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Metalworking-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.a0003507
EISBN: 978-1-62708-180-1
...Abstract Abstract This article describes the general root causes of failure associated with wrought metals and metalworking. This includes a brief review of the discontinuities or imperfections that may be the common sources of failure-inducing defects in bulk working of wrought products...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c0048156
EISBN: 978-1-62708-235-8
... Tensile stress 6150 UNS G61500 Metalworking-related failures The face of a 6150 flat spring was under tensile stress. Although small flaws were visible on the surface ( Fig. 1 ), the failure began at the dark spot on the edge, where roughness resulted from shearing during the blanking operation...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001541
EISBN: 978-1-62708-235-8
... failures Introduction Diagnosis Selected Reference Selected Reference • Failures Related to Metalworking , Failure Analysis and Prevention , Vol 11 , ASM Handbook , ASM International , 2002 , p 81 – 102 10.31399/asm.hb.v11.a0003507 A forging of 7075-T6 aluminum (a support...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c0048128
EISBN: 978-1-62708-225-9
... drawing Spring steel Surface treatment related failures Metalworking-related failures Figure 1 shows light streaks arranged in a diagonal direction on the wire surface. The streaks are parallel to the wire axis. A darker depressed area is visible between the streaks and below the center...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.med.c0047158
EISBN: 978-1-62708-226-6
... at the source, and the inspection of the finished product will help detect obscure seams. Cracking (fracturing) Forceps Forgings Seams Stainless steel Metalworking-related failures The pointed ends of several stainless steel forceps split or completely fractured where split portions broke off...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c0048131
EISBN: 978-1-62708-225-9
... in the load test due to the split wire. The reason for the condition was interpreted to be overdrawing which resulted in intense internal strains, high circumferential surface tension, and decreased ductility. Ductility Strain Surface tension Wire drawing Spring steel Metalworking-related failures...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.marine.c9001195
EISBN: 978-1-62708-227-3
... to fatigue by the notch effect of coarse scale-filled folds formed during forging. Connecting rods Forging defects Steel Metalworking-related failures Fatigue fracture The connecting rod was broken in two places at the small end. The general view of the reassembled pieces in Fig. 1 shows...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001456
EISBN: 978-1-62708-229-7
... an internal plug. The diam of this portion of the tube was reduced by local collapse and folding of the section rather than by longitudinal extension of the tube itself. Defects Optical microscopy Superheaters Tubemaking Steel tube Metalworking-related failures Corrosion fatigue A tube...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c0047161
EISBN: 978-1-62708-235-8
... environment, such a surface flaw can become the initiating site for a fatigue crack or a corrosion-related failure. Cracking (fracturing) Forgings Seams Shafts (power) Surface defects 4130 UNS G41300 Metalworking-related failures Routine magnetic-particle inspection revealed crack...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c0048787
EISBN: 978-1-62708-235-8
... is done at a lower temperature to avoid formation of ferrite streaks. Cracking (fracturing) Fire extinguishers Overheating Spinning (metals) 1541 UNS G15410 Metalworking-related failures The top of a fire-extinguisher case ( Fig. 1a ) was closed by spinning. The case was made from 1541...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.marine.c0047151
EISBN: 978-1-62708-227-3
... fracture. No recommendations were made. Connecting rods Folds Forgings Carbon steel Metalworking-related failures Fatigue fracture A motorboat-engine connecting rod forged from carbon steel fractured in two places and cracked at the small end during service. The locations of the fracture...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.matlhand.c9001262
EISBN: 978-1-62708-224-2
... probable that the real damage was done during the heat-up forging (drop-forging) and could not be removed during heat-treatment. Chains Cracking (fracturing) Drop forgings Overheating 30CrMoV 9 Metalworking-related failures A chain link which was part of the hoisting mechanism of a drop...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.machtools.c0047154
EISBN: 978-1-62708-223-5
... by the coarse fissures at the fold zones. Cracking (fracturing) Folds Forgings Fe-0.4C-0.34Cr Metalworking-related failures A head of a socket spanner made of heat-treated 0.40C-0.34Cr steel cracked in service. One half of the head, longitudinally sectioned, is shown in Fig. 1...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.auto.c0046182
EISBN: 978-1-62708-218-1
... surfaces before machining and before putting the part into service. Connecting rods Forgings Nonmetallic inclusions 15B41 UNS H15411 Fatigue fracture Metalworking-related failures A connecting cap ( Fig. 1a ) from a truck engine fractured after 65,200 km (40,500 miles) of service. The cap...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001188
EISBN: 978-1-62708-235-8
... flame cutting of the middle section of the slide. The initial crack acted as a sharp notch favoring the formation of the fatigue fracture which lead to the failure of the slide. Flame cutting Friction press Thermal stresses Ck 35 Metalworking-related failures Fatigue fracture A short...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001194
EISBN: 978-1-62708-235-8
... the influence of tensile stresses that arose during bending. This phenomenon is known as “solder brittleness.” Bending Boiler tubes Brittleness Overheating 15Mo 3 Metalworking-related failures A seamless hot-drawn boiler tube NW 300 of 318 mm O. D. and 9 mm wall thickness made of steel 15 Mo 3...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.machtools.c9001183
EISBN: 978-1-62708-223-5
...) additions of copper, nickel, and cobalt. A steel of similar composition, X38Cr-MoV5 1 (W-No. 2343) was used for hot working tools. The sliver originated from a damaged press tool. Hot working Impurities Studs Aluminum Metalworking-related failures In a continuously cast aluminum press stud...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.design.c0047181
EISBN: 978-1-62708-233-4
..., for example, modified AMS 2301. Quenching cracks Seamless tubes 4140 UNS G41400 Metalworking-related failures Heat treating-related failures Hydraulic cylinder housings were being fabricated from 4140 grade seamless steel tubing. During production, magnetic-particle inspection indicated...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c9001216
EISBN: 978-1-62708-217-4
... Metalworking-related failures Countersunk riveted joints in aluminium sheet are widely employed in the aircraft industry. The preparation of the sheet for the riveting process consists either of countersinking where the sheet is sufficiently thick or of dimpling. The dimples can either be pressed (pulled...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001227
EISBN: 978-1-62708-235-8
... gave rise to the conclusion that it was formed either by the sole or contributive effect of these stresses. Cooling rate Cracking (fracturing) Pipe bends St 35.29 (Other, general, or unspecified) fracture Metalworking-related failures An elbow of 70 mm O. D. and 10 mm wall thickness...