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Structural steel
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.bldgs.c9001611
EISBN: 978-1-62708-219-8
... Abstract Cold cracking of structural steel weldments is a well-documented failure mechanism, and extensive work has been done to recognize welding and materials selection parameters associated with it. These efforts, however, have not fully eliminated the occurrence of such failures...
Abstract
Cold cracking of structural steel weldments is a well-documented failure mechanism, and extensive work has been done to recognize welding and materials selection parameters associated with it. These efforts, however, have not fully eliminated the occurrence of such failures. This article examines a case of cold cracking failure in the construction industry. Fortunately, the failure was identified prior to final erection of the structural members and the weld was successfully reworked. The article explains how various welding parameters, such as electrode/wire selection, joint design, and pre/postheating, played a role in the failure. Human factors and fabrication practices that contributed to the problem are covered as well.
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Published: 01 January 2002
Fig. 2 Picral-etched specimen of structural steel that was exposed to contaminated agricultural ammonia showing nonbranched stress-corrosion cracks. 75×
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Published: 01 January 2002
Fig. 39 Example of a brittle fracture of A36 structural steel, after sustaining fatigue cracking initially (at arrows). Source: Ref 41
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Published: 15 January 2021
Fig. 3 S - N curve for cruciform metal-active-gas-welded joints (structural steel S355, ASTM A572 grade 5). LCF, low-cycle fatigue; HCF, high-cycle fatigue; P F , probability of failure
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in Failure of a Structural Bolt Due to Reversed-Bending Fatigue
> ASM Failure Analysis Case Histories: Buildings, Bridges, and Infrastructure
Published: 01 June 2019
Fig. 1 Failure of a structural steel bolt in the rail assembly of an overhead crane. (a) Illustration of the crane rails and attendant support beams. (b) Shank portion of the failed bolt. (c) Fracture surface of the bolt showing evidence of reversed-bending fatigue
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Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.design.c0046155
EISBN: 978-1-62708-233-4
... to the member ( Fig. 1 ). At failure, the part was receiving the second set of loads up to 103.6% of design load. The post was made of D-6ac steel and was heat treated to a tensile strength of 1517 to 1655 MPa (220 to 240 ksi). Fig. 1 Structural member (post) of D-6ac steel that failed by fatigue...
Abstract
A structure had been undergoing fatigue testing for several months when a post-like member heat treated to a tensile strength of 1517 to 1655 MPa (220 to 240 ksi) ruptured. The fracture occurred in the fillet of the post that contacted the edge of a carry-through box bolted to the member. At failure, the part was receiving a second set of loads up to 103.6% of design load. Visual investigations showed rubbing and galling of the fillet. Microscopic and metallographic examination revealed beach marks on the fracture surface and evidence of cold work and secondary cracking in the rubbed and galled area. Electron fractography confirmed that cracking had initiated at a region of tearing and that the cracks had propagated by fatigue. Mechanical properties of all specimens exceeded the minimum values specified for the post. This evidence supports the conclusion that fatigue was the primary cause of failure. Rubbing of the faying surfaces worked the interference area on the post until small tears developed. These small tears became stress-concentration points that nucleated fatigue cracks. Recommendations included rounding the edge of the box in the area of contact with the post to ensure a tangency fit.
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in Fatigue Fracture of a D-6ac Steel Structural Member at the Line of Contact With Another Member
> ASM Failure Analysis Case Histories: Design Flaws
Published: 01 June 2019
Fig. 1 Structural member (post) of D-6ac steel that failed by fatigue cracking. The cracking was initiated by rubbing and galling from a mating carry-through box that was bolted to the post.
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.bldgs.c0047113
EISBN: 978-1-62708-219-8
... Abstract A portion of a 19 mm (0.75 in.) diam structural steel bolt was found on the floor of a manufacturing shop. This shop contained an overhead crane system that ran on rails supported by girders and columns. Inspection of the crane system revealed that the bolt had come from a joint...
Abstract
A portion of a 19 mm (0.75 in.) diam structural steel bolt was found on the floor of a manufacturing shop. This shop contained an overhead crane system that ran on rails supported by girders and columns. Inspection of the crane system revealed that the bolt had come from a joint in the supporting girders and could be considered one of the principal fasteners in the track system. Analysis (visual inspection, metallographic exam, and hardness testing) supported the conclusions that fatigue induced by the overhead movement of the crane produced failure of the bolt. The bolt was deficient in strength for the cyclic applied loads in this case and probably was not tightened sufficiently. Recommendations included removing the remaining bolts in the crane support assembly and replacing them with a higher-strength, more fatigue-resistant bolt, for example, SAE grade F, 104 to 108 HRB. The bolts should be tightened according to the specifications of the manufacturer, and the system should be periodically inspected for correct tightness.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001208
EISBN: 978-1-62708-229-7
... Abstract A spindle made of hardenable 13% chromium steel X40 Cr13 (Material No. 1.4034) that was fastened to a superheated steam push rod made of high temperature structural steel 13Cr-Mo44 (Material No. 1.7335) by means of a convex fillet weld, fractured at the first operation of the rod...
Abstract
A spindle made of hardenable 13% chromium steel X40 Cr13 (Material No. 1.4034) that was fastened to a superheated steam push rod made of high temperature structural steel 13Cr-Mo44 (Material No. 1.7335) by means of a convex fillet weld, fractured at the first operation of the rod directly next to the weld bead. Investigation showed that the fracture of the superheated steam push rod spindle was caused by hardening and hardening crack formation in the weld seams and adjoining areas. It would have been preferable to avoid welding near the cross sectional transitions altogether in consideration of the crack sensitivity of high hardenability steels. If for some reason this was not possible, then all precautions should have been taken that are applicable to the particular steel, such as preheating, slow cooling and stress relief tempering after welding. The selection of an austenitic additive material should have been considered because it could have equalized stresses due to its high elongation. Most probably, however, a material of lower hardenability should have been selected for the spindle if high operating properties were of paramount importance.
