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engineering design

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Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003502
EISBN: 978-1-62708-180-1
... Abstract This article provides assistance to a failure analyst in broadening the initial scope of the investigation of a physical engineering failure in order to identify the root cause of a problem. The engineering design process, including task clarification, conceptual design, embodiment...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.conag.c9001500
EISBN: 978-1-62708-221-1
... operations. The primary failure was associated with the 4820H NiMo alloy steel pinion, and thus the gear was not examined. The mode of failure was rolling contact fatigue, and the cause of failure improper engineering design. The pattern of continual overload was restricted to a specific concentrated area...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003501
EISBN: 978-1-62708-180-1
... Abstract Materials selection is an important engineering function in both the design and failure analysis of components. This article briefly reviews the general aspects of materials selection as a concern in proactive failure prevention during design and as a possible root cause of failed...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0047541
EISBN: 978-1-62708-217-4
... condition that resulted in catastrophic, brittle fracture under normal applied loads. The design was altered to eliminate the weld adjacent to the threaded portion of the rod. Aerospace engines Design Post heating Welded joints Medium-carbon steel Brittle fracture Intergranular fracture Joining...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.auto.c9001732
EISBN: 978-1-62708-218-1
...Abstract Abstract Statistical techniques provide the design engineer with a powerful tool for the analysis of failure data. By means of an actual case study, steps required to design a test yielding statistically meaningful data and procedures used in graphical analysis of results are presented...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c9001742
EISBN: 978-1-62708-217-4
...) inadequate tightening during assembly, and (3) engine overspeed. The assigned main causes were, design deficiency, improper maintenance during overhaul, and abnormal service operation. Fig. 1 Failed connecting rod pieces (left) show arrows that indicate mating fracture surfaces of fatigue fracture...
Series: 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
... 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...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0047986
EISBN: 978-1-62708-217-4
... ball bearings. The ball bearings were both of the single-row deep-groove type with split inner rings, manufactured for use in jet-aircraft engines. The bearings were made of vacuum-melted 52100 steel and were designed to operate at a maximum temperature of 175 °C (350 °F). The bearings were side...
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006753
EISBN: 978-1-62708-295-2
... from which they are constructed cannot “fail” in the same sense as humans. They respond to their environments in ways which designers/engineers/scientists should understand and anticipate. So, the failure presented for analysis is really a failure to meet expectations. Whose expectations? Understanding...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.design.c9001424
EISBN: 978-1-62708-233-4
.... In the second case the machine was a 200 kW alternator, direct-driven by a diesel engine running at 750 rpm. Both the foregoing failures reveal the same basic weakness, i.e., insufficient rigidity when subjected to variations or reversals of torque. In the first case, the bars welded to the arms were...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c9001743
EISBN: 978-1-62708-217-4
...Abstract Abstract Cylinder fatigue can result from abnormal heating in service. Fatigue can be experienced also by piston heads, exhaust valves, and turbosupercharger housings (castings). Pistons from different engines series can sometimes fit, but because of slight design modifications...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.usage.c9001597
EISBN: 978-1-62708-236-5
... cast steel crankshaft failures. Three parties performed their own failure analyses: (1) the engine manufacturer responsible for component design, specification, and application; (2) the steel supplier and forging supplier responsible for making the steel, forging the shape, and preliminary heat...
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001037
EISBN: 978-1-62708-214-3
... circumferential cracks on the surface of the central zone. Some of the cracks had progressed for most of the 360° of the pin. Both samples showed some evidence of scoring on the outer diameter. Six wrist pins designed especially for a high-performance six-cylinder automotive engine failed after 4800 km (3000...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003500
EISBN: 978-1-62708-180-1
... in a direction other than longitudinal. Design-caused failures include inappropriate geometries (as defined on the engineering drawing), which may lead to a compromise of component or system capabilities. Examples of inappropriate geometries include improper joint preparation for welding or brazing...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c9001486
EISBN: 978-1-62708-234-1
... Abstract Cavitation damage of diesel engine cylinder liners is due to vibration of the cylinder wall, initiated by slap of the piston under the combined forces of inertia and firing pressure as it passes top dead center. The occurrence on the anti-thrust side may possibly result from bouncing...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c0047710
EISBN: 978-1-62708-225-9
... Abstract A 9310 steel gear was found to be defective after a period of engine service. A linear crack approximately was discovered by routine magnetic-particle inspection of an electron beam welded joint that attached a hollow stub shaft to the web of the gear. The welding procedure had...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.steel.c9001668
EISBN: 978-1-62708-232-7
... testing and exemplar tests were performed on the bolt material. Mechanical engineering analysis and leak-before-break criteria were extensively analyzed. Results led to only one possible conclusion: that an explosion occurred within the autoclave. Suggestions for autoclave design are presented as a result...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.auto.c0047846
EISBN: 978-1-62708-218-1
...Abstract Abstract An 8640 steel shaft installed in a fuel-injection-pump governor that controlled the speed of a diesel engine used in trucks and tractors broke after few days of operation. The mechanism that drove the shaft was designed to include a slip clutch to protect the governor shaft...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c9001903
EISBN: 978-1-62708-217-4
... in a failed control rotor spar tube assembly made of cadmium-plated AISI 4130 Cr-Mo alloy steel. Inadequate design was responsible for the failure. A lower tine of the main rotor blade cuff failed in fatigue. The rotor blade cuff was forged of 2014-T6 aluminum alloy. Initial stages of crack growth displayed...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0047059
EISBN: 978-1-62708-217-4
...Abstract Abstract The governor on an aircraft engine failed and upon disassembly of the unit, it was discovered that the retainer for the flyweight pivot pins was broken. The channel-shaped retainer was made of 0.8 mm (0.030 in.) thick 1018 or 1020 steel. The part was plated with copper, which...