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Luther M. Gammon, Michael V. Hyatt, G. Hari Narayanan, Henry J. Oberson, Harcayal B. Singh
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001669
EISBN: 978-1-62708-229-7
... the bottom of the scatterband compared to unexposed 2– 1 4 Cr-1Mo steel. The life of the creep damaged longitudinal seam-weld metal is between one-fifth to one-half that of the base material. References References 1. Henry J. F. , “ Field Metallography: The Applied Techniques...
Abstract
As the result of a leak detected in a plate-formed header at PENELEC'S Shawville Unit No. 3, an extensive failure investigation was initiated to determine the origin of cracking visible along the longitudinal weld seam. Fabricated from SA387-D material and designed for a superheater outlet temperature of 566 deg C, the 11.4 cm thick header had operated for approximately 187,000 h at the time of the failure. Discussion focuses on the results of a metallographic examination of boat samples removed from the longitudinal seam weldment in the vicinity of the failure and at other areas of the header where peak temperatures were believed to have been reached. The long-term mechanical properties of the service-exposed base metal and creep-damaged weld metal were determined by creep testing. Based on the utility's decision to replace the header within one to three years, an isostress overtemperature lead specimen approach was taken, whereby failure of a test specimen in the laboratory would precede failures in the plant. These tests revealed approximately a 2:1 difference in life for the base metal as compared to weld metal.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.usage.c9001545
EISBN: 978-1-62708-236-5
Abstract
The presence of secondary, branching intergranular stress-corrosion cracking in a type 440C stainless bearing caused the analyst to overlook the real culprit, which was a mechanically-initiated, primary transgranular crack that propagated through the steel's hard chromium carbide. Failure was actually caused by overload. Had the original conclusion been accepted, a relatively exotic alloy would have been specified. In another case, brass heat exchanger tube failure was automatically attributed to attack by an acidic cleaner, and a decision was made to stop using the solution. A more thorough analysis showed failure was caused by tube vibration. In a third case, a type 304 stainless steel bellows in a test loop was thought to have failed because of chloride stress corrosion. The report concluded with a recommendation that carbon steel be used as an alternative bellows material. Caustic, not chloride, stress corrosion was the culprit. Had material substitutions been made on the original premise of countering chloride stress corrosion, most of the loop's highly stressed components would have eventually failed.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c9001529
EISBN: 978-1-62708-217-4
Abstract
On 16 July 1999, a Boeing 737-800 on final approach for landing sustained a major lightning strike. Damage to the fuselage structure primarily was in the form of melting or partial melting of widely-separated rivets and adjacent Alclad 2024-T3 fuselage skin. The damage was confined to a 0.25-in. (6.4-mm) radii around the affected rivets. The repair process involved removal of the locally-affected material and addition of a skin doubler to restore the aircraft structure to the originally designed condition. Damage features are described briefly.
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001790
EISBN: 978-1-62708-241-9
.... Bates R.C. and Clark W.G. : “ Fractography and Fracture Mechanics ,” Trans. Am. Soc. Met. , June 1969 , 62 , pp. 380 – 389 . 4. Boring R.L. , Davidson G.M. , Hammel A. , Henry S.D. , Lampman S.R. , Reidenback F. , and Scott W.W. Jr. , ed...
Abstract
The failure of a high-speed pinion shaft from a marine diesel engine was investigated. The shaft, which had been in service for more than 30 years, failed shortly after the bearings were replaced. Examination of the shaft revealed cyclic fatigue, with a substantial distribution of nonmetallic inclusions near the fracture initiation site. Fracture mechanics analysis indicated that, if stresses acting on the shaft were induced only by normal service loads, there was little likelihood that the inclusions served as failure initiation sites. Further examination of the bearing elements revealed an abnormal wear pattern, consistent with the application of elevated bending loads. The root cause of failure was determined to be an increase in service stresses after bearing replacement along with the presence of nonmetallic inclusions in the shaft.
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
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.