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Food processing
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Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001336
EISBN: 978-1-62708-215-0
... assemblies began to corrode at the outer pipe bends within 2 days of installation. A simultaneous darkening of the processed food product suggested that corrosion was also occurring at the pipe inner bends. No changes in the regular service schedules or the regular maintenance schedules were reported...
Abstract
Catastrophic pitting corrosion occurred in type 304L stainless steel pipe flange assemblies in an industrial food processor. During regular service the pumped medium was pureed vegetables. In situ maintenance procedures included cleaning of the assemblies with a sodium hypochlorite solution. It was determined that the assemblies failed due to an austenite-martensite galvanic couple activated by a chlorine bearing electrolyte. The martensitic areas resulted from a transformation during cold-forming operations. Solution annealing after forming, revision of the design of the pipe flange assemblies to eliminate the forming operation, and removal of the source of chlorine were recommended.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.homegoods.c0091857
EISBN: 978-1-62708-222-8
... of a stand-off washer between the wavy washer and the bottom shoulders of the blade or modification of the shape of the wavy washer to prevent contact with the blade shoulders was recommended. Design Food processing Mixer blades Cold-formed 300 series stainless steel (Austenitic wrought stainless...
Abstract
After the mixing machines were introduced into service, excessive assembly stresses and inappropriate detail design caused the premature failures of ice cream drink mixer blades shortly. The mixer blade is slightly deformed by the contact between the wavy washer at the bottom of the assembly and the bends at the bottom shoulders of the two mixer arms. Multiple fatigue crack origins on the inside radii of the bends at the bottom shoulders was revealed by analysis of the failed mixer blades. It was revealed by metallographic examination that the shoulders on the arms were cold bent, introducing tensile residual stresses on the inside radii of the shoulders and creating a localized area of fatigue susceptibility due to the inherent notch sensitivity of cold-formed 300 series stainless steel. It was established that the physical root cause was the design of the mixer blade. The addition of a stand-off washer between the wavy washer and the bottom shoulders of the blade or modification of the shape of the wavy washer to prevent contact with the blade shoulders was recommended.
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001274
EISBN: 978-1-62708-215-0
... microwave food tray collapsed with hot food in it. Microscopic examination of the failed tray revealed no structural or material defects. Five additional trays of like construction were also tested to determine the conditions necessary to simulate the permanent deflection of the tray handles that had...
Abstract
A laminated-paper microwave food tray collapsed with hot food in it. Microscopic examination of the failed tray revealed no structural or material defects. Five additional trays of like construction were also tested to determine the conditions necessary to simulate the permanent deflection of the tray handles that had occurred in the failed tray. Full distortion of the handles was obtained experimentally only by dropping a full hot tray on its end onto the floor. The test results indicated that the tray had slipped from the hand of the user.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.bldgs.c9001168
EISBN: 978-1-62708-219-8
... Abstract Steel pipes, used for years in a food factory soft water preheater, were found to leak as a result of corrosion. The pipes, made of 18/8 steel, were immersed in steam maintained at 0.5 atm and 150 deg C. They carried desalinated process water, heating it to approximately 100 deg C...
Abstract
Steel pipes, used for years in a food factory soft water preheater, were found to leak as a result of corrosion. The pipes, made of 18/8 steel, were immersed in steam maintained at 0.5 atm and 150 deg C. They carried desalinated process water, heating it to approximately 100 deg C. Inspection revealed a reddish-brown coating on the outside of the pipe with a few flat pitting holes and incipient cracks. Corrosion was also observed on the inner walls of the pipe, consisting of rust patches with pitting scars, branching out to predominantly transcrystalline cracks. In this case, leaking appears to be the result of a combination of pitting and stress corrosion, most likely due to chlorides. The factory was recommended to use molybdenum-alloyed steels (type 18/10 or 18/12) which are more resistant to local disruption of passivating films and pitting than molybdenum-free types such as 18/8.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001150
EISBN: 978-1-62708-235-8
.... Had the poor transverse properties of thick-section plate been recognized, and all the bars properly cut with respect to the rolling direction, the premature fractures would not have occurred. Diffusers Food processing Rolling direction Steel plate Fe-0.18C-1.10Mn Fe-0.20C-1.04Mn Brittle...
