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deformation
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Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003537
EISBN: 978-1-62708-180-1
... describes the general features of fatigue fractures in terms of crack initiation and fatigue crack propagation. brittle fracture crack initiation creep fracture deformation ductile fracture failure analysis fatigue crack growth fatigue crack propagation fatigue fracture fractography fracture...
Abstract
This article provides an overview of fractography and explains how it is used in failure analysis. It reviews the basic types of fracture processes, namely, ductile, brittle, fatigue, and creep, principally in terms of fracture appearances, such as microstructure. The article also describes the general features of fatigue fractures in terms of crack initiation and fatigue crack propagation.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003573
EISBN: 978-1-62708-180-1
... Abstract Distortion failure occurs when a structure or component is deformed so that it can no longer support the load it was intended to carry. Every structure has a load limit beyond which it is considered unsafe or unreliable. Estimation of load limits is an important aspect of design...
Abstract
Distortion failure occurs when a structure or component is deformed so that it can no longer support the load it was intended to carry. Every structure has a load limit beyond which it is considered unsafe or unreliable. Estimation of load limits is an important aspect of design and is commonly computed by classical design or limit analysis. This article discusses the common aspects of failure by distortion with suitable examples. Analysis of a distortion failure often must be thorough and rigorous to determine the root cause of failure and to specify proper corrective action. The article summarizes the general process of distortion failure analysis. It also discusses three types of distortion failures that provide useful insights into the problems of analyzing unusual mechanisms of distortion. These include elastic distortion, ratcheting, and inelastic cyclic buckling.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.conag.c0092155
EISBN: 978-1-62708-221-1
... was conducted to determine the cause of the malfunction and to recommend corrective measures that would prevent similar failures in other vehicles. Fig. 1 Gas-nitrided 4140 steel (27–31 HRC) drive-gear assembly in which gear teeth deformed because of faulty design and low core hardness. Details A and B...
Abstract
Component slippage in the left-side final drive train of a tracked military vehicle was detected after the vehicle had been driven 13,700 km (8500 miles) in combined highway and rough-terrain service. The slipping was traced to the mating surfaces of the final drive gear and the adjacent splined coupling sleeve. Specifications included that the gear and coupling be made from 4140 steel bar oil quenched and tempered to a hardness of 265 to 290 HB (equivalent to 27 to 31 HRC) and that the finish-machined parts be single-stage gas nitrided to produce a total case depth of 0.5 mm (0.020 in.) and a minimum surface hardness equivalent to 58 HRC. Investigation (visual inspection, low-magnification images, 500X images of polished sections etched in 2% nital, spectrographic analysis, and hardness testing) supported the conclusion that the failure occurred by crushing, or cracking, of the case as a result of several factors. Recommendations included reducing the high local stresses at the pitch line to an acceptable level with a design modification. Also suggested was specification of a core hardness of 35 to 40 HRC to provide adequate support for the case and to permit attainment of the specified surface hardness of 58 HRC.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.conag.c0047212
EISBN: 978-1-62708-221-1
... to fracture. No evidence of a defective design, improper microstructure, high inclusion count, or other stress-raising condition was observed. No recommendations were made. Earthmoving equipment Plastic deformation Shafts (power) 4340 UNS G43400 Fatigue fracture A steering knuckle used...
Abstract
A steering knuckle used on an earthmover failed in service. The component fractured into a flange portion and a shaft portion. The flange was 27.9 cm (11 in.) in diam around which there were 12 evenly spaced 16 mm diam bolt holes. The shaft was hollow with a 10.5 cm (4 in.) OD and a wall thickness of 17 mm. The steering knuckle was made of 4340 steel and heat treated to a hardness of about 415 HRB (yield strength of about 1069 MPa, or 155 ksi). The vehicle had been involved in a field accident six months before the steering knuckle failed. Several components, including portions of the frame, had been damaged and replaced, but there was no observed damage to the steering. Analysis supported the conclusion that the fracture was the result of the prior accident, the most likely explanation being that the shaft was bent and that continued use caused a crack to initiate and propagate to fracture. No evidence of a defective design, improper microstructure, high inclusion count, or other stress-raising condition was observed. No recommendations were made.
Book Chapter
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006797
EISBN: 978-1-62708-295-2
..., errors in the specification of the material, and faulty process and their corrective measures to meet specifications. It discusses the general process of material failure analysis and special types of distortion and deformation failure. deformation distortion material failure analysis...
Abstract
Distortion often is observed in the analysis of other types of failures, and consideration of the distortion can be an important part of the analysis. This article first considers that true distortion occurs when it was unexpected and in which the distortion is associated with a functional failure. Then, a more general consideration of distortion in failure analysis is introduced. Several common aspects of failure by distortion are discussed and suitable examples of distortion failures are presented for illustration. The article provides information on methods to compute load limits, errors in the specification of the material, and faulty process and their corrective measures to meet specifications. It discusses the general process of material failure analysis and special types of distortion and deformation failure.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006774
EISBN: 978-1-62708-295-2
... of a component of interest in a failure investigation. Details on the mechanisms of deformation, brittle transgranular fracture, intergranular fracture, fatigue fracture, and environmentally affected fracture are also provided. brittle transgranular fracture creep fracture deformation ductile fracture...
