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Joining-related failures

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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0047677
EISBN: 978-1-62708-217-4
... Abstract Resistance spot welds joining aluminum alloy 2024-T8511 stiffeners to the aluminum alloy 6061-T62 skin of an aircraft drop tank failed during slosh and vibration testing. Visual examination of the fracture surfaces showed that the failure was by tensile or bending overload...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0047673
EISBN: 978-1-62708-217-4
... positioning. The problem could be solved by better forming procedures to provide an accurate fit-up that would not interfere with electrode alignment. Aircraft components Fuel tanks Welding parameters 2024-T62 UNS A92024 Joining-related failures A series of resistance spot welds joining Z...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c0047579
EISBN: 978-1-62708-234-1
...-gradient and phase-change stresses. Joining the studs to the flanges by welding should be discontinued. They should be attached by screw threads, using a key and keyway to prevent turning in service. Flanges Heat affected zone Phase transformations Studs 414 UNS S41400 Joining-related failures...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c0091048
EISBN: 978-1-62708-235-8
.... Cracking (fracturing) Heat exchangers Weld defects Welded joints Ferritic stainless steel Brittle fracture Joining-related failures A welded ferritic stainless steel heat exchanger cracked prior to service. The sheet steel weld joint design is depicted in Fig. 1(a) . The welding filler metal...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c0047749
EISBN: 978-1-62708-235-8
.... Stress relief treatment of tube before brazing and immediate cleaning of brazing residual fluorides was recommended to avoid failure. Brazing fluxes Residual stress Residues Swaging 321 UNS S32100 Stress-corrosion cracking Joining-related failures A pressure-tube assembly of type 321...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.matlhand.c0048095
EISBN: 978-1-62708-224-2
... was attributed to the misalignment of the sling during loading. Aluminum alloy 5183 or 5356 filler metal was recommended to be used to avoid brittle welds. Alignment Cranes Filler metal Welded joints 5083 UNS A95083 5086 UNS A95086 Joining-related failures Brittle fracture The T-section cross...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0047583
EISBN: 978-1-62708-217-4
.... Aircraft components Stress concentration Supports 321 UNS S32100 Fatigue fracture Joining-related failures An aircraft fuel-nozzle-support assembly exhibited cracks along the periphery of a fusion weld that attached a support arm to a fairing in a joint that approximated a T-shape in cross...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0047072
EISBN: 978-1-62708-217-4
... to the T6 temper after forming. Aircraft components Gas turbine engines Spot welds 2024-T42 UNS A92024 6061-T6 UNS A96061 Joining-related failures Fatigue fracture Heat treating-related failures Postflight inspection of a gas-turbine aircraft engine that had experienced compressor stall...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c0047621
EISBN: 978-1-62708-229-7
..., and flange and more skillful welding techniques to avoid undercutting and unfused interfaces. Arc welding Combustion chamber Flanges Gas turbine engines Pipe fitting Undercuts Welding defects Inconel 718 (Nickel-base superalloy) UNS N07718 Fatigue fracture Joining-related failures...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0089722
EISBN: 978-1-62708-217-4
... Butt welds Design Elbows Fatigue cracking Lap welds Tubes Vibratory stresses Welded joints 321 UNS S32100 Joining-related failures Fatigue fracture The welded elbow assembly shown in Fig. 1 was part of a hydraulic-pump pressure line for a jet aircraft. The other end of the tube...
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.process.c0048154
EISBN: 978-1-62708-235-8
.... Helical springs Medium-carbon steel Joining-related failures Fatigue fracture A medium-carbon helical spring was installed in a machine assembly that was welded into its final location. During welding, which was conducted several inches from the spring, no shield was used to prevent spatter from...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c0047753
EISBN: 978-1-62708-235-8
... and separation between braze and housing. Brazed joints Fatigue cracking Welding defects 347 UNS S34700 Fatigue fracture Joining-related failures A rectangular segment broke from the type 347 stainless steel housing of a pressure-probe assembly used in experimental instrumentation. The pressure...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c0048356
EISBN: 978-1-62708-229-7
...-wall tubes in the row, replacing the broken tube, and repairing cracks in other tubes by welding. ASME SA226 Joining-related failures Fatigue fracture In a new stationary boiler, furnace water-wall tubes were welded to the top of a dust bin for rigid support ( Fig. 1a ). The tubes measured...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c0047681
EISBN: 978-1-62708-229-7
... current to reduce the temperature, by an increase in the electrode force, or both. Compressors Gas turbine engines Welding parameters Ti-6Al-4V UNS R56406 Joining-related failures Fatigue fracture A fluorescent liquid-penetrant inspection of an experimental stator vane of a first-stage...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001211
EISBN: 978-1-62708-235-8
... particularly favorable conditions for corrosion in the defective welded seam (crevice corrosion). The tube material itself is perfectly satisfactory and in no way responsible for the failure. Pipe Weld defects Welded joints Welded steel Joining-related failures Crevice corrosion The elbow made...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.petrol.c0048808
EISBN: 978-1-62708-228-0
.... Cracking (fracturing) Dilution Pressure vessels Welded joints 405 ASTM A515 UNS S40500 Joining-related failures Repeated cracking occurred in the welds joining the liner and shell of a fluid catalytic cracking unit that operated at a pressure of 140 kPa (20 psi) and a temperature of 480 ┬░C (895...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c0047632
EISBN: 978-1-62708-235-8
... opening. Eutectics Grain boundaries Melting 2219-T62 UNS A92219 Intergranular fracture Joining-related failures An air bottle, machined from a solid block of aluminum alloy 2219-T852, displayed liquid-penetrant crack indications after assembly welding ( Fig. 1a ). The air bottle...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.matlhand.c0048048
EISBN: 978-1-62708-224-2
... the fatigue failure by acting as stress raisers. The welding method was changed by the manufacturer and all chains were replaced with defect free chains. Cranes Resistance welding Stress concentration 4615 UNS G46150 Joining-related failures Fatigue fracture A resistance-welded chain link...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0047720
EISBN: 978-1-62708-217-4
...-related failures Creep fracture/stress rupture Airfoil-shape impingement cooling tubes were fabricated of 0.25-mm (0.010-in.) thick Hastelloy X sheet stock, then pulsed laser beam butt welded to cast Hastelloy X base plugs. Each weldment was then inserted through the base of a hollow cast turbine...