Abstract
A number of rotating blades in a diffuser at a sugar beet processing plant fabricated from rectangular bars cut from rolled carbon-manganese steel plate fractured brittlely. However, apparently identical blades underwent significant plastic deformation without fracture. Inspection of both fractured and bent blades revealed similar preexisting cracks at the toes of bar attachment welds. Metallographic examination of the bent and the fractured bars revealed they had been cut parallel and transverse, respectively, to the rolling direction of the steel plate. Due to the combined effects of the low fracture toughness of the plate on planes parallel in the rolling direction, the presence of the preexisting cracks, and the relatively large section thickness of the bars, the bars whose lengths were transverse to the rolling direction fractured brittlely when subjected to impact loads. Had the poor transverse properties of thick-section plate been recognized, and all the bars properly cut with respect to the rolling direction, the premature fractures would not have occurred.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c9001593
EISBN: 978-1-62708-234-1
... in several demanding applications including food processing, medical components, and fluid handling. 1 The polysulfone body of the failed sensor had been injection molded around a tubular stainless steel insert to form the final component. Background information obtained on the application showed...
Abstract
A failure analysis was conducted on a flow-sensing device that had cracked while in service. The polysulfone sensor body cracked radially, adjacent to a molded-in steel insert. This article describes the investigative methods used to conduct the failure analysis. The techniques utilized included scanning electron microscopy, Fourier transform infrared spectroscopy, differential scanning calorimetry, thermomechanical analysis, and melt flow rate determination. It was the conclusion of the investigation that the part failed via brittle fracture, with evidence also indicating low cycle fatigue associated with cyclic temperature changes from normal service. The design of the part and the material selection were significant contributing factors because of stresses induced during molding, physical aging of the amorphous polysulfone resin, and the substantial differential in coefficients of thermal expansion between the polysulfone and the mating steel insert.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c9001604
EISBN: 978-1-62708-234-1
... Background A food manufacturer uses SO 2 vapor generated in a heat exchanger ( Fig. 1 ) as part of a processing step. The heat exchanger is approximately 0.45 m in diameter and 2.5 m tall. The SO 2 liquid enters the heat exchanger approximately 28 cm from the bottom tubesheet. A sketch of the heat...
Abstract
Critical heat exchanger components are usually manufactured from durable steels, such as stainless steel, which exhibit good strength and corrosion resistance. Failure of a heat exchanger occurred due to specification of a plain carbon steel that did not survive service in the SO2 vapor environment. However, failure analysis showed that cavitation erosion was the responsible failure mechanism, not corrosion as might be expected.
Book Chapter
Series: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006939
EISBN: 978-1-62708-395-9
..., with maximum migration observed when acetic acid was used as a food simulant ( Ref 185 ). Food packaging ZnO quantum dots in a polystyrene film or a polyvinylpyrrolidone (PVP) gel Purified colloidal ZnO quantum dots were dissolved in polystyrene and cast as films; alternatively, PVP-capped ZnO quantum...
Abstract
Polymer materials are key building blocks of the modern world, commonly used in packaging, automobiles, building materials, electronics, telecommunications, and many other industries. These commercial applications of polymeric materials would not be possible without the use of additives. This article is divided into five sections: mechanical property modifiers, physical property modifiers, biological function modifiers, processing aids, and colorants. It describes three classes of additives that are used to inhibit biological activity, six classes of mechanical property modifiers, three classes of physical property modifiers, and two classes of both colorants and processing aids.
Series: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006935
EISBN: 978-1-62708-395-9
... vacuum and pressure forming are used for high-volume production of low-cost food containers, trays, and cups, using both solid and foamed starting materials. Twin-sheet forming is very similar to blow molding, except that instead of using a hot tube as the starting point, it uses two plastic sheets...
Abstract
Manufacturing process selection is a critical step in plastic product design. The article provides an overview of the functional requirements that a part must fulfil before process selection is attempted. A brief discussion on the effects of individual thermoplastic and thermosetting processes on plastic parts and the material properties is presented. The article presents process effects on molecular orientation. It also illustrates the thinking that goes into the selection of processes for size, shape, and design factors. Finally, the article describes how various processes handle reinforcement.
Series: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006868
EISBN: 978-1-62708-395-9
... recreation, and for military applications. They can be fabricated under sterile conditions, allowing for sanitary handling and preservation of foods, and for specialized medical components to be used in the operating arena during life-saving procedures. The process of developing a part to be manufactured...
Abstract
This article presents the benefits of selecting plastics for products to be manufactured. It discusses the four key considerations for plastic part design: material, process, tooling, and design. The article provides a detailed discussion of the development sequence for plastic parts. The basis for the development sequence is twofold: first, to create the best solution for the application, and second, to minimize potential project risks through careful and thoughtful work habits.
