machine, which had three short longitudinal slits distributed uniformly over its surface; welding to repair worn out bearing or fits, and a broken rear axle tube of a bus are described.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c9001575
EISBN: 978-1-62708-217-4
... Abstract An oil scavenge pump was found to have failed when a protective shear neck fractured during the start of a jet engine. Visual inspection revealed that the driven gear in one of the bearing compartments was frozen as was the corresponding drive gear. Spacer wear and thermal...
Abstract
An oil scavenge pump was found to have failed when a protective shear neck fractured during the start of a jet engine. Visual inspection revealed that the driven gear in one of the bearing compartments was frozen as was the corresponding drive gear. Spacer wear and thermal discoloration (particularly on the driven gear) were also observed. The gears were made from 32Cr-Mo-V13 steel, hardened and nitrided to 750 to 950 HV. Micrographic inspection of the gear teeth revealed microstructural changes that, in context, appear to be the result of friction heating. The spacers consist of Cu alloy (AMS4845) bushings force fit into AA2024-T3 Al alloy spacing elements. It was found that uncontrolled fit interference between the two components had led to Cu alloy overstress. Thermal cycling under operating conditions yielded the material. The dilation was directed inward to the shaft, however, because the bushing had only a few microns of clearance. The effect caused the oil to squeeze out, resulting in metal-to-metal contact, and ultimately failure.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c9001485
EISBN: 978-1-62708-225-9
... be present. It has also been found in the roller bearing axle-boxes of railway wagons which have been standing for some time in sidings and subjected to vibrations from passing trains. In many instances, the occurrence of stationary indentation remains unsuspected until the machine is started up, when...
Abstract
Factors which may lead to premature roller bearing failure in service include incorrect fitting, excessive pre-load during installation, insufficient or unsuitable lubrication, over-load, impact load vibration, excessive temperature, contamination by abrasive matter, ingress of harmful liquids, and stray electric currents. Most common modes of failure include flaking or pitting (fatigue), cracks or fractures, creep, smearing, wear, softening, indentation, fluting, and corrosion. The modes of failure are illustrated with examples from practice.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.rail.c9001450
EISBN: 978-1-62708-231-0
... that was equipped with an automatic control to maintain the air-gas ratio at such a value that reducing conditions were obviated. It was also stated that the rivets had been inserted from the fireside, therefore the original heads would be on that side of the box. Microscopical examination revealed that while...
Abstract
A locomotive type boiler was fitted with a copper firebox of orthodox construction. Flanged tube- and firehole-plates were attached to a wrapper plate by means of copper rivets. Shortly after it was put into service the fireside heads of a number of rivets broke off at different parts of the seams. By the time the investigation was begun a total of fifty heads had broken off. Repairs had been effected from time to time by fitting screwed rivets, none of which gave trouble in service. Microscopic examination confirmed the fracture path to be wholly intergranular. In the region of the fracture the grain boundaries were delineated as a near-continuous network of cavities and films of oxide. It was evident that the failure of the rivets in service was attributable to intergranular weakness in the material due to gassing.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001810
EISBN: 978-1-62708-180-1
... not guarantee immunity, particularly where pronounced vibrations from diesel engines may be present. False brinelling has also been found in the roller-bearing axle boxes of railway cars that have been standing for some time in sidings and that are subjected to vibrations from passing trains. In many...
Abstract
Rolling-element bearings use rolling elements interposed between two raceways, and relative motion is permitted by the rotation of these elements. This article presents an overview of bearing materials, bearing-load ratings, and an examination of failed bearings. Rolling-element bearings are designed on the principle of rolling contact rather than sliding contact; frictional effects, although low, are not negligible, and lubrication is essential. The article lists the typical characteristics and causes of several types of failures. It describes failure by wear, failure by fretting, failure by corrosion, failure by plastic flow, failure by rolling-contact fatigue, and failure by damage. The article discusses the effects of fabrication practices, heat treatment and hardness of bearing components, and lubrication of rolling-element bearings with a few examples.
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
... 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...
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.
Book Chapter
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003562
EISBN: 978-1-62708-180-1
... to fretting wear. fretting wear impact fretting mechanical components normal load residual stress rolling-element bearings slip surface finish vibration frequency FRETTING is a wear phenomenon that occurs between two mating surfaces; initially, it is adhesive in nature, and vibration...
Abstract
This article reviews the general characteristics of fretting wear in mechanical components with an emphasis on steel. It focuses on the effects of physical variables and the environment on fretting wear. The variables include the amplitude of slip, normal load, frequency of vibration, type of contact and vibration, impact fretting, surface finish, and residual stresses. The form, composition, and role of the debris are briefly discussed. The article also describes the measurement, mechanism, and prevention of fretting wear. It concludes with several examples of failures related to fretting wear.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.design.c9001578
EISBN: 978-1-62708-233-4
... and did reduce the microscope vibrations to an acceptable level. Case #4: Torsional Vibration on a Reciprocating Pump A 66 rpm reciprocating water pump driven by a gear box and belt reduction experienced excessive torsional vibration that was being picked up at the gear case when the pump...
Abstract
Vibration analysis can be used in solving both rotating and nonrotating equipment problems. This paper presents case histories that, over a span of approximately 25 years, used vibration analysis to troubleshoot a wide range of problems.
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