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electroplating
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c0048143
EISBN: 978-1-62708-235-8
... surface. The kernel was assumed to have resulted from extreme localized overheating. These springs were reported to have been barrel electroplated after fabrication. The intermittent contact with the dangler (suspended cathode contact) as the barrel rotated allowed high local currents when the last...
Abstract
A cadmium-plated music-wire return spring that operated in a pneumatic cylinder designed for infinite life at a maximum stress level of 620 MPa failed after 240,000 cycles. An extremely hard and small kernel, which looked like a weld deposit, was observed at the center of the fractured surface. The kernel was assumed to have resulted from extreme localized overheating. These springs were reported to have been barrel electroplated after fabrication. The intermittent contact with the dangler (suspended cathode contact) as the barrel rotated allowed high local currents when the last contact was broken was revealed to have resulted in an arc that caused local melting of the metal being plated. The molten metal was interpreted to have been quenched instantly by the plating solution and by the mass of the cold metal of the spring. The hard spot caused by arcing during plating was concluded to be the reason of the fatigue failure. Rack plating or barrels with fixed button contacts at many points instead of dangler-type contacts were recommended to avoid hard spots.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.homegoods.c0048674
EISBN: 978-1-62708-222-8
... to clamp onto the framework prior to springback. The heat treatment cycle of the fasteners consisted of austenitizing, quenching, tempering to obtain a tempered martensite microstructure, acid cleaning, zinc electroplating, coating with a clear dichromate and thereafter baking to remove the nascent...
Abstract
Fasteners, made in high-production progressive dies from 0.7 mm thick cold-rolled 1060 steel, were used to secure plastic fabric or webbing to the aluminum framework of outdoor furniture. It was found that approximately 30% of the fasteners cracked and fractured as they were compressed to clamp onto the framework prior to springback. The heat treatment cycle of the fasteners consisted of austenitizing, quenching, tempering to obtain a tempered martensite microstructure, acid cleaning, zinc electroplating, coating with a clear dichromate and thereafter baking to remove the nascent hydrogen. It was revealed that fasteners treated in this manner were brittle due to hydrogen embrittlement as the baking process was found to not be able to remove all the nascent hydrogen which had induced during acid cleaning and electroplating. The heat treatment cycle was modified to produce a bainitic structure and the method of plating the fastener with zinc was changed from electroplating to a mechanical deposition process to thus avoid hydrogen embrittlement.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c0048626
EISBN: 978-1-62708-225-9
..., all would have failed within two weeks. The bolts were baked, as specified by ASTM B 242, at 205 deg C (400 deg F) for 30 min. No further failures occurred. Baking for 30 min is the minimum baking time; however, baking times up to 24 h are recommended for greater safety. Electroplating Hydrogen...
Abstract
Cadmium-plated high-strength steel bolts were used to facilitate quick disassembly of a vehicle. One bolt was found fractured across the root of a thread after being torqued in place for one week. The bolts were made of 8735 steel heat treated to a tensile strength of 1241 to 1379 MPa (180 to 200 ksi) with a hardness of 39 to 43 HRC, followed by cadmium plating. The bolt that failed and several that did not were examined. It was found that failure of the bolts was the result of time-dependent hydrogen embrittlement. Had the remaining bolts been torqued to the normal stress levels, all would have failed within two weeks. The bolts were baked, as specified by ASTM B 242, at 205 deg C (400 deg F) for 30 min. No further failures occurred. Baking for 30 min is the minimum baking time; however, baking times up to 24 h are recommended for greater safety.
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Published: 01 January 2002
Fig. 24 Zinc-electroplated 1060 steel fastener that failed by hydrogen embrittlement. The part was used to secure fabric to lawn-furniture framework. Dimensions given in inches
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Published: 01 January 2002
Fig. 22 Two views of a notched specimen that was electroplated with copper, wrapped with copper wire, and tested for 3 h at 1100 °C (2010 °F) without application of a load. No grain-boundary penetration of copper or intergranular cracking is evident, but there is evidence of minor bulk
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Published: 30 August 2021
Fig. 24 Zinc-electroplated 1060 steel fastener that failed by hydrogen embrittlement. The part was used to secure fabric to lawn furniture framework. Dimensions given in inches
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in Failure of a Zinc-Electroplated 1060 Steel Fastener
> ASM Failure Analysis Case Histories: Household Products and Consumer Goods
Published: 01 June 2019
Fig. 1 Zinc-electroplated 1060 steel fastener that failed by hydrogen embrittlement. The part was used to secure fabric to lawn-furniture framework. Dimensions given in inches
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001613
EISBN: 978-1-62708-235-8
... Abstract The electroplated tappet adjusting screws used in diesel engines failed during initial bend testing. The analysis of the failure showed that the fracture was nucleated from the subsurface of the screw. The fracture surface was intergranular at the ID and OD region and microvoid...
