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Shrinkage
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.auto.c0047263
EISBN: 978-1-62708-218-1
... 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...
Abstract
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.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.bldgs.c0089530
EISBN: 978-1-62708-219-8
... 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...
Abstract
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.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.machtools.c0089534
EISBN: 978-1-62708-223-5
... 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...
Abstract
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.
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in Mechanisms and Appearances of Ductile and Brittle Fracture in Metals
> Failure Analysis and Prevention
Published: 01 January 2002
Fig. 60 Dendritic shrinkage porosity in aluminum alloy A356. Shrinkage porosity is a common imperfection in cast components and also a common location for fracture initiation. (a) Fracture surface from a fatigue specimen. 30×. (b) Same specimen as in part (a) but at lower magnification (13
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in Broken Back up Rolls from a Broad Strip Mill
> ASM Failure Analysis Case Histories: Steelmaking and Thermal Processing Equipment
Published: 01 June 2019
Fig. 7 Micro-shrinkage cavity with carbon segregation (ledeburite). Etched in picral. 50 ×
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in Fatigue Fracture of Alloy Steel Valve Springs Because of Pipe
> ASM Failure Analysis Case Histories: Processing Errors and Defects
Published: 01 June 2019
Fig. 1 Valve-spring failure due to residual shrinkage pipe. (a) Macrograph showing fracture, as indicated by arrow. (b) Fracture surface; pipe is indicated by arrow.
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in Plating Blemishes in Zinc Die Castings
> ASM Failure Analysis Case Histories: Processing Errors and Defects
Published: 01 June 2019
Fig. 2 Scanning electron micrograph of shrinkage porosity in a steel weld
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in Plating Blemishes in Zinc Die Castings
> ASM Failure Analysis Case Histories: Processing Errors and Defects
Published: 01 June 2019
Fig. 3 Detail of shrinkage porosity in steel weldment. Note that the secondary dendrite arms are spaced at 90° in this cubic crystal structure material, unlike snowflakes formed from water, which prefer a hexagonal crystal habit.
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in Catastrophic Failure of a Fan in a Diesel Engine Cooler
> ASM Failure Analysis Case Histories: Automobiles and Trucks
Published: 01 June 2019
Fig. 7 SEM photograph of the peeled off nugget surface showing shrinkage porosity, insufficient melting and penetration, and gas evolution (which could be due to presence of moisture, oil, etc. at the interface) at the interface
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in Catastrophic Failure of a Fan in a Diesel Engine Cooler
> ASM Failure Analysis Case Histories: Automobiles and Trucks
Published: 01 June 2019
Fig. 9 Microstructure of the weld showing (a) shrinkage porosity in the nugget, (b) intergranular cracks emanating from the fusion zone, W1
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in Coolant Leakage Through a Cylinder-Head Exhaust Port Caused by Shrinkage Porosity
> ASM Failure Analysis Case Histories: Automobiles and Trucks
Published: 01 June 2019
Fig. 1 Section from a failed cylinder-head exhaust port. The shrinkage porosity allowed engine coolant to leak into the exhaust port. Not polished, not etched. 0.9×
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in Failure Analysis of a Cast Steel Crosshead
> ASM Failure Analysis Case Histories: Chemical Processing Equipment
Published: 01 June 2019
Fig. 7 Dendritic structure in a primary shrinkage cavity. 16×.
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in Damaged Impellers in a Rotary Pump
> ASM Failure Analysis Case Histories: Failure Modes and Mechanisms
Published: 01 June 2019
Fig. 4 Porous zone under a fracture edge of impeller I (shrinkage zone in Fig. 5 ). 20 ×
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in Ductile Overload Failure of a T-Hook That Fractured in Service
> ASM Failure Analysis Case Histories: Material Handling Equipment
Published: 01 June 2019
Fig. 4 Graphite structure in the areas of the shrinkage condition. An estimated 90% is ASTM types I and II, with 150 nodules/mm 2 . As-polished. 54×
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in Ductile Overload Failure of a T-Hook That Fractured in Service
> ASM Failure Analysis Case Histories: Material Handling Equipment
Published: 01 June 2019
Fig. 4 Graphite structure in the areas of the shrinkage condition. An estimated 90% is ASTM types I and II, with 150 nodules/mm 2 . As-polished. 54×
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in Brittle Fracture of Cast Low- Alloy Steel Jaws Because of Shrinkage Porosity and Low Ductility of Case and Core
> ASM Failure Analysis Case Histories: Machine Tools and Manufacturing Equipment
Published: 01 June 2019
Fig. 1 Wire-stretching jaws that broke because of shrinkage porosity and low ductility of case and core. The jaws, sand cast from low-alloy steel, were used to stretch wire for prestressed concrete beams. (a) Two pairs of movable jaws. 0.7×. (b) Two pairs of stationary jaws. 0.7×. (c) and (d
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in Failure of Steel Jaws
> ASM Failure Analysis Case Histories: Machine Tools and Manufacturing Equipment
Published: 01 June 2019
Fig. 1 About half of the broken parts had this dendritic appearance. Shrinkage porosity was found to be the primary cause of failure.
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in Study on Failure Analyses and Material Characterizations of a Damaged Booster Pump
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 3 Shrinkage pit and void found in the pump’s body
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Published: 01 January 2002
Fig. 3 Shrinkage porosity at bolt-hole bosses in a ductile-iron cylinder head
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Published: 01 January 2002
Fig. 5 Wire-stretching jaws that broke because of shrinkage porosity and low ductility of case and core. The jaws, sand cast from low-alloy steel, were used to stretch wire for prestressed concrete beams. (a) Two pairs of movable jaws. 0.7×. (b) Two pairs of stationary jaws. 0.7×. (c) and (d
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