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axial cracks
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in Fracture and Wear Failure of a Locomotive Turbocharger-Bearing Sleeve
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
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in Analysis of Failed Nuclear Plant Components[1]
> ASM Failure Analysis Case Histories: Power Generating Equipment
Published: 01 June 2019
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in Failure Analysis of High-Speed Pinion Gear Shaft
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
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Published: 30 August 2021
Fig. 7 (a) Photograph of turbine vane. (b) Photograph showing axial cracking at midheight of leading edge. (c) Composite optical micrograph showing leading-edge crack in cross section. Etched with Marble’s reagent. Original magnification: 100×. (d) Scanning electron micrographs showing gamma
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in Fatigue Failure of a Diesel Engine Piston Pin
> ASM Failure Analysis Case Histories: Offshore, Shipbuilding, and Marine Equipment
Published: 01 June 2019
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in Fatigue Failure of a Diesel Engine Piston Pin
> ASM Failure Analysis Case Histories: Offshore, Shipbuilding, and Marine Equipment
Published: 01 June 2019
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in Fatigue Failure of a Diesel Engine Piston Pin
> ASM Failure Analysis Case Histories: Offshore, Shipbuilding, and Marine Equipment
Published: 01 June 2019
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in Fractography of Steel Drive Cables
> ASM Failure Analysis Case Histories: Mechanical and Machine Components
Published: 01 June 2019
Fig. 5 Laboratory brittle torsion failure shows longitudinal, or axial, crack growth. Magnification 55 times.
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Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.marine.c9001417
EISBN: 978-1-62708-227-3
... of fatigue failure were present with origins at about the mid-thickness of the pin located each side of the step in the fracture surface. In addition, cracking was evident in the axial direction. The crack ran into one of the radial oil holes near the end of the pin. A further section was taken transverse...
Abstract
A marine diesel running at 350 rpm had satisfactorily completed 13,000 h before failure of one of the piston pins took place. The pin, 17 in. long, with a central bore of 3 in. diam, failed transversely approximately 3 in. from one end. The characteristic conchoidal markings indicative of fatigue failure were present with origins at about the mid-thickness of the pin located each side of the step in the fracture surface. In addition, cracking was evident in the axial direction. The crack ran into one of the radial oil holes near the end of the pin. A further section was taken transverse to the crack surface and subsequent examination confirmed the presence of a slag inclusion on the edge of the crack. The inclusion ran the full length of the component. The stress raising effect of the inclusion in combination with the residual and service stresses served to initiate the cracking in the longitudinal direction. Although the longitudinal crack preceded the transverse ones, it would appear that once initiated, the latter developed at a greater rate than the former.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001421
EISBN: 978-1-62708-235-8
.... The cracks were located in the part of the flange that formed a continuation of the pipe bore. The majority of them originated at the end of the flange bore and extended axially along the pipe and radially across the flange face. Magnetic crack detection revealed a further number of cracks in the weld...
Abstract
The bottom flange of a vertical pipe coupled to an isolating valve in a steam supply line to a turbine failed. Steam pressure was 1,500 psi and the temperature 416 deg C (780 deg F). Multiple cracking occurred in the bore of the flange. A quarter-segment was cut out and examined. The cracks were located in the part of the flange that formed a continuation of the pipe bore. The majority of them originated at the end of the flange bore and extended axially along the pipe and radially across the flange face. Magnetic crack detection revealed a further number of cracks in the weld deposit. While the fracture in the weld metal was of the ductile type exhibiting a fine fibrous appearance, that in the flange material was of the cleavage type. Microscopic examination revealed that the cracks were blunt-ended fissures of the type characteristic of corrosion-fatigue. It was concluded that cracking was due to corrosion-fatigue, which arose from the combined effect of a fluctuating tensile stress in the presence of a mildly corrosive environment.
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001847
EISBN: 978-1-62708-241-9
... sleeve fatigue fracture insufficient nitriding tangential stress chromium steel axial cracks beach marks microstructural analysis nitriding depth 38CrMoAl (chromium-molybdenum-aluminum alloy steel) Background A bearing sleeve assembled with the locomotive turbocharger-main shaft...
