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Ductile fracture
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Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c0047879
EISBN: 978-1-62708-234-1
... to be martensitic as the fusion line was approached. The forged steel shaft was concluded to have failed by ductile fracture and possible reasons were discussed. Corrective measures adopted in the replacement shaft were specified. Agitators Chemical reactors Nuts (fasteners) O-ring seals 316 UNS S31600...
Abstract
The stub-shaft assembly which was part of the agitator shaft in a polyvinyl chloride reactor, fractured in service after a nut that retained a loose sleeve around the smaller-diam section of the shaft had been tightened several times to reduce leakage. The shaft was made of ASTM A105, grade 2 steel, and the larger-diam section was covered with a type 316 stainless steel end cap. The cap was welded to each end using type ER316 stainless steel filler metal. The forged steel shaft was revealed to have fractured at approximately 90 deg to the shaft axis in the weld metal and not in the heat-affected zone of the forged steel shaft. Microscopic investigation and chemical analysis of the steel shaft revealed presence of martensite (offered a path of easy crack propagation) around the fusion line and dilution of the weld metal by the carbon steel shaft. The microstructure was found to be martensitic as the fusion line was approached. The forged steel shaft was concluded to have failed by ductile fracture and possible reasons were discussed. Corrective measures adopted in the replacement shaft were specified.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c0046015
EISBN: 978-1-62708-235-8
... of the T-sections; however, this condition was not a primary cause of failure. Extension ladders Extrusions 6061-T6 UNS A96061 Metalworking-related failures Ductile fracture Plastic bending A two-section aluminum extension ladder, owned by the fire department of a large city, broke...
Abstract
A two-section extension ladder, made from 6061-T6 aluminum alloy extrusions and stampings that were riveted together at each rung location and at the ends of side rails, broke in service after having been used at the sites of several fires by the fire department of a large city. The fracture surfaces were examined visually and by optical (light) stereomicroscopy. Material testing showed a sample to be within the specified material limits for aluminum alloy 6061. Microscopic examination showed no significant differences in microstructure or grain size among the four T-sections, and thickness measurements at various locations indicated that thicknesses were well within standard industry tolerances for aluminum extrusions in this size range. However, hardness testing of the four T-sections showed that in two, hardness was considerably lower than the acceptable hardness for the T6 temper and were within the range for 6061-T4 (acceptable hardness, 19 to 45 HRB). This indicated they had been naturally aged at room temperature after solution heat treatment instead of artificially aged as per specs. Edge cracking in two of the T-sections was the result of improper conditions during extrusion of the T-sections; however, this condition was not a primary cause of failure.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006775
EISBN: 978-1-62708-295-2
... and fracture. Next, the mechanisms of void nucleation and void coalescence are briefly described. Macroscale and microscale appearances of ductile and brittle fracture are then discussed for various specimen geometries (smooth cylindrical and prismatic) and loading conditions (e.g., tension compression...
Abstract
This article focuses on characterizing the fracture-surface appearance at the microscale and contains some discussion on both crack nucleation and propagation mechanisms that cause the fracture appearance. It begins with a discussion on microscale models and mechanisms for deformation and fracture. Next, the mechanisms of void nucleation and void coalescence are briefly described. Macroscale and microscale appearances of ductile and brittle fracture are then discussed for various specimen geometries (smooth cylindrical and prismatic) and loading conditions (e.g., tension compression, bending, torsion). Finally, the factors influencing the appearance of a fracture surface and various imperfections or stress raisers are described, followed by a root-cause failure analysis case history to illustrate some of these fractography concepts.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003538
EISBN: 978-1-62708-180-1
... Abstract This article provides a description of the microscale models and mechanisms for deformation and fracture. Macroscale and microscale appearances of ductile and brittle fracture are discussed for various specimen geometries and loading conditions. The article reviews the general...
Abstract
This article provides a description of the microscale models and mechanisms for deformation and fracture. Macroscale and microscale appearances of ductile and brittle fracture are discussed for various specimen geometries and loading conditions. The article reviews the general geometric factors and materials aspects that influence the stress-strain behavior and fracture of ductile metals. It highlights fractures arising from manufacturing imperfections and stress raisers. The article presents a root cause failure analysis case history to illustrate some of the fractography concepts.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.design.c0089657
EISBN: 978-1-62708-233-4
... fracture Casting-related failures The gun mount used for two types of self-propelled artillery (175 mm guns and 205 mm howitzers) involved a recoil cylinder and a sand-cast ductile-iron piston containing orifices through which oil was forced in order to absorb the recoil energy of the gun. A rod...
