An engine cylinder head failed after operating just 3.2 km (2 mi) because of coolant leakage through the exhaust port. Visual examination of the exhaust ports revealed a casting defect on the No. 7 exhaust-port wall. A 0.9x examination of an unpolished, unetched longitudinal section through the defect indicated shrinkage porosity. This defect was found to interconnect the water jacket and the exhaust gas flow chamber. No cracks were found by magnetic-particle inspection. The gray iron cylinder head had a hardness of 229 HRB on the surface of the bottom deck. The microstructure consisted of type A size 4 flake graphite in a matrix of pearlite with small amounts of ferrite. this evidence supported the conclusion that the cylinder-head failure resulted from the presence of a casting defect (shrinkage) on the No. 7 cylinder exhaust-port wall interconnecting the water jacket with the exhaust-gas flow chamber. No recommendations were made.

A sand-cast steel eye connector used to link together two 54,430 kg capacity floating-bridge pontoons failed prematurely in service. The pontoons were coupled by upper and lower eye and clevis connectors that were pinned together. The eye connector was found to be cast from low-alloy steel conforming to ASTM A 148, grade 150-125. The crack was found to have originated along the lower surface initially penetrating a region of shrinkage porosity. It was observed that cracking then propagated in tension through sound metal and terminated in a shear lip at the top of the eye. The fracture of the eye connector was concluded to have occurred by tensile overload because of shrinkage porosity. Sound metal was ensured by radiographic examination of subsequent castings.

The specially designed sand-cast low-alloy steel jaws that were implemented to stretch the wire used in prestressed concrete beams fractured. The fractures were found to be macroscale brittle and exhibited very little evidence of deformation. The surface of the jaws was disclosed by metallographic examination to be case carburized. The case was found to be martensite with small spheroidal carbides while the core consisted of martensite plus some ferrite. The fracture was revealed to be related to shrinkage porosity. Tempering was revealed to be probably limited to about 150 deg C by the hardness values (close to the maximum hardness values attainable) for the core. It was interpreted that the low tempering temperature used may have contributed to the brittleness. The procedures used for casting the jaws were recommended to be revised to eliminate the internal shrinkage porosity. Tempering at a slightly higher temperature to reduce surface and core hardness was recommended.