Abstract
The electroplated tappet adjusting screws used in diesel engines failed during initial bend testing. The analysis of the failure showed that the fracture was nucleated from the subsurface of the screw. The fracture surface was intergranular at the ID and OD region and microvoid coalescence in the center. The improper baking after electroplating of the screw led to H2-induced blistering/cracking. The high strength of the threaded region of the adjusting screw increased the failure propensity.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c0048634
EISBN: 978-1-62708-225-9
..., indicating hydrogen embrittlement. An investigation was conducted to determine the extent of hydrogen embrittlement in the various lots of cadmium-plated 8740 steel fasteners. It was found that hydrogen embrittlement was caused by the use of a bright, impervious cadmium electroplate that hindered diffusion...
Abstract
During an inspection of a structure two weeks after assembly, the heads of several cadmium-plated AISI 8740 steel fasteners were found to be completely separated from their respective shanks. SEM examination of the fracture surfaces revealed a brittle, intergranular fracture mode, indicating hydrogen embrittlement. An investigation was conducted to determine the extent of hydrogen embrittlement in the various lots of cadmium-plated 8740 steel fasteners. It was found that hydrogen embrittlement was caused by the use of a bright, impervious cadmium electroplate that hindered diffusion of mobile hydrogen outward from the surface of the pin. After the cadmium layer was removed, the mobile hydrogen contained on the surface of the steel and in the electroplated deposit was released, and the embrittlement problem was alleviated. To prevent reoccurrence, the bright cadmium layer was stripped from the pins, which were then baked and repeated with a dull, porous cadmium layer that allowed outward diffusion of hydrogen. The pins were baked again after deposition of the porous cadmium layer. This eliminated the problem.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.marine.c0091036
EISBN: 978-1-62708-227-3
..., and prior hydrogen charging that occurred during manufacturing. The probable source of charging was the electroplating, although postplating baking was reportedly performed as well. Recommendations included examining the manufacturing process in detail. Cap screws Electroplating Intergranular...
Abstract
Socket head cap screws used in a naval application were failing in service due to delayed fracture. The standard ASTM A 574 screws were zinc plated and dichromate coated. Investigation (visual inspection, 1187 SEM images, chemical analysis, and tension testing) of both the failed screws and two unused, exemplar fasteners from the same lot supported the conclusion that the cap screws appear to have failed due to hydrogen embrittlement, as revealed by delayed cracking and intergranular fracture morphology. Static brittle overload fracture occurred due to the tension preload, and prior hydrogen charging that occurred during manufacturing. The probable source of charging was the electroplating, although postplating baking was reportedly performed as well. Recommendations included examining the manufacturing process in detail.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0048630
EISBN: 978-1-62708-217-4
... Abstract Two clevis-head self-retaining bolts used in the throttle-control linkage of a naval aircraft failed on the aircraft assembly line. Specifications required the bolts to be heat treated to a hardness of 39 to 45 HRC, followed by cleaning, cadmium electroplating, and baking to minimize...
Abstract
Two clevis-head self-retaining bolts used in the throttle-control linkage of a naval aircraft failed on the aircraft assembly line. Specifications required the bolts to be heat treated to a hardness of 39 to 45 HRC, followed by cleaning, cadmium electroplating, and baking to minimize hydrogen embrittlement. The bolts broke at the junction of the head and shank. The nuts were, theoretically, installed fingertight. The failure was attributed to hydrogen embrittlement that had not been satisfactorily alleviated by subsequent baking. The presence of burrs on the threads prevented assembly to finger-tightness, and the consequent wrench torquing caused the actual fractures. The very small radius of the fillet between the bolt head and the shank undoubtedly accentuated the embrittling effect of the hydrogen. To prevent reoccurrence, the cleaning and cadmium-plating procedures were stipulated to be low-hydrogen in nature, and an adequate post plating baking treatment at 205 deg C (400 deg F), in conformity with ASTM B 242, was specified. A minimum radius for the head-to-shank fillet was specified at 0.25 mm (0.010 in.). All threads were required to be free of burrs. A 10-day sustained-load test was specified for a sample quantity of bolts from each lot.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.petrol.c9001185
EISBN: 978-1-62708-228-0
... temperature, and electroplated with cadmium for protection against corrosion. Each fracture showed seven or eight kidney-shaped cracks. At the origins of these cracks on the concave inner surface of the springs, crater-like depressions and beads of melted and resolidified material were found. Fracture...
