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Casting-related failures

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Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003508
EISBN: 978-1-62708-180-1
... of these. A design-related failure is one in which even a perfect casting (free from unexpected deficiencies and meeting specified requirements) does not perform to the requirements of the application. Correspondingly, a defect-related failure is one resulting from a condition that falls outside of the established...
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006831
EISBN: 978-1-62708-329-4
... component misuse or abuse, or a combination of these—just as they do for wrought components. A design-related failure is one in which even a perfect casting (free from unexpected deficiencies and meeting specified requirements) does not perform to the requirements of the application, or the application...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.auto.c0047263
EISBN: 978-1-62708-218-1
... with the exhaust-gas flow chamber. No recommendations were made. Castings Cylinder heads Porosity Shrinkage Gray iron Casting-related failures An engine cylinder head failed after operating just 3.2 km (2 miles) because of coolant leakage through the exhaust port. Investigation The left-bank...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.machtools.c9001014
EISBN: 978-1-62708-223-5
... of adequate tempering was the secondary cause. Castings Porosity Prestressed concrete Shrinkage Stretching Tools Carburizing steel Casting-related failures This tool is used to stretch reinforcement wires in prestressed concrete. Reinforcement wires are apparently inserted into a hole...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.steel.c9001201
EISBN: 978-1-62708-232-7
... spot. This led to the conclusion that a shrinkage cavity was present. Metallographic examination confirmed that the fracture of the swivel head was caused or favored by a cavity. Castings Shrinkage Spindles Steel casting Casting-related failures The swivel head of a driving spindle...
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
... not significant as far as its usage was concerned. The failure could have been avoided by providing support underneath the overhanging member. Freight transportation Motor trucks Packaging Presses Irons and steels Casting-related failures An automatic press for making burlap bags that had been...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.med.c0089543
EISBN: 978-1-62708-226-6
.... Bone screws Casting defects Screws Surgical implants ASTM F75 Casting-related failures Portions of the threads of the screw shown in Fig. 1(a) had broken off, and other threads had cracked. The screw was made from a cast Co-Cr-Mo alloy. A longitudinal section through the screw revealed gas...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c9001222
EISBN: 978-1-62708-225-9
... and were primarily responsible for the failure of the lift disk. Cracking (fracturing) Die castings Inclusions Porosity Aluminum brass Casting-related failures The full lift disk, made of die cast brass, which served as a lifting aid in a safety valve, had cracked in service at a number...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.pulp.c0048804
EISBN: 978-1-62708-230-3
... rates, and variation in tensile strength to be noted during inspection were described. Cracking (fracturing) Dryer rolls Paper machines Gray iron Casting-related failures (Other, general, or unspecified) fracture Unlike the individual examples of failures discussed throughout...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c0090974
EISBN: 978-1-62708-235-8
..., and reevaluation of the casting design was suggested to minimize shrinkage. Brackets Castings Inclusions Manganese sulfide Shrinkage ASTM A148 grade 135-125 UNS D51250 Casting-related failures Brittle fracture A cast steel bracket manufactured in accordance with ASTM A 148 grade 135/125 failed...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001522
EISBN: 978-1-62708-235-8
... process. Foundry practice Gating and risering Housings Permanent mold castings Porosity A357 UNS A13570 Casting-related failures A concerted research effort undertaken to improve the strength properties of cast aluminum forward housing assemblies for guided munitions may improve...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.auto.c0089526
EISBN: 978-1-62708-218-1
.... Controlled pouring temperatures, improved design and use of chills were recommended to avoid the casting defects. Casting defects Cracking (fracturing) Cylinder heads Microporosity Shrinkage Gray iron Casting-related failures A cracked cylinder head was removed from an engine after...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c0046233
EISBN: 978-1-62708-235-8
... and instituting receiving inspection of the connection castings. Castings Porosity Trailers Trucks Welded defects Welded joints Welded steel Joining-related failures Casting-related failures Fatigue fracture A drawbar connecting the two tank-type trailers of a highway gasoline rig broke while...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c0089696
EISBN: 978-1-62708-220-4
... castings be properly inspected before machining. Revision of foundry practice to reduce or eliminate porosity was also recommended. ASTM A148 grade 105-85 (Medium-carbon steel casting) UNS D50800 Joining-related failures Casting-related failures Fatigue fracture Background The cast steel...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c0047220
EISBN: 978-1-62708-220-4
..., reheated to 870 deg C (1600 deg F), and oil quenched. The larger gear should be tempered to 200 to 240 HRB, and the smaller gear to 240 to 280 HRB. Gears Materials selection Oil pumps Residual stress 100-70-03 Class 40 UNS F34800 UNS F12801 Casting-related failures Brittle fracture...
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001284
EISBN: 978-1-62708-215-0
... dies, design Die castings Sporting goods AM60A UNS M10600 Casting-related failures Background Compound bow handle risers that had failed in service and during assembly along with an unassembled riser were submitted for analysis. The risers were die cast from magnesium-base alloy AM60A...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0089563
EISBN: 978-1-62708-217-4
... lever. Aircraft components Casting defects Castings Cold shuts Fuel control lever Nondestructive testing 410 UNS J91150 Casting-related failures The lever shown in Fig. 1 was a component of the main fuel-control linkage of an aircraft engine. After a service life of less than 50 h...
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001089
EISBN: 978-1-62708-214-3
... that crosshead castings be properly inspected before machining. Revision of foundry practice to reduce or eliminate porosity was also recommended. Compressors Porosity Repair welding Welded joints Welding parameters ASTM A148 grade 105-85 UNS D50800 Joining-related failures Casting-related failures...
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001074
EISBN: 978-1-62708-214-3
... cavities. Investment castings Materials handling Nuclear reactor components Porosity Radioactive materials Servomechanisms Shrinkage 420 UNS S42000 Casting-related failures Background The yoke body pin of a master slave manipulator, a remote-controlled device used for handling...
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001029
EISBN: 978-1-62708-214-3
... originated in hot tear locations in the castings. Microprobe analysis of fracture surfaces in the hot tear region indicated a much higher silicon-to-aluminum ratio compared with the overload fracture area. No microstructural anomalies related to the failure were found during metallographic examination...