Series: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006925
EISBN: 978-1-62708-395-9
...-injection-molded polyurethane, both unfilled and filled (20% glass flakes parallel to the flow direction of the mold-filling process). Data supplied by Mobay Corp. (d) Reinforced with 40 wt% glass fibers. (e) Typical property value ranges for diglycidyl ether of bisphenol A epoxy (refer to text...
Abstract
This introductory article describes the various aspects of chemical structure that are important to an understanding of polymer properties and thus their eventual effect on the end-use performance of engineering plastics. The polymers covered include hydrocarbon polymers, carbon-chain polymers, heterochain polymers, and polymers containing aromatic rings. The article also includes some general information on the classification and naming of polymers and plastics. The most important properties of polymers, namely, thermal, mechanical, chemical, electrical, and optical properties, and the most significant influences of structure on those properties are then discussed. A variety of engineering thermoplastics, including some that are regarded as high-performance thermoplastics, are covered in this article. In addition, a few examples of commodity thermoplastics and biodegradable thermoplastics are presented for comparison. Finally, the properties and applications of six common thermosets are briefly considered.
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006838
EISBN: 978-1-62708-329-4
... Abstract This article provides an overview of metal additive manufacturing (AM) processes and describes sources of failures in metal AM parts. It focuses on metal AM product failures and potential solutions related to design considerations, metallurgical characteristics, production...
Abstract
This article provides an overview of metal additive manufacturing (AM) processes and describes sources of failures in metal AM parts. It focuses on metal AM product failures and potential solutions related to design considerations, metallurgical characteristics, production considerations, and quality assurance. The emphasis is on the design and metallurgical aspects for the two main types of metal AM processes: powder-bed fusion (PBF) and directed-energy deposition (DED). The article also describes the processes involved in binder jet sintering, provides information on the design and fabrication sources of failure, addresses the key factors in production and quality control, and explains failure analysis of AM parts.
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001808
EISBN: 978-1-62708-241-9
... is usually associated with colonies of bacteria near a food source, often in an anaerobic environment. On carbon steel, the colonies produce biofilm and tubercles with their metabolic excretion products corroding the metal. The observed corrosion and the background were consistent with MIC. Inherent...
Abstract
Six cases of failure attributed to microbiologically influenced corrosion (MIC) were analyzed to determine if any of the failures could have been avoided or at least predicted. The failures represent a diversity of applications involving typical materials, primarily stainless steel and copper alloys, in contact with a variety of liquids, chemistries, and substances. Analytical techniques employed include stereoscopic examination, energy dispersive x-ray spectroscopy (EDS), temperature and pH testing, and metallographic analysis. The findings indicate that MIC is frequently the result of poor operations or improper materials selection, and thus often preventable.
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001034
EISBN: 978-1-62708-214-3
... chemicals and food products are often made from type 316L stainless steel. In the manufacture of these trailers, the inteiiors are polished to match the finish of the original steel, and great care is taken to avoid the formation of scratches and crevices that could serve as initation sites for corrosion...
Abstract
The interior surface of a type 316L stainless steel trailer barrel used to haul various chemicals showed evidence of severe pitting after less than 1 year of service. Two sections were cut from the barrel and microscopically examined. Metallographic sections were also prepared at the weld areas and away from the weld zones. Terraced, near-surface pits with subsurface caverns and a high level of sulfur in the pit residue, both indicative of bacteria-induced corrosion, were found. No evidence of weld defects or defective material was present. Testing of the water used at the wash station and implementation of bacteria control measures (a special drying process after washing and use of a sanitizing rinse) were recommended.
Series: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006915
EISBN: 978-1-62708-395-9
... (PVDC) enhance absorption of oxygen, nitrogen, carbon dioxide, and water but its tightly packed chain arrangement restricts diffusion of these species. Thus, PVDC films (commonly used as plastic wrap) are extremely valuable in food packaging. As shown in Fig. 20 , permeability can also be inhibited...
