Friction and wear are important when considering the operation and efficiency of components and mechanical systems. Among the different types and mechanisms of wear, adhesive wear is very serious. Adhesion results in a high coefficient of friction as well as in serious damage to the contacting surfaces. In extreme cases, it may lead to complete prevention of sliding; as such, adhesive wear represents one of the fundamental causes of failure for most metal sliding contacts, accounting for approximately 70% of typical component failures. This article discusses the mechanism and failure modes of adhesive wear including scoring, scuffing, seizure, and galling, and describes the processes involved in classic laboratory-type and standardized tests for the evaluation of adhesive wear. It includes information on standardized galling tests, twist compression, slider-on-flat-surface, load-scanning, and scratch tests. After a discussion on gear scuffing, information on the material-dependent adhesive wear and factors preventing adhesive wear is provided.

Reinforced polymers (RPs) are widely used in structural, industrial, automotive, and engineering applications due to their ecofriendly nature and the potential to manipulate their properties. This article addresses the technical synthesis of RPs, referring to their tribological behavior, to provide insights into the contribution and interaction of influential parameters on the wear behavior of polymers. It provides a brief discussion on the effects of significant parameters on RP tribology. The article describes abrasive and adhesive wear and provides a theoretical synthesis of the literature regarding the wear mechanisms of RPs. It also describes the synthesis of abrasive wear failure of different types of RPs and highlights the contribution of these influential parameters. The article addresses the synthesis of adhesive wear failure of different types of RPs.

In the course of a general overhaul, the crankpins and main journals (3 in. diam) of the crankshaft of a four-cylinder oil engine were built up by metal spraying. Four weeks later, the shaft broke through the pin remote from the flywheel (driving) end. The fracture was of the fatigue type. A creeping crack originated in the fillet at the inside surface of the pin and extended parallel to the plane of the web across practically the entire section before complete rupture occurred. The sprayed metal on the fractured pin had very poor adhesion. The surfaces of the main journals had not been grooved but appeared to have been roughened by shot or grit-blasting prior to spraying and the deposit was more firmly adherent to these surfaces than in the case of the pins. It is doubtful, however, whether the adhesion of sprayed metal to a surface prepared even in this manner would always be satisfactory under severe loading conditions, such as those to which a crankpin is subjected in service.

A longeron assembly constructed of Alclad 2024, some parts being in the T3 condition, others in the T42 condition, failed at a rivet hole. Plastic deformation at the crack site was found, but no plastic deformation was found in similar failed components. It was concluded that the numerous hairline cracks in the Alclad layer adjacent to the main fracture were fatigue cracks. In another case, bonded samples of 2024-T3 sheet were fatigue tested at various stress levels. Failures could be separated into three groups: those that failed in the adhesive bond, those that failed in the base material, and those that exhibited a dual failure. The last category failed in the adhesive bond and also showed a type of pitting on one face of the base material. In a third case, a 2024-T4 extrusion section was found to exhibit blistering after chemical milling. The presence of interconnecting microcracks between adjacent discontinuities supported a hydrogen blistering diagnosis.

Wear, a form of surface deterioration, is a factor in a majority of component failures. This article is primarily concerned with abrasive wear mechanisms such as plastic deformation, cutting, and fragmentation which, at their core, stem from a difference in hardness between contacting surfaces. Adhesive wear, the type of wear that occurs between two mutually soluble materials, is also discussed, as is erosive wear, liquid impingement, and cavitation wear. The article also presents a procedure for failure analysis and provides a number of detailed examples, including jaw-type rock crusher wear, electronic circuit board drill wear, grinding plate wear failure analysis, impact wear of disk cutters, and identification of abrasive wear modes in martensitic steels.

This article reviews the abrasive and adhesive wear failure of several types of reinforced polymers, including particulate-reinforced polymers, short-fiber reinforced polymers (SFRP), continuous unidirectional fiber reinforced polymers (FRP), particulate-filled composites, mixed composites (SFRP and particulate-filled), unidirectional FRP composites, and fabric reinforced composites. Friction and wear performance of the composites, correlation of performance with various materials properties, and studies on wear-of failure mechanisms by scanning electron microscopy are discussed for each of these types.

A forging die in a 250-ton press producing brass valves began to show signs of fatigue after a few thousand hits. By the time it reached 30,000 hits, the die was badly damaged and was submitted for analysis along with one of the last forgings produced. The investigation included visual and macroscopic inspection, metallographic and chemical analysis, SEM imaging, optical profilometry, mechanical property testing, and EDX analysis. The die was made of chromium hot-work tool steel and the forgings were made of CuZn39Pb3 heated to an initial working temperature 700 deg C. The entire surface of the die was covered with fatigue cracks and many fillets had been plastically deformed. Several other types of damage were also observed, including areas of oxidation, corrosion pits, voids, abrasive wear, die adhesion, and thermal fatigue. Fatigue cracking was the primary cause of failure with significant contributions from the other damage mechanisms.