Abstract
Engineering component and structure failures manifest through many mechanisms but are most often associated with fracture in one or more forms. This article introduces the subject of fractography and aspects of how it is used in failure analysis. The basic types of fracture processes (ductile, brittle, fatigue, and creep) are described briefly, principally in terms of fracture appearances. A description of the surface, structure, and behavior of each fracture process is also included. The article provides a framework from which a prospective analyst can begin to study the fracture of a component of interest in a failure investigation. Details on the mechanisms of deformation, brittle transgranular fracture, intergranular fracture, fatigue fracture, and environmentally affected fracture are also provided.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c9001487
EISBN: 978-1-62708-234-1
... silver-bearing copper was not available. The use of hard-drawn silver-bearing copper for a rewind, in conjunction with special attention to blocking up the end windings, is confidently expected to effect a complete cure. Alternators Deformation Cu-Ag (Other, general, or unspecified) distortion...
Abstract
Copper shortening has been found to occur in the rotor windings of turbo alternators and takes the form of a progressive reduction in the length of the coils leading to distortion of the end windings. The trouble results from the high loading which develops between successive layers of the strip conductor due to centrifugal force. This leads to a high frictional binding force between turns and prevents axial expansion under normal heating in service. Rotor trouble which proved to be due to copper shortening was found in a set rated at 27.5 MW. It was manufactured in 1934 at which time silver-bearing copper was not available. The use of hard-drawn silver-bearing copper for a rewind, in conjunction with special attention to blocking up the end windings, is confidently expected to effect a complete cure.
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in Oxidation Cracking and Residual Creep Life of an Incoloy 800H Bottom Manifold in a Steam Reformer at 800 °C
> ASM Failure Analysis Case Histories: Chemical Processing Equipment
Published: 01 June 2019
Fig. 10 Deformation mechnaism map for Incoloy 800H 7 . The deformation mechanism is given as a function of homologue temperature (T/Tm) and homologue stress (σ/G).
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Published: 01 January 2002
Fig. 7 (a) Abrasive wear mechanisms and surface deformation as a function of pressure, P ; material hardness, H ; and fracture energy, G Ic . (b) Curves 1 to 3 correspond to the schematic in (a), possible schematic of the wear rate, W as a function of hardness, H of wearing material
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Published: 01 January 2002
Fig. 14 Deformation from threads that left impressions on the inside surface of a hole as the members sheared with respect to each other.
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Published: 01 January 2002
Fig. 21 Simplified deformation behavior (Ashby) maps of unalloyed annealed metals with (a) face-centered cubic crystal structure and (b) body-centered cubic crystal structure. Engineering alloys may behave somewhat differently than unalloyed metals, but these general trends are relatively
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Published: 01 January 2002
Fig. 3 Stages of creep deformation. (a) Strain curve for the three stages of creep under constant-load testing (curve A) and constant-stress testing (curve B). (b) Relationship of strain rate, or creep rate, and time during a constant-load creep test. The minimum creep rate is attained during
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Published: 01 January 2002
Fig. 4 Typical creep deformation and intergranular cracking in a jet-engine turbine blade. Courtesy of J. Schijve
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Published: 01 January 2002
Fig. 16 Bulk deformation failure of WC-Co coating, indicating cracks in the middle of the wear track and substrate migration at the edge of the wear track
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Published: 01 January 2002
Fig. 22 Deformation and fracture surface for (a) plane strain and (b) plane stress. In plane strain, the lateral constraint of a thick section develops a stress along the crack plane (σ z , Eq 41a ).
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Published: 01 January 2002
Fig. 21 Example of plastic deformation detected metallographically by the presence of bent annealing twins. (a) Annealed 80–20 brass. (b) Cold worked 20% 80–20 brass. Plastic deformation can be detected metallographically by the presence of bent annealing twins, the presence of deformation
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Published: 01 January 2002
Fig. 22 Deformation and fracture map for (a) magnesium and (b) magnesium oxide. Mode 1, 2, and 3 represent regions of brittle fracture mechanisms (cleavage or IG fracture) with the following conditions: Region 1, pre-existing cracks propagate; Region 2, slip or twin-nucleated cracks propagate
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Published: 01 January 2002
Fig. 24 Deformation and fracture map for spheroidized 1045 steel. Source: Ref 40
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Published: 01 January 2002
Fig. 25 Deformation map for various failure mechanisms as a function of temperature and sulfur contents for preoriented polyisoprenes. Source: Ref 41
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