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001777
EISBN: 978-1-62708-241-9
... fracture weld defects structural steel oxidation fractography anisotropy ASTM A36 (structural steel) UNS K02599 Introduction The failure of huge industrial structures such as bucket-wheel stacker reclaimers (BSRs) draws considerable attention from interested stakeholders, including operators...
Abstract
The structural collapse of an iron-ore bucket-wheel stacker reclaimer at the beginning of operation was investigated by means of mechanical tests, microstructural characterization, and computational structural analysis. The mechanical failure was a consequence of a brittle fracture by cleavage. The crack followed the heat-affected zone of a welded joint connecting a rectangular hollow section member and a plate flange. The main factors contributing to failure were related with a combination of design-in and manufacturing-in factors like high load-strength ratio at the point of failure, local stress concentration as a result of geometry restrictions, and weld defects. This particular section was responsible for the load transfer between the front tie member and the boom extremity, and its failure was the main cause of the catastrophic failure of the equipment.
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001094
EISBN: 978-1-62708-214-3
... Abstract Cadmium-coated type 410 martensitic stainless steel 1 4 -14 self-drilling tapping screws fractured during retorquing tests within a few weeks after installation. The screws were used to assemble structural steel frames for granite panels that formed the outer skin of a high...
Abstract
Cadmium-coated type 410 martensitic stainless steel 1 4 -14 self-drilling tapping screws fractured during retorquing tests within a few weeks after installation. The screws were used to assemble structural steel frames for granite panels that formed the outer skin of a high-rise building. Fractographic and metallographic examination showed that the fractures occurred in a brittle manner from intergranular crack propagation. Laboratory and simulated environmental tests showed that an aqueous environment was necessary for the brittle fracture/cracking phenomenon. The cracks were singular and intergranular with little branching. Secondary subsurface cracks suggested possible hydrogen embrittlement. The 410 screws had been introduced to replace conventional case-hardened carbon steel screws that conform to SAE specification J78. Carbon steel screws had a proven record of acceptable performance for the intended application. It was recommended that use of the 410 screws be discontinued in preference to the case-hardened carbon steel screws.
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Published: 01 January 2002
Fig. 23 Graphitized microstructure of SA-210-A-1 plain carbon steel. The structure is ferrite and graphite with only a trace of spheroidized carbon remaining. Etched with nital. 500×
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in Failure Analysis and Life Assessment of Structural Components and Equipment
> Failure Analysis and Prevention
Published: 01 January 2002
Fig. 7 Effect of welding on the life of a carbon steel structure. (a) and (b) 46 cm (18 in.) long crack found in a carbon steel as-forged nozzle that was arc gouged. Failure occurred after five years in service during cold start-up procedure. (c) Micrograph showing a hardened layer
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in Internal Cracks in Cast Steel With 9% Ni for Cryogenic Applications
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1992
Fig. 7 Dendritric structures. (a) Steel F with 0.03% Mo. Mold thickness: 30 mm (1.2 in.). (b) Steel E, with 0.03% Mo. Mold thickness: 200 mm (8 in.). Dendritic structures. (c) Steel H, with 0.26% Mo. Moid thickness: 30 mm (1.2 in.). (d) Steel G, with 0.26% Mo. Mold thickness: 200 mm (8 in.).
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Published: 01 June 2019
Fig. 2 a). Edge structure of a steel with 0.73% C after 4 h annealing in wet hydrogen of 1 atm pressure, etched in picral, 100 ×. 700° C. b) Edge structure of a steel with 0.73% C after 4 h annealing in wet hydrogen of 1 atm pressure, etched in picral, 100 ×. 800° C. c) Edge structure
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Published: 01 June 2019
Fig. 4 Edge structure of a spring washer of silicon steel, broken ahead of time in a fatigue test. Cross section, etched in nital. 100 ×
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Published: 01 June 2019
Fig. 10 a). Change in structure by hydrogen attack, etched in nital. 200 ×. Steel with 0,45% C. a). Initial state. b). Change in structure by hydrogen attack, etched in nital. 200 ×. Steel with 0,45% C. 10.0 h, 400°C, 300 atü H 2 . c). Change in structure by hydrogen attack, etched in nital
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in Problems Associated with Heat Treated Parts
> Analysis and Prevention of Component and Equipment Failures
Published: 30 August 2021
Fig. 12 Effect of austenitizing temperature on structure of 1% C steel. (a) Quenched from 1000 °C (1830 °F). Coarse martensite plates (gray) and retained austenite (white). Vickers hardness of 745. (b) Quenched from 750 °C (1380 °F). Spheroidized carbides (white) in a fine martensite matrix
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in Problems Associated with Heat Treated Parts
> Analysis and Prevention of Component and Equipment Failures
Published: 30 August 2021
Fig. 13 Structure at the surface of a steel that was carburized and then subjected to decarburization. (a) Below Ac 1 . (b) Between Ac 1 and Ac 3 . (c) Above Ac 3
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in Failure Prevention through Life Assessment of Structural Components and Equipment
> Analysis and Prevention of Component and Equipment Failures
Published: 30 August 2021
Fig. 7 Effect of welding on the life of a carbon steel structure. (a) and (b) show the 46 cm (18 in.) long crack found in a carbon steel as-forged nozzle that was arc gouged. Failure occurred after five years in service during a cold start-up procedure. (c) Micrograph showing a hardened layer
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