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forging design

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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c9001510
EISBN: 978-1-62708-217-4
... susceptible direction that must be considered of primary importance in material selection for design configuration. A Navy UH-1N helicopter main rotor blade grip manufactured from a 2014-T6 aluminum alloy forging failed because of a design flaw that left a high residual tensile stress along the short...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c0048795
EISBN: 978-1-62708-220-4
...Abstract Abstract A large pressure vessel designed for use in an ammonia plant failed during hydrostatic testing. It was fabricated from ten Mn-Cr-Ni-Mo-V steel plates which were rolled and welded to form ten cylindrical shell sections and three forgings of similar composition. The fracture...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.auto.c0001784
EISBN: 978-1-62708-218-1
... with a maximum working stress of 475 MPa (69 ksi) gives a safe margin above the 390 MPa (57 ksi) requirement for design stress. Interpreting these values, the forged surface should have a life expectancy of 1,000,000 cycles of stress. However, because the load cycle was somewhat uncertain, the machined radius...
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
...Abstract Abstract This case study involves two continuously 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...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.matlhand.c0089766
EISBN: 978-1-62708-224-2
... of improved design were attributed to fatigue cracks initiating at the aluminum oxide inclusions in the flange fillet. Recommendations included retaining the improved design of the flange with the weld approximately 50 mm (2 in.) from the fillet, but changing the metal to a forging of AISI 4140 steel, oil...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.design.c0047817
EISBN: 978-1-62708-233-4
... and by the decarburized layer. Decarburization occurred during heat treatment and was caused by the atmosphere trapped in the cavity formed by friction welding. The design of the pushrod was changed to a one-piece forging. To produce a high-quality welded pushrod, it would be necessary to provide radii at the corners...
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.chem.c9001437
EISBN: 978-1-62708-220-4
...Abstract Abstract A steam jacketed autoclave of orthodox design was fabricated from mild steel for a working pressure of 320 psi. The only unusual feature in its construction was a protective layer of weld metal, which was deposited on the internal surface of the upper half of the 1 in. thick...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003507
EISBN: 978-1-62708-180-1
..., and scabs. The article provides a discussion on the imperfections found in steel forgings. The problems encountered in sheet metal forming are also discussed. The article concludes with information on the causes of failure in cold formed parts. anisotropy blisters centerline shrinkage chemical...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c0047879
EISBN: 978-1-62708-234-1
... A, “Original design,” Fig. 1 ). The face of the outboard section of the shaft had a groove approximately 6.4 mm (0.25 in.) deep by 7.9 mm (0.3 in.) wide around its circumference. This step followed the shape of the weld metal on the mating piece. The fracture surface along the weld metal contained no forged...
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001005
EISBN: 978-1-62708-215-0
... is normally designed to expel the surface oxide scale with the flash at the parting line. The inner bend radius was too sharp, however, and some of the oxide scale was entrapped within the forging instead of being expelled with the flash. Many steering arms, both new and unused, as well as those returned from...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0047165
EISBN: 978-1-62708-217-4
... in the flange area The forging blank contained less than the optimum volume of metal in the flange area, resulting in an underfill condition Forging-die design was inefficient The forging operation was unduly fast for the specific design Some metal was removed from the surface during the forging...
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001270
EISBN: 978-1-62708-215-0
...Abstract Abstract An investigation was conducted to determine the factors responsible for the occasional formation of cracks on the parting lines of medium plain carbon and low-alloy medium-carbon steel forgings. The cracks were present on as-forged parts and grew during heat treatment...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c9001731
EISBN: 978-1-62708-217-4
... in aircraft parts. The results of the laboratory studies indicate that unusual care is necessary in the processing and fabrication of ultra-high-strength steel and in the design and maintenance of the structures in which it is used. Aircraft components Forgings Landing gear Ultrahigh strength steels...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001814
EISBN: 978-1-62708-180-1
.... Fig. 4 Fixture made from AISI O1 tool steel that cracked during oil quenching. This design is poor for liquid quenching. A nick in the fillet region helped to initiate cracking. 0.75× Fig. 5 Threaded part made from AISI W2 tool steel that cracked during quenching at an undercut at the base...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.matlhand.c0048060
EISBN: 978-1-62708-224-2
... examination which indicated that the material was in the as-forged condition (which meant lower fatigue strength). The fracture was concluded to have occurred due to stress concentration in the root of the last thread. Normalizing of the crane hook after forging was suggested as a corrective measure. A stress...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0046146
EISBN: 978-1-62708-217-4
... in the “Improved design” view in Detail A in Fig. 1 . The faces of the lug were shot peened for added resistance to fatigue failure. Also, the forging material was changed to aluminum alloy 7175-T736 for its higher mechanical properties. ...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001811
EISBN: 978-1-62708-180-1
... Origins Failures occur for a number of reasons, which may be related to operation, design, material selection, material quality, and manufacturing practices. The largest portion of lifting-equipment failures are of operational origin. Overloading of a lifting mechanism is a common practice and often...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c9001724
EISBN: 978-1-62708-234-1
... will vary considerably from end bell to end bell and from forgemaster to forgemaster. “This is a feature which neither metallurgist nor designer likes. It has led to investigations into alternative methods of manufacture, including forging on a mandrel under a more powerful press, expanding on tapered...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c9001553
EISBN: 978-1-62708-217-4
.... If decarburization remains, design consideration for fatigue life should be given. Always shot-peen forged parts adequately. Selected References Selected References • Totten G.E. , Narazaki M. , Blackwood R.R. and Jarvis L.M. , Failures Related to Heat Treating Operations , Failure...