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Book Chapter
Failures Related to Hot Forming Processes
Available to PurchaseSeries: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006835
EISBN: 978-1-62708-329-4
.... discontinuities hot forming ingot casting metalworking defects nonferrous forging steel forging wrought metal products Introduction to Failures Related to Hot Forming Processes Wrought forms are produced by a wide variety of metalworking operations that can be roughly divided into bulk-working...
Abstract
The primary purpose of this article is to describe general root causes of failure that are associated with wrought metals and metalworking. This includes a brief review of the discontinuities or imperfections that may be common sources of failure-inducing defects in the bulk working of wrought products. The article addresses the types of flaws or defects that can be introduced during the steel forging process itself, including defects originating in the ingot-casting process. Defects found in nonferrous forgings—titanium, aluminum, and copper and copper alloys—also are covered.
Book Chapter
An Investigation of the Development of Defects During Flow Forming of High Strength Thin Wall Steel Tubes
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001601
EISBN: 978-1-62708-235-8
... Abstract Flow forming technology has emerged as a promising, economical metal forming technology due to its ability to provide high strength, high precision, thin walled tubes with excellent surface finish. This paper presents experimental observations of defects developed during flow forming...
Abstract
Flow forming technology has emerged as a promising, economical metal forming technology due to its ability to provide high strength, high precision, thin walled tubes with excellent surface finish. This paper presents experimental observations of defects developed during flow forming of high strength SAE 4130 steel tubes. The major defects observed are fish scaling, premature burst, diametral growth, microcracks, and macrocracks. This paper analyzes the defects and arrives at the causative factors contributing to the various failure modes.
Book Chapter
Forming Cracks on Stainless Steel Wire
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c0090932
EISBN: 978-1-62708-235-8
... Abstract Cold-drawn type 303 stainless steel wire sections, 6.4 mm (0.25 in.) in diameter, failed during a forming operation. All of the wires failed at a gradual 90 deg bend. Investigation (visual inspection and 5.3x/71x/1187x SEM views) supported the conclusion that the wires cracked due...
Abstract
Cold-drawn type 303 stainless steel wire sections, 6.4 mm (0.25 in.) in diameter, failed during a forming operation. All of the wires failed at a gradual 90 deg bend. Investigation (visual inspection and 5.3x/71x/1187x SEM views) supported the conclusion that the wires cracked due to ductile overload. The forming stresses were sufficient to initiate surface ruptures, suggestive of having exceeded the forming limit. Recommendations included examining the forming process, including lubrication and workpiece fixturing.
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006801
EISBN: 978-1-62708-329-4
... Abstract Sheet forming failures divert resources from normal business activities and have significant bottom-line impact. This article focuses on the formation, causes, and limitations of four primary categories of sheet forming failures, namely necks, fractures/splits/cracks, wrinkles/loose...
Abstract
Sheet forming failures divert resources from normal business activities and have significant bottom-line impact. This article focuses on the formation, causes, and limitations of four primary categories of sheet forming failures, namely necks, fractures/splits/cracks, wrinkles/loose metal, and springback/dimensional. It discusses the processes involved in analytical tools that aid in characterizing the state of a formed part. In addition, information on draw panel analysis and troubleshooting of sheet forming failures is also provided.
Book Chapter
Forming Process Anomalies in Diesel Fuel Injection Control Sleeve
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.auto.c0089258
EISBN: 978-1-62708-218-1
Abstract
The cold start advance solenoid sleeve was found leaking through the wall during troubleshooting complain of a diesel engine that failed to start in cold weather. The component was revealed to be a tubular product with a “bulb” section at one end and threads on the other. The manufacturing method used to create the bulb shape was hydroforming, using a 300 series stainless steel tube in the full-hard condition. The leak was attributed to a crack in the sleeve in the radius between the bulb area and the cylindrical portion of the sleeve. Fatigue cracks initiated at multiple sites near the OD of the sleeve were revealed by scanning electron microscopy of the broken-open crack. It was revealed by analysis that during the hydroforming process, heavy biaxial strains were imparted to the sleeve wall. It was interpreted that when combined with the heavy strains inherently present in the full-hard 300 series stainless steel, the hydroforming strains in the radius caused the microcracking. The root cause for this failure was identified to be omission of an intermediate stress relief or annealing treatment prior to hydroforming to the final shape.
Book Chapter
Forms of Corrosion
Available to PurchaseSeries: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003548
EISBN: 978-1-62708-180-1
... Abstract This article addresses the forms of corrosion that contribute directly to the failure of metal parts or that render them susceptible to failure by some other mechanism. It describes the mechanisms of corrosive attack for specific forms of corrosion such as galvanic corrosion, uniform...
Abstract
This article addresses the forms of corrosion that contribute directly to the failure of metal parts or that render them susceptible to failure by some other mechanism. It describes the mechanisms of corrosive attack for specific forms of corrosion such as galvanic corrosion, uniform corrosion, pitting and crevice corrosion, intergranular corrosion, and velocity-affected corrosion. The article contains a table that lists combinations of alloys and environments subjected to selective leaching and the elements removed by leaching.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006783
EISBN: 978-1-62708-295-2
... Abstract Corrosion is the electrochemical reaction of a material and its environment. This article addresses those forms of corrosion that contribute directly to the failure of metal parts or that render them susceptible to failure by some other mechanism. Various forms of corrosion covered...
