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Leland E. Shields, Robert A. Clark, Roland Huet
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Charlie R. Brooks, Ashok Choudhury
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Friedrich Karl Naumann, Ferdinand Spies
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Book Chapter
Stress-Corrosion Cracking Caused by Residual Stresses in Chromium Silicon Alloy Steel Helical Compression Springs
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001119
EISBN: 978-1-62708-214-3
... Abstract To samples of helical compression springs were returned to the manufacturer after failing in service well short of the component design life. Spring design specifications required conformance to SAE J157, “Oil Tempered Chromium Silicon Alloy Steel Wire and Springs.” Each spring...
Abstract
To samples of helical compression springs were returned to the manufacturer after failing in service well short of the component design life. Spring design specifications required conformance to SAE J157, “Oil Tempered Chromium Silicon Alloy Steel Wire and Springs.” Each spring was installed in a separate heavy truck engine in an application in which spring failure can cause total engine destruction. The springs were composed of chromium-silicon steel, with a hardness ranging from 50 to 54 HRC. Chemical composition and hardness were substantially within specification. Failure initiated from the spring inside coil surface. Examination of the fracture surface using scanning electron microscopy showed no evidence of fatigue. Final fracture occurred in torsion. X-ray diffraction analysis revealed high inner-diameter residual stresses, indicating inadequate stress relief from spring winding. It was concluded that failure initiation was caused by residual stress-driven stress-corrosion cracking, and it was recommended that the vendor provide more effective stress relief.
Book Chapter
Metallurgical Failure Analysis of a Broken Compression Hip Screw Surgical Implant
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.med.c9001664
EISBN: 978-1-62708-226-6
... Abstract A compression hip screw is a device designed to hold fractures in the area of the femur in alignment and under compression. A side plate, which is an integral part of the device, is attached by screws to the femur, and it holds the compression screw in position. The device analyzed had...
Abstract
A compression hip screw is a device designed to hold fractures in the area of the femur in alignment and under compression. A side plate, which is an integral part of the device, is attached by screws to the femur, and it holds the compression screw in position. The device analyzed had broken across the eighth hole (of nine holes) from the end of the plate. The detailed metallurgical failure analysis of the device, including metallography and fractography, is reported here. It was found that the device had adequate metallurgical integrity for the application for which it was intended. It is believed that failure was caused by the lack of a screw in the ninth hole. Evidence is also presented which indicates that the device was bent prior to insertion, and the local plastic deformation may have caused structural changes leading to premature crack initiation.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c0046210
EISBN: 978-1-62708-235-8
... AFNOR 38CD4 (similar to AISI type 4140H) and was in the quenched-and-tempered condition, with a yield strength of about 760 MPa (110 ksi). It was treated to have compressive surface stresses, and the prior-austenite grain size was ASTM 8. Analysis (visual inspection, stress analyses, and macrographs...
Abstract
Several crankshaft failures occurred in equipment that was being used in logging operations in subzero temperatures. Failure usually initiated at a cracked pin oil hole, and the failure origin was approximately 7.6 mm (0.3 in.) from the shaft surface. The holes were produced by gun drilling, giving rise to surface defects. The fracture surface was characteristic of fatigue in that it was flat, relatively shiny, and exhibited beach marks. The crack surface was at a 45 deg angle to the axis of the shaft, indicating dominant tensile stresses. The material was the French designation AFNOR 38CD4 (similar to AISI type 4140H) and was in the quenched-and-tempered condition, with a yield strength of about 760 MPa (110 ksi). It was treated to have compressive surface stresses, and the prior-austenite grain size was ASTM 8. Analysis (visual inspection, stress analyses, and macrographs) supported the conclusion that failure was caused by fatigue stress caused by surface defects in the oil holes. Recommendation includes drilling the oil holes by a technique that essentially eliminates surface defects.
Book Chapter
Compression Fracture of a Graphite-Epoxy Test Structure Due to a Buckling Instability
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c0048498
EISBN: 978-1-62708-234-1
... of the compression-loading skin panel were revealed by nondestructive visual examination. A band of de-lamination between the areas of through-thickness skin fracture at the front and rear spar was revealed. A map of the local directions of crack propagation over the fracture surface was generated by the orientation...
Abstract
A graphite-epoxy tapered-box structure, which consisted of two honeycomb skin panels fastened to a spanwise spar with intermediate chordwise ribs, fractured during testing. Hinge-line deflection of the front spar was revealed. Through-thickness cracks in the forward and trailing edges of the compression-loading skin panel were revealed by nondestructive visual examination. A band of de-lamination between the areas of through-thickness skin fracture at the front and rear spar was revealed. A map of the local directions of crack propagation over the fracture surface was generated by the orientation of river patterns and resin microflow during microscopic examination of sectioned samples of the panel. It was discovered that crack initiation occurred at the periphery of a fastener hole located at the front spar. Propagation occurred chordwise across the compression-loaded skin panel. As a corrective measure, the fastener spacing was reduced to prevent the buckling mode that precipitated fracture.
