In a steel foundry, tensile and bend specimens of castings made in a 2-ton basic arc furnace showed, at irregular intervals, regions with coarse-grained fractures where the specimens broke prematurely, so that the specified strength and toughness values could not be reached. Several cast tensile specimens and some forcibly-broken pieces of the flanges of armature yokes made of cast steel GS C 25 according to DIN 17 245 were investigated. Microscopic examination showed that the cause of damage was the superabundant use of aluminum as deoxidizer. According to recommendations, the aluminum addition was reduced by one-half. Since then, there have been no additional rejects due to insufficient tensile and bend values.

Following a freight train derailment, part of a fractured side frame was retained for study because a portion of its fracture surface exhibited a rock candy appearance and black scale. It was suspected of having failed, thereby precipitating the derailment. Metallography, scanning electron microscopy, EDXA, and x-ray mapping were used to study the steel in the vicinity of this part of the fracture surface. It was found to be contaminated with copper. Debye-Scherrer x-ray diffraction patterns obtained from the scale showed that it consisted of magnetite and hematite. It was concluded that some copper was accidentally left in the mold when the casting was poured. Liquid copper, carrying with it oxygen in solution, penetrated the austenite grain boundaries as the steel cooled. The oxygen reacted with the steel producing a network of scale outlining the austenite grain structure. When the casting fractured as a result of the derailment, the fracture followed the scale in the contaminated region thus creating the “rock candy” fracture.

A failed crosshead of an industrial compressor was examined using optical and SEM. The crosshead was an ASTM A148 grade 105-85 steel casting. On the basis of the observations reported and available background information, it was concluded that the failure began with the initiation of cracks at slag inclusions and sharp fillets in weld-repair areas in the casting. The weld-repair procedures were unsatisfactory. The cracks propagated in a fatigue mode. he casting quality was judged unacceptable because of the presence of excessive shrinkage porosity. It was recommended that crosshead castings be properly inspected before machining. Revision of foundry practice to reduce or eliminate porosity was also recommended.

A failed crosshead of an industrial compressor was examined using optical and scanning electron microscope. The crosshead was an ASTM A148 grade 105-85 steel casting. On the basis of the observations reported and available background information, it was concluded that the failure began with the initiation of cracks at slag inclusions and sharp fillets in weld-repair areas in the casting. The weld-repair procedures were unsatisfactory. The cracks propagated in a fatigue mode. he casting quality was judged unacceptable because of the presence of excessive shrinkage porosity. It was recommended that crosshead castings be properly inspected before machining. Revision of foundry practice to reduce or eliminate porosity was also recommended.

A roadarm for a tracked vehicle failed during preproduction vehicle testing. The arm was a weldment of two cored low-alloy steel sand castings specified to ASTM A 148, grade 120–95. A maximum carbon content of 0.32% was specified. The welding procedure called for degreasing and gas metal arc welding; neither preheating nor postheating was specified. The filler metal was E70S-6 continuous consumable wire with a copper coating to protect it from atmospheric oxidation while on the reel. Analysis of the two castings revealed that the carbon content was higher than specified, ranging from 0.40 to 0.44%. The fracture occurred in the HAZ , where quenching by the surrounding metal had produced a hardness of 55 HRC. Some roadarms of similar carbon content and welded by the same procedure had not failed because they had been tempered during a hot-straightening operation. Brittle fracture of the roadarm was caused by a combination of too high a carbon equivalent in the castings and the lack of preheating and postheating during the welding procedure. A pre-heat and tempering after welding were added to the welding procedure.

The causes of internal cracking that occurred in 9% Ni steel castings during manufacture were investigated using a series of eight laboratory castings containing varying amounts of molybdenum. The effect of mold thickness was also investigated. The laboratory castings were subjected to three-point bend testing, and fracture surfaces were examined using SEM fractography, metallography, and depth analysis (SIMS) of the fracture surface. The cracks were found to originate at austenitic grain boundaries that coincided with primary dendrite interfaces. The cracking was attributed to a decrease in grain-boundary cohesion resulting from sulfur segregation. Addition of molybdenum proved effective in preventing cracking. The molybdenum promoted MnS precipitation in the grain and preferentially segregated to the interfaces.

A type 316 stainless steel pipe reducer section failed in service of bleached pulp stock transfer within 2 years in a pulp and paper mill. The reducer section fractured in the heat-affected zone of the flange-to-pipe weld on the flange side. The pipe reducer section consisted of 250 and 200 mm (10 and 8 in.) diam flanges welded to a tapered pipe section. The tapered pipe section was 3.3 mm (0.13 in.) thick type 316 stainless steel sheet, and the flanges were 5 mm (0.2 in.) thick CF8M (type 316) stainless steel castings. Visual and metallographic analysis indicated that the fracture was caused by intergranular corrosion/stress-corrosion cracks that initiated from the external surface of the pipe reducer section. Contributory factors were the sensitized condition of the flange and the concentration of corrosive elements from the bleach stock plant environment on the external surface. In the absence of the sensitized condition of the flange, the service of the pipe reducer section was acceptable. A type 316L stainless steel reducer section was recommended to replace the 316 component because of its superior resistance to sensitization.