Abstract
The gun mount used in two types of self-propelled artillery consists of an oil-filled recoil cylinder and a sand-cast (MIL-I-11466, grade D7003) ductile-iron piston that connects to the gun tube through a threaded rod. The piston contains several orifices through which oil is forced as a means of absorbing recoil energy. During operation, the piston is stressed in tension, pulled by oil pressure on one end and the opposing force of the gun tube on the other. The casting specification stipulated that the graphite be substantially nodular and that metallographic test results be provided for each lot. Investigation (visual inspection, fatigue testing, 0.25x/0.35x/50x magnifications, 2% nital etched 60x/65x magnifications, and SEM views) showed that most of the service fractures occurred in pistons containing vermicular graphite. Recommendations included ultrasonic testing of pistons already in the field to identify and reject those containing vermicular graphite. In addition, metallographic control standards were suggested for future production lots.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.matlhand.c0047321
EISBN: 978-1-62708-224-2
... at a temperature differential of up to 555 deg C (1000 deg F). With the adoption of this procedure, brake drums failed by wear only. Alignment Clearances Diameters Sand castings Spacers Winches Ductile iron Brittle fracture A 58.4-cm (23-in.) diam heavy-duty brake drum that was a component...
Abstract
A 58.4 cm (23 in.) diam heavy-duty brake drum component of a cable-wound winch broke into two pieces during a shutdown period. Average service life of these drums was two weeks; none had failed by wear. The drums were sand cast from ductile iron. During haul-out, the cable on the cable drum drove the brake drum, and resistance was provided by brake bands applied to the outside surface of the brake drum. Friction during heavy service was sufficient to heat the brake drum, clutch mount, and disk to a red color. Examination of the assembly indicated that the brake drum would cool faster than its mounts and would contract onto them. Brittle fracture of the brake drum occurred as a result of thermal contraction of the drum web against the clutch mount and the disk. The ID of the drum web was enlarged sufficiently to allow for clearance between the web and the clutch mount and disk at a temperature differential of up to 555 deg C (1000 deg F). With the adoption of this procedure, brake drums failed by wear only.
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Published: 01 January 2002
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Published: 01 January 2002
Fig. 41 Three micromechanisms of fracture in metals. (a) Ductile fracture. (b) Cleavage fracture. (c) Intergranular fracture. Source: Ref 43
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Published: 15 January 2021
Fig. 35 Three micromechanisms of fracture in metals. (a) Ductile fracture. (b) Cleavage fracture. (c) Intergranular fracture. Source: Ref 42
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in Broken Milling Machine Arbors Made of 16 Mn Cr 5 E
> ASM Failure Analysis Case Histories: Machine Tools and Manufacturing Equipment
Published: 01 June 2019
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Published: 01 January 2002
Fig. 27 Charpy V-notch impact data for pipe lengths in which ductile fracture propagated and arrested. End A, fracture arrest; End B, fracture arrest
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in Mechanisms and Appearances of Ductile and Brittle Fracture in Metals
> Failure Analysis and Prevention
Published: 01 January 2002
Fig. 69 Schematic figure of the brittle-to-ductile fracture transition. The relative area on the fracture surface of the three microscale fracture mechanisms (stretch zone, dimple zone, and cleavage zone) are indicated. Source: Ref 78
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in Mechanisms and Appearances of Ductile and Brittle Fracture in Metals
> Failure Analysis and Prevention
Published: 01 January 2002
Fig. 90 A model for ductile fracture due to Rice and Johnson. The model considers pure tearing on the plane of maximum normal stress. The preexisting flaw is assumed to blunt during yield to create a large strain field in front of the flaw. Debonding and growth at a particle interface occurs
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Published: 01 January 2002
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Published: 01 January 2002
Fig. 38 Apparent ductile fracture in a 321 stainless steel superheater tube (ASME SA-213 grade TP 321H). (a) Fracture is macroscale brittle because it is on a hoop plane. (b) Intergranular cracking is revealed and at magnification of 4 1 2 ×. (c) Higher magnification (100 ×) does
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in Mechanisms and Appearances of Ductile and Brittle Fracture in Metals
> Failure Analysis and Prevention
Published: 01 January 2002
Fig. 16 Examples of ductile fracture on shear planes. (a) Void sheets from propagation of a crack between widely spaced inclusions within a shear band in a 4340 steel. Stress axis is vertical. Source: Ref 41 . (b) Ductile crack growth in HSLA steel (A710). Source: Ref 77
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in Hydrogen Embrittlement Failure of Socket Head Cap Screws
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1992
Fig. 3 SEM micrograph showing a ductile fracture mode, observed over the majority of both fracture surfaces. 1000×.
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in Failure of an Aluminum Connector in an Electrical Transmission Cable
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1992
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in Stress Corrosion Cracking of Tough Pitch Copper in a Bolting Application
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 2 Typical knife-edge ductile fracture around the internal hole of a suspect lot pin at room temperature
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Published: 15 January 2021
Fig. 39 Apparent ductile fracture in a 321 stainless steel superheater tube (ASME SA-213 grade TP 321H). (a) Fracture is macroscale brittle because it is on a hoop plane. (b) Intergranular cracking is revealed and at magnification of 4½×. (c) Higher magnification (100×) does not show evidence
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