Abstract
U-shaped leaf springs, intended to serve as spacers between oil tank floats and the inner walls of the containers, broke while being fitted, or after a short time in use, in the bend of the U. The springs were made of tempered strip steel of type C 88 with 0.84 % C, bent at room temperature, and electroplated with cadmium for protection against corrosion. Each fracture showed seven or eight kidney-shaped cracks. At the origins of these cracks on the concave inner surface of the springs, crater-like depressions and beads of melted and resolidified material were found. Fracture of the springs was caused by stress cracks as a consequence of local hardening. The hardening caused by melting and resolidification, and therefore the cracks in the springs, was the result of a faulty procedure during cadmium electroplating.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001641
EISBN: 978-1-62708-235-8
... minimized. Die castings Electroplating Porosity Shrinkage Surface defects Zinc Casting-related failures Near-surface porosity in zinc die castings that were subsequently plated with copper, nickel, and bright chromium was causing blemishes in the plating. The platers had already performed...
Abstract
Near-surface porosity in zinc die castings that were subsequently plated with copper, nickel, and bright chromium was causing blemishes in the plating. Identifying die casting turbulence and hot spots were keys to process modifications that subsequently allowed porosity to be greatly minimized.
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in Plating Blemishes in Zinc Die Castings
> ASM Failure Analysis Case Histories: Processing Errors and Defects
Published: 01 June 2019
Fig. 1 A classical “gas” pore in a zinc die casting. It has been opened to the surface of the part by the buffing operation performed prior to electroplating.
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Image
Published: 01 January 2002
Fig. 12 Cadmium-plated 8740 steel aircraft-wing assembly nut that failed by hydrogen embrittlement. The nut was not baked after electroplating to release hydrogen. (a) Overall view. 5×. (b) Fracture surface. 9×. (c) Scanning electron micrograph of typical intergranular fracture shown in box
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Image
Published: 30 August 2021
Fig. 12 Cadmium-plated 8740 steel aircraft-wing assembly nut that failed by hydrogen embrittlement. The nut was not baked after electroplating to release hydrogen. (a) Overall view. Original magnification: 5×. (b) Fracture surface. Original magnification: 9×. (c) Scanning electron micrograph
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in Termination Delamination of Surface-Mount Chip Resistors
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1993
was actually resin separation from the epoxy binder in the thick-film ink. The following features can be discerned: area 1 is the alumina substrate; area 2 is the cermet metallization; area 3 is the thick-film polymer ink; area 4 is the electroplated nickel barrier; and area 5 is the lead-tin surface alloy
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Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0006448
EISBN: 978-1-62708-217-4
... to ensure that a source of hydrogen is not introduced during the plating operation. Electroplating Martensitic stainless steels Nondestructive testing 440C UNS S44004 Stress-corrosion cracking Pitting corrosion Hydrogen damage and embrittlement Three wing flap hinge bearings were received...
Abstract
Three wing flap hinge bearings were received by the laboratory for analysis. The bearings were fabricated from chromium-plated type 440C martensitic stainless steel. The intergranular fracture pattern seen in the electron fractographs, coupled with the corrosion pits observed on the inner diam of the bearings, strongly suggested that failure initiated by pitting and progressed by SCC or hydrogen embrittlement from the plating operation. It was recommended that the extent of the flap hinge bearing cracking problem be determined by using nondestructive inspection because it is possible to crack hardened type 440C during the chromium plating process. An inspection for pitting on the bearing inner diam was also recommended. It was suggested that electroless nickel be used as a coating for the entire bearing. A review of the chromium plating and baking sequence was recommended also to ensure that a source of hydrogen is not introduced during the plating operation.
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001291
EISBN: 978-1-62708-215-0
... examination. Arrow indicates region that was hard chromium plated. Wheel axle is at lower end. Testing Procedure and Results Nondestructive Evaluation Dye Penetrant Inspection Dye penetrant inspection of the electroplated hard chromium band revealed cracking with a distinct helically banded...
Abstract
Examination of several fighter aircraft main landing gear legs revealed unusual cracking in the hard chromium plating that covered the sliding section of the inner strut. The cracking was associated with cracks in the 35 NCD 16 steel beneath the plating. A detailed investigation revealed that the cracking was caused by the combination of incorrect grinding procedure, the presence of hydrogen, and fatigue. The grinding damage generated tensile stresses in the steel, which caused intergranular cracking during the plating cycle. The intergranular cracks were initiation sites for fatigue crack growth during service. It was recommended that the damaged undercarriage struts be withdrawn from service pending further analysis and development of a repair technique.
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006805
EISBN: 978-1-62708-329-4
Abstract
This article first provides an overview of the types of mechanical fasteners. This is followed by sections providing information on fastener quality and counterfeit fasteners, as well as fastener loads. Then, the article discusses common causes of fastener failures, namely environmental effects, manufacturing discrepancies, improper use, or incorrect installation. Next, it describes fastener failure origins and fretting. Types of corrosion in threaded fasteners and their preventive measures are then covered. The performance of fasteners at elevated temperatures is addressed. Further, the article discusses the types of rivet, blind fastener, and pin fastener failures. Finally, it provides information on the mechanism of fastener failures in composites.
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