Abstract
This article provides practical information and data on property development in engineering plastics. It discusses the effects of composition on submolecular and higher-order structure and the influence of plasticizers, additives, and blowing agents. It examines stress-strain curves corresponding to soft-and-weak, soft-and-tough, hard-and-brittle, and hard-and-tough plastics and temperature-modulus plots representative of polymers with different degrees of crystallinity, cross-linking, and polarity. It explains how viscosity varies with shear rate in polymer melts and how processes align with various regions of the viscosity curve. It discusses the concept of shear sensitivity, the nature of viscoelastic properties, and the electrical, chemical, and optical properties of different plastics. It also reviews plastic processing operations, including extrusion, injection molding, and thermoforming, and addresses related considerations such as melt viscosity and melt strength, crystallization, orientation, die swell, melt fracture, shrinkage, molded-in stress, and polymer degradation.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.marine.c9001703
EISBN: 978-1-62708-227-3
..., it exhibits a ductile to brittle transition which can result in low fracture toughness at room temperature ( 1 ). This steel is a general purpose grade typically used in food processing and chemical containment. Although ferritic grades have very good resistance to sustained load cracking ( 2...
Abstract
This paper describes the metallurgical investigation of a broken spindle used to attach an antenna to the mast of a naval vessel. Visual inspections of both failed and intact fastener assemblies were carried out both on-board ship and in the laboratory followed by metallographic and fractographic examinations. Simulations were also performed on stressed material in a suitable environment to assess the relative importance of postulated failure mechanisms. Factors contributing to this failure including assembly procedures and applied preloads, service loading and environment, and material selection and specification. The discussion considers whether this failure was an isolated incident or is likely to be a fleet-wide problem, and suggests ways to prevent reoccurrence.
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006811
EISBN: 978-1-62708-329-4
.... The conclusion of this article presents several case studies illustrating the various failure modes discussed throughout. bone plates bone screws cardiovascular implants corrosion failure analysis fracture orthopedic implants surgical tools wear History and Benefits The United States Food...
Abstract
Bearing in mind the three-legged stool approach of device design/manufacturing, patient factors, and surgical technique, this article aims to inform the failure analyst of the metallurgical and materials engineering aspects of a medical device failure investigation. It focuses on the device "failures" that include fracture, wear, and corrosion. The article first discusses failure modes of long-term orthopedic and cardiovascular implants. The article then focuses on short-term implants, typically bone screws and plates. Lastly, failure modes of surgical tools are discussed. The conclusion of this article presents several case studies illustrating the various failure modes discussed throughout.
Series: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006922
EISBN: 978-1-62708-395-9
... transparent does the material have to be? Does it need to be water-clear, or can it be translucent? What regulatory requirements need to be met? For example: NSF/ANSI for water contact FDA for food contact USP for pharmaceuticals RoHS that restricts the use of 10 substances in plastic...
Abstract
There are many reasons why plastic materials should not be considered for an application. It is the responsibility of the design/materials engineer to recognize when the expected demands are outside of what the plastic can provide during the expected life-time of the product. This article reviews the numerous considerations that are equally important to help ensure that part failure does not occur. It provides a quick review of thermoplastic and thermoset plastics. The article focuses primarily on thermoset materials that at room temperature are below their glass transition temperature. It describes the motivation for material selection and the goal of the material selection process. The use of material datasheets for material selection as well as the processes involved in plastic material selection and post material selection is also covered.
Series: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006917
EISBN: 978-1-62708-395-9
... morphology, without evidence of such microductility. Often the SEM examination reveals the presence of multiple, otherwise unseen individual crack-initiation sites clustered in close proximity ( Fig. 16 ). Housings from pumps used for a food processing application failed during service. The housings had...
Abstract
While there are many fracture mechanisms that can lead to the failure of a plastic component, environmental stress cracking (ESC) is recognized as one of the leading causes of plastic failure. This article focuses on unpacking the basic concepts of ESC to provide the engineer with a better understanding of how to evaluate and prevent it. It then presents factors that affect and contribute to the susceptibility of plastic to ESC: material factors, chemical factors, stress, and environmental factors. The article includes the collection of background information to understand the circumstances surrounding the failure, a fractographic evaluation to assess the cracking, and analytical testing to evaluate the material, design, manufacturing, and environmental factors.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003515
EISBN: 978-1-62708-180-1
.... Nondestructive evaluation is used in that context in this section. Attention is restricted to structural components, but applications exist in a wide range of other industries such as electronic, agricultural, food processing, biomedical, and so forth. Quantitative interpretation is an important issue...
Abstract
This article provides information on life assessment strategies and conceptually illustrates the interplay of nondestructive evaluation (NDE) and fracture mechanics in the damage tolerant approach. It presents information on probability of detection (POD) and probability of false alarm (PFA). The article describes the damage tolerance approach to life management of cyclic-limited engine components and lists the commonly used nondestructive evaluation methods. It concludes with an illustration on the role of NDE, as quantified by POD, in fully probabilistic life management.
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