Book Chapter
Broken Helical Compression Spring
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c9001220
EISBN: 978-1-62708-225-9
... Abstract A helical compression spring with ten turns made of 1.8 mm thick wire which was under high pressure during tension applied to a rocker arm broke on the test stand in the third turn. The fracture was a torsion fracture that initiated in the highly loaded inner fiber and showed in its...
Abstract
A helical compression spring with ten turns made of 1.8 mm thick wire which was under high pressure during tension applied to a rocker arm broke on the test stand in the third turn. The fracture was a torsion fracture that initiated in the highly loaded inner fiber and showed in its origin the characteristics of a fatigue fracture. A longitudinal fold was located at the fracture crack breakthrough which could still be observed at the fourth and fifth turns, where a further incipient crack originated. A metallographic section was made directly next to the fracture path and the fold was cut. It showed decarburized edges in the outer slanted part and this most likely occurred during rolling. The inner radially proceeding part, however, was probably a fatigue fracture originating in the fold. The fracture of this highly stressed spring was therefore accelerated by a rolling defect. In order to decrease the stress, the construction has meantime been modified.
Image
Crack initiation on type 316LR stainless steel dynamic compression plate. (...
Available to PurchasePublished: 01 January 2002
Fig. 15 Crack initiation on type 316LR stainless steel dynamic compression plate. (a) Anterior-posterior radiograph. The plate was used to treat the nonunion of a fracture between the fourth and seventh screws. The plate was bent intraoperatively to fit the contour of the bone. (b) Radiograph
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Image
Compression curl of bend fracture surface. (a, b) Angle views. (c) Top view...
Available to Purchase
in Mechanisms and Appearances of Ductile and Brittle Fracture in Metals
> Failure Analysis and Prevention
Published: 01 January 2002
Fig. 49 Compression curl of bend fracture surface. (a, b) Angle views. (c) Top view showing radial marks emanating from the origin
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Image
Tension and compression side of a gray iron loaded in bending. The fracture...
Available to Purchase
in Mechanisms and Appearances of Ductile and Brittle Fracture in Metals
> Failure Analysis and Prevention
Published: 01 January 2002
Fig. 59 Tension and compression side of a gray iron loaded in bending. The fracture surface is devoid of any markings to indicate the fracture origin or direction of crack propagation. However, examination of the edge of the component at the fracture surface indicates that the tension side
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Image
Crack-initiation locations in compression loading. Crack initiation may occ...
Available to Purchase
in Mechanisms and Appearances of Ductile and Brittle Fracture in Metals
> Failure Analysis and Prevention
Published: 01 January 2002
Fig. 89 Crack-initiation locations in compression loading. Crack initiation may occur along the centerline and at the surface on a hoop plane. Further deformation may close the centerline crack.
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Image
Cancellous bone screws and the seven-hole narrow dynamic compression plate....
Available to Purchase
in Fatigue Fracture of 316L Stainless Steel Screws Employed for Surgical Implanting
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1992
Fig. 1 Cancellous bone screws and the seven-hole narrow dynamic compression plate.
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Image
in Failure Analysis of Induction Hardened Automotive Axles
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 6 Fracture in a glass rod demonstrates a symmetrical compression chip
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Image
SEM image that shows a NiTi wire in compression with cracks at the intrados...
Available to Purchase
in Failure Analysis of NiTi Wires Used in Medical Applications
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 7 SEM image that shows a NiTi wire in compression with cracks at the intrados and no cracking at the extrados
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Image
SEM image of slip lines and small cracks in a compression-damaged sample su...
Available to Purchase
in Failure Analysis of NiTi Wires Used in Medical Applications
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 8 SEM image of slip lines and small cracks in a compression-damaged sample subjected to 27% strain
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Image
SEM image of slip lines and cracks in a compression-damaged NiTi wire sampl...
Available to Purchase
in Failure Analysis of NiTi Wires Used in Medical Applications
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 9 SEM image of slip lines and cracks in a compression-damaged NiTi wire sample subjected to 31% strain
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Image
SEM image of compression-induced cracks in a NiTi wire sample subjected to ...
Available to Purchase
in Failure Analysis of NiTi Wires Used in Medical Applications
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 10 SEM image of compression-induced cracks in a NiTi wire sample subjected to 50% strain
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Image
SEM image of compression-damaged NiTi wire that fractured at very low loads...
Available to Purchase
in Failure Analysis of NiTi Wires Used in Medical Applications
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 12 SEM image of compression-damaged NiTi wire that fractured at very low loads in tension
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Image
SEM image of initiation area (indicated by arrow) in compression-damaged sp...
Available to Purchase
in Failure Analysis of NiTi Wires Used in Medical Applications
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 13 SEM image of initiation area (indicated by arrow) in compression-damaged specimen that fractured at low tensile loads
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Image
in Failure Analysis of NiTi Wires Used in Medical Applications
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 14 Tension and compression behavior in NiTi tubing
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Image
Compression curl of bend fracture surface. (a, b) Angle views. (c) Top view...
Available to PurchasePublished: 15 January 2021
Fig. 3 Compression curl of bend fracture surface. (a, b) Angle views. (c) Top view showing radial marks emanating from the origin
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