This article focuses on the general root causes of failure attributed to the casting process, casting material, and design with examples. The casting processes discussed include gravity die casting, pressure die casting, semisolid casting, squeeze casting, and centrifugal casting. Cast iron, gray cast iron, malleable irons, ductile iron, low-alloy steel castings, austenitic steels, corrosion-resistant castings, and cast aluminum alloys are the materials discussed. The article describes the general types of discontinuities or imperfections for traditional casting with sand molds. It presents the international classification of common casting defects in a tabular form.

A large shackle used in operating a dragline bucket failed in service. The shackle was made of a cast low-alloy steel (similar to AISI 4320) heat treated to a hardness of 415 BN. The shackle failed by fracturing through the load-bearing region. Examination of the fracture surface revealed a fatigue crack through about one-third of the cross section. A secondary fatigue crack, perpendicular to the main fracture, was also observed. The composition of the weld deposit corresponded to a heat treatable flux-cored arc welding filler material that was known to have been used for repair welding of these products. This shackle failed because of fatigue initiating at hydrogen cracks that had occurred in the HAZ of a repair weld. The weld had been made with a heat-treatable filler material, and a full postweld heat treatment had been performed. However, a low-hydrogen filler material had not been used to make the weld. Repair welds in high-strength steel castings should always be made with low-hydrogen filler materials.

Two suction rolls at the first press section of a 25 ft. wide paper machine developed cracks within two years of service. The rolls were austenitic stainless steel castings made of ASTM A 351 Grade CF8M alloy containing molybdenum. The rolls were exposed to slightly acidic white water (pH approximately 4.7) containing chlorides (45 ppm). Visual and liquid penetrant inspections of the rolls revealed extensive cracking at the roll inside surface. The cracks penetrated more than 30 percent of the wall thickness and a few cracks were several inches long. The cracks were preferentially oriented along the roll length and primarily at the roll inside surface. Field metallographic examination showed significant grain boundary chromium-carbide precipitation and intergranular corrosion. The roll failures were attributed to chromium depletion along the grain boundaries (sensitization) resulting from slow cooling of the casting to avoid large residual stresses. The roll manufacturer recommended a proprietary ferritic/austenitic stainless steel as the replacement material for the rolls.

Several back up rolls of 1400 mm barrel diam from a broad strip mill broke after a relatively short operating time as a result of bending stresses when the rolls were dismantled. The fracture occurred in the conical region of the neck at about 600 mm diam. The rolls were shaped steel castings with 0.8 to 1.0% C, 1% Mn, 1% Cr, 0.5% Mo and 0.4% Ni and were heat treated to a tensile strength of 950 N/sq mm. Because the bending stress on mounting was only 42 N/sq mm in the fracture cross section, it was evident at the outset that material defects had promoted the fracture. In the case of this roll and the other broken rolls, the cracking and fracture were promoted by various casting defects. Investigation of the rolls showed that both the breaking off of the neck and the disintegration of the barrel edges was caused by material defects, more exactly casting defects. The fractures on the other rolls examined were so badly rusted or contaminated that they were incapable of yielding any information.

A desuperheater diffuser nozzle in the steam supply line failed within nine months of service in an 8.25 MN/sq m (1200 psig) steam line. The nozzle was an austenitic stainless steel casting in conformance to material. The nozzle had numerous cracks on the inside and outside surfaces, and the cracks had penetrated through the wall thickness in several areas. The fracture surfaces had distinct beach markings delineating the crack front, representative of crack propagation stages. The cracks were transgranular and, unlike classical corrosion-fatigue cracks, exhibited branching, characteristic of chloride-induced SCC in austenitic stainless steels. The failure resulted from chloride-induced SCC, possibly assisted by cyclic stress. The recommendation for alternate material for the desuperheater nozzle included nickel base alloys per ASTM B 564, Grades 600 or 800 titanium alloy per ASTM B 367, Grades C3/C4, or ferritic stainless steel alloy per ASTM 182, Grade FXM27.

There was a fracture of an anchor link that rides on a post with a spherical surface. No bevel or radius was called for, leaving an extremely sharp edge. A fatigue crack grew from the top sharp edge. The casting had good toughness and strength (1448 MPa, or 210 ksi, tensile strength). This fatigue failure was the result of poor design, which incorporated a notch that acted as a stress raiser, leading to fatigue-crack growth. A generous radius was recommended to avoid similar failures.