Abstract
Corrosion is the electrochemical reaction of a material and its environment. This article addresses those forms of corrosion that contribute directly to the failure of metal parts or that render them susceptible to failure by some other mechanism. Various forms of corrosion covered are galvanic corrosion, uniform corrosion, pitting, crevice corrosion, intergranular corrosion, selective leaching, and velocity-affected corrosion. In particular, mechanisms of corrosive attack for specific forms of corrosion, as well as evaluation and factors contributing to these forms, are described. These reviews of corrosion forms and mechanisms are intended to assist the reader in developing an understanding of the underlying principles of corrosion; acquiring such an understanding is the first step in recognizing and analyzing corrosion-related failures and in formulating preventive measures.
Image
Failure caused by improper quenching. (a) AISI W1 tool steel wire-forming d...
Available to PurchasePublished: 01 January 2002
Fig. 29 Failure caused by improper quenching. (a) AISI W1 tool steel wire-forming die that broke prematurely during service. (b) Cold etching (10% aqueous nitric acid) of a disk cut behind the fracture revealed that the bore-working surface was not hardened; only the dull gray region
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Image
Forming cracks on stainless steel wire ( example 2 ). (a) The fracture, whi...
Available to PurchasePublished: 01 January 2002
Fig. 3 Forming cracks on stainless steel wire ( example 2 ). (a) The fracture, which occurred during bending shows many parallel fissures. 5.3×. (b) A typical fissure on the wire surface. Scanning electron micrograph. 71×. (c) The interior of the fissures and the fracture surface exhibit
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Image
Schematic workability diagrams for bulk forming processes. Strain path (a) ...
Available to PurchasePublished: 01 January 2002
Fig. 36 Schematic workability diagrams for bulk forming processes. Strain path (a) would lead to failure for material A. Both strain paths (a and b) can be used for the successful forming of material B.
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in Failure Analysis of Cracks Formed at Extrados of Bend Pipe of API 5L X65M Grade
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 7 Cu/Cu-alloys used during JCOE forming
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Image
Typical creep voids forming on transverse grain boundaries from solid, equi...
Available to Purchase
in Stress-Rupture Characterization in Nickel-Based Superalloy Gas Turbine Engine Components
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 13 Typical creep voids forming on transverse grain boundaries from solid, equiaxed turbine blade casting. Void coalescence will eventually lead to a stress-rupture crack
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Image
in Stress-Rupture Characterization in Nickel-Based Superalloy Gas Turbine Engine Components
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 14 Creep voids forming near the trailing edge of SX turbine blade casting at ∼ 5% airfoil span. Casting contains no grain boundaries. Etchant: 33% glycerol, 33% nitric acid, 33% acetic acid, and 1–3% hydrofluoric acid
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Image
Metal consumption over time for an alloy forming a protective scale under v...
Available to PurchasePublished: 30 August 2021
Fig. 18 Metal consumption over time for an alloy forming a protective scale under various turbine cycling conditions. The solid black line indicates metal consumption in a thermal cycling regime, with each parabola representing oxidation after effective loss of the protective oxide layer
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Image
Failure caused by improper quenching. (a) AISI W1 tool steel wire-forming d...
Available to PurchasePublished: 30 August 2021
Fig. 29 Failure caused by improper quenching. (a) AISI W1 tool steel wire-forming die that broke prematurely during service. (b) Cold etching (10% aqueous nitric acid) of a disk cut behind the fracture revealed that the bore working surface was not hardened; only the dull gray region
More
Image
Forming cracks on stainless steel wire (Example 2). (a) The fracture, which...
Available to PurchasePublished: 15 January 2021
Fig. 3 Forming cracks on stainless steel wire (Example 2). (a) The fracture, which occurred during bending, shows many parallel fissures. Original magnification: 5.3×. (b) A typical fissure on the wire surface. Scanning electron micrograph. Original magnification: 71×. (c) The interior
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Image
Creep voids forming near the trailing edge of single-crystal turbine blade ...
Available to PurchasePublished: 15 January 2021
Fig. 12 Creep voids forming near the trailing edge of single-crystal turbine blade casting at ~5% airfoil span. Etchant: 33% glycerol, 33% nitric acid, 33% acetic acid, and 1–3% hydrofluoric acid. Casting contains no grain boundaries. Source: Ref 20
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Image
Deep caustic gouging beneath heavy insulating deposits. Steam forming under...
Available to PurchasePublished: 15 January 2021
Fig. 13 Deep caustic gouging beneath heavy insulating deposits. Steam forming under the insulating deposit escapes and concentrates caustic capable of dissolving metal. Courtesy of NACE International
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Schematic drawings of (a) positive (male) forming, (b) negative (female) fo...
Available to PurchasePublished: 15 May 2022
Fig. 21 Schematic drawings of (a) positive (male) forming, (b) negative (female) forming, (c) plug-assisted vacuum forming, and (d) billow-plug forming
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Image
Forming cracks on stainless steel wire. (a) The fracture, which occurred du...
Available to Purchase
in Forming Cracks on Stainless Steel Wire
> ASM Failure Analysis Case Histories: Processing Errors and Defects
Published: 01 June 2019
Fig. 1 Forming cracks on stainless steel wire. (a) The fracture, which occurred during bending shows many parallel fissures. 5.3×. (b) A typical fissure on the wire surface. Scanning electron micrograph. 71×. (c) The interior of the fissures and the fracture surface exhibit dimple rupture
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