Abstract
An investigation was conducted to determine what caused a bearing sleeve in a locomotive turbocharger to fail. The sleeve, which is made of nitrided 38CrMoAl steel, fractured at the transition fillet between the cylinder and plate. Visual examination revealed significant wear on the external surface of the cylinder, with multiple origin fatigue fracture appearing to be the dominant fracture mechanism. Metallurgical examination indicated that the nitrided layer was not as deep as it was supposed to be and had worn away on the outer surface of the sleeve, exposing the soft matrix underneath. This led to further wear and an increase in friction between the sleeve and bearing bush. Fatigue crack initiation occurred at the root fillet because of stress concentration and large frictional forces. Insufficient nitriding depth facilitated the propagation of fatigue cracks.
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in Investigation of Fatigue-Induced Socket-Welded Joint Failures for Small-Bore Piping Used in Power Plants
> ASM Failure Analysis Case Histories: Power Generating Equipment
Published: 01 June 2019
Fig. 4 Photomicrographs at an axial weld toe showing a fatigue-initiated crack that extended through the pipe wall
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in Stress Corrosion Cracking of Expansion Bellows of Steam Main
> ASM Failure Analysis Case Histories: Power Generating Equipment
Published: 01 June 2019
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001755
EISBN: 978-1-62708-241-9
... of fatigue crack(s) in the inner race. When the crack reached the critical size, the collar of the race fractured, causing subsequent damage. The cage also failed due to excessive stresses in the axial direction, and its material was smeared on the steel balls and the outer race. aircraft bearings...
Abstract
An aero engine failed due to the misalignment of the ball bearing fitted on the main shaft of the engine. The aero engine incorporates two independent compressors: a six-stage axial flow LP compressor and a nine-stage axial flow HP compressor. The bearing under consideration is a HP location bearing and is fitted at the rear of the nine-stage compressor. It was supposed to operate for at least 5000 h, but failed catastrophically after 1300 h, rendering the engine unserviceable. Unusually high stresses caused by misalignment and uneven axial loading resulted in the generation of fatigue crack(s) in the inner race. When the crack reached the critical size, the collar of the race fractured, causing subsequent damage. The cage also failed due to excessive stresses in the axial direction, and its material was smeared on the steel balls and the outer race.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001515
EISBN: 978-1-62708-229-7
... of the tube confirmed the axial length of the crack ( Figure 2 ). The crack was tightly closed along most of its length and made several shallow angle bends, 10 – 20°, before coming to a stop. There was no evidence of crack branching, nor did the crack bifurcate and tear circumferentially around the tube...
Abstract
This paper describes the analysis of the failure of a Zr-2.5Nb pressure tube in a CANDU reactor. The failure sequence was established as: (1) the existence of an undetected manufacturing flaw in the form of a lamination, (2) in-service development of the flaw by oxidation of the lamination, (3) delayed hydride cracking, which extended the flaw through the wall of the tube, resulting in leakage, and (4) rupture of the tube by cold pressurization while the reactor was shut down. The comprehensive failure analysis led to a remedial action plan that permitted the reactor to be returned to full-power operation and ensured a low probability of a similar occurrence for all CANDU reactors.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.steel.c9001149
EISBN: 978-1-62708-232-7
... large axial thermal bending stresses. Thermal cycling of the system initiated fatigue cracks at the stiffener rings. When the critical crack size was reached, fast fracture occurred. The system was redesigned by eliminating the redundant restraints and by modifying the stiffener rings to permit free...
Abstract
A large diameter steel pipe reinforced by stiffening rings with saddle supports was subjected to thermal cycling as the system was started up, operated, and shut down. The pipe functioned as an emission control exhaust duct from a furnace and was designed originally using lengths of rolled and welded COR-TEN steel plate butt welded together on site. The pipe sustained local buckling and cracking, then fractured during the first five months of operation. Failure was due to low cycle fatigue and fast fracture caused by differential thermal expansion stresses. Thermal lag between the stiffening rings welded to the outside of the pipe and the pipe wall itself resulted in large radial and axial thermal stresses at the welds. Redundant tied down saddle supports in each segment of pipe between expansion joints restrained pipe arching due to circumferential temperature variations, producing large axial thermal bending stresses. Thermal cycling of the system initiated fatigue cracks at the stiffener rings. When the critical crack size was reached, fast fracture occurred. The system was redesigned by eliminating the redundant restraints and by modifying the stiffener rings to permit free radial thermal breathing of the pipe.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c9001733
EISBN: 978-1-62708-225-9
.... Magnification 510 (left) and 485 times (right). A brittle torsion failure 18 is shown in Fig. 5 . This type of longitudinal (axial) crack growth results quite often in wires which are metallurgically or chemically out of specification. Figure 6 shows a type of torsion failure which commonly occurs...