A batch of bimetal foil/epoxy laminates was rejected because of poor peel strength. The laminates were manufactured by sintering a nickel/phosphorus powder layer to a copper foil, cleaning, then chromate conversion coating the nickel-phosphorus surface, and laminating the nickel-phosphorus side of the clad bimetal onto an epoxy film, so that the end product contained nickel-phosphorus sandwiched between copper and epoxy, with a chromate conversion layer on the epoxy side of the nickel-phosphorus. Peel testing showed abnormally low adhesion strength for the bad batch of peel test samples. Comparison with normal-strength samples using XPS indicated an 8.8% Na concentration on the surface of the bad sample; the good example contained less than 1% Na on the surface. After 15 min of argon ion etching, depth profiling showed high concentrations of sodium were still evident, indicating that the sodium was present before the chromate conversion treatment was performed. A review of the manufacturing procedures showed that sodium hydroxide was used as a cleaning agent before the chromate conversion coating. Failure cause was that apparently the sodium hydroxide had not been properly removed during water rinsing. Thus, recommendation was to modify that stage in the processing.

Gears can fail in many different ways, and except for an increase in noise level and vibration, there is often no indication of difficulty until total failure occurs. This article reviews the major types of gears and the basic principles of gear-tooth contact. It discusses the loading conditions and stresses that effect gear strength and durability. The article provides information on different gear materials, the common types and causes of gear failures, and the procedures employed to analyze them. Finally, it presents a chosen few examples to illustrate a systematic approach to the failure examination.

This article focuses on the types of activities required for the resolution of wear problems. These include examining and characterizing the tribosystem; characterizing and modeling the wear process; obtaining and evaluating wear data; and evaluating and verifying the solution.

A 5000-gal (20,000-L) hot-water holding tank fractured at a large automotive manufacturing plant. The tank was made from Type 304 austenitic stainless steel. The inner diameter of the tank displayed a macroscopic, web-like network of cracks that deceptively suggested intergranular stress-corrosion cracking. The problem, however, originated on the outside surface of the tank where a tensile stress (due to low applied stress and fabrication-induced residual stresses) accelerated the growth of numerous stress corrosion cracks that eventually broke through to the inner surface, causing leakage and ultimately failure.

Plastic product failures are directly attributed to one of the following four reasons: omission of a critical performance requirement, improper materials specification, design error, and processing/manufacturing error. Therefore, product failures can be minimized or eliminated if all of these parameters are comprehensively examined during the design process. This article focuses on all of these factors, except processing-related failures, which are outside the design and engineering domain. It is dedicated to the identification and avoidance of common problems associated with the selection and designing of plastic parts. The article provides information on the material-related design criteria that depend on the applications, environmental conditions of use, and performance requirements. It discusses physical properties of plastics based on their relevance to real-world environmental conditions. The most-common design problems related to design considerations are also covered.

When a roller-bearing assembly was removed from an aircraft for inspection after a short time in service, several areas of apparent galling were noticed around the inside surface of the inner cone of the bearing. These areas were roughly circular spots of built-up metal. The bearing had not seized, and there was no evidence of heat discoloration in the galled areas. The inner cone, made of modified 4720 steel and carburized for wear resistance, rode on an AISI type 630 (17-4 PH) stainless steel spacer. Consequently, it was desirable to determine whether the galled spots contained any stainless steel from the spacer. Other items for investigation were the nature of the bond between the galled spot and the inner cone and any evidence of overtempering or rehardening resulting from localized overheating. Analysis (visual inspection, electron probe x-ray microanalysis, microscopic examination, and hardness testing) supported the conclusions that galling had been caused by a combination of local overload and abnormal vibration of mating parts of the roller-bearing assembly. No recommendations were made.

Corrosion is the deterioration of a material by a reaction of that material with its environment. The realization that corrosion control can be profitable has been acknowledged repeatedly by industry, typically following costly business interruptions. This article describes the electrochemical nature of corrosion and provides the typical analysis of environmental- and corrosion-related failures. It presents common methods of testing of laboratory corrosion and discusses the processes involved in the prevention of environmental- and corrosion-related failures of metals and nonmetals.

In 1975, a manufacturer was awarded a contract to produce modular air-traffic control towers for the U.S. Navy. The specifications called for painted steel siding, but the manufacturer convinced the Navy to substitute aluminum-bonded-to-plywood panels that were provided by a supplier. In less than one year, the panels began to delaminate and the aluminum began to crack. It was found that the failure was the result of chloride-induced intergranular corrosion caused by chemicals in the adhesive and excessive moisture in the wood introduced during manufacturing.

This article describes the preliminary stages and general procedures, techniques, and precautions employed in the investigation and analysis of metallurgical failures that occur in service. The most common causes of failure characteristics are described for fracture, corrosion, and wear failures. The article provides information on the synthesis and interpretation of results from the investigation. Finally, it presents key guidelines for conducting a failure analysis.

An oxygen line that was part of a mobile, truck -mounted oxygen-acetylene welding unit exploded in service. Analysis revealed that the failure occurred at the flexible hose-to-valve connection. It was further determined that a steel adapter had been installed at the point of failure to make the connection. Use of the adapter which joined with a brass nipple, created an unacceptable dissimilar metal joint. The steel also provided a source for the generation of sparks. Loctite, a hydrocarbon sealant that is highly flammable and explosive in contact with pure oxygen, had been used to seal the threaded joint. It was recommended that only brass fittings be used to assemble removable joints and that use of washers, sealants, and hydrocarbon lubricants be strictly avoided.