Abstract
Drive cables from a rubber processing machine were failing in less than 8 h of operation, the expected service life being much greater than 100 h. Comparison cables were tested to failure under known stress conditions, including tensile overload, torsional loading, reversed bending alternating stress, and buckling (compressive) cyclic loading. The mode of failure was found to be reversed bending fatigue caused by drive cables moving over guide pulleys of small radii. Modifications of the machinery and drive cable system were suggested.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001536
EISBN: 978-1-62708-229-7
... axially into semicircular pieces. Dye-penetrant examinations and radiographic inspection revealed the presence of approximately 40 cracks at the inner surface in the three circumferential weld regions examined. Virtually all of the cracks were in the base metal HAZ of the forged elbow and wedge material...
Abstract
Argonne National Laboratory has conducted analyses of failed components from nuclear power-generating stations since 1974. The considerations involved in working with and analyzing radioactive components are reviewed here, and the decontamination of these components is discussed. Analyses of four failed components from nuclear plants are then described to illustrate the kinds of failures seen in service. The failures discussed are (1) intergranular stress-corrosion cracking of core spray injection piping in a boiling water reactor, (2) failure of canopy seal welds in adapter tube assemblies in the control rod drive head of a pressurized water reactor, (3) thermal fatigue of a recirculation pump shaft in a boiling water reactor, and (4) failure of pump seal wear rings by nickel leaching in a boiling water reactor.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c0048845
EISBN: 978-1-62708-229-7
... to tube seat were revealed by surface inspection. Cracks were found to originate from inside the header, extend axially in the tube penetrations and radially from those holes into the ligaments. Cracks in 94 locations, ranging from small radial cracks to full 360Ý cracks were revealed by dye-penetrant...
Abstract
The maximum life of base-loaded headers and piping is not possible to be predicted until they develop microcracking. The typical elements of a periodic inspection program after the occurrence of the crack was described extensively. Cracks caused by creep swelling in the stub-to-header welds in the secondary superheater outlet headers (constructed of SA335-P11 material) of a major boiler were described as an example. The OD of the header was measured to detect the amount of swelling and found to have increased 1.6% since its installation. Ligament cracks extending from tube seat to tube seat were revealed by surface inspection. Cracks were found to originate from inside the header, extend axially in the tube penetrations and radially from those holes into the ligaments. Cracks in 94 locations, ranging from small radial cracks to full 360Ý cracks were revealed by dye-penetrant inspection. The unit was operated under reduced-temperature conditions and with less load cycling than previously until a redesigned SA335-P22 header was installed.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c0046963
EISBN: 978-1-62708-229-7
... Abstract A turbine spacer made of AMS 5661 alloy (Incoloy 901; composition: Fe-43Ni-13Cr-6Mo-2.5Ti) was removed from service because of a crack in the forward side of the radial rim. The crack extended axially for a distance of 16 mm across the spacer rim; radially, it extended to a depth...
Abstract
A turbine spacer made of AMS 5661 alloy (Incoloy 901; composition: Fe-43Ni-13Cr-6Mo-2.5Ti) was removed from service because of a crack in the forward side of the radial rim. The crack extended axially for a distance of 16 mm across the spacer rim; radially, it extended to a depth of 6.4 mm into the web section. Analysis (visual inspection, 5000 and 10,000x TEM fractographs, chemical analysis, and 9x metallographic examination) supported the conclusions that cracking on the forward rim of the spacer occurred in fatigue that initiated on the forward rim face and that progressed into the rim and web areas. Because there was no apparent metallurgical cause for the cracking, the problem was assigned to engineering.
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