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manufacturing-installation defects

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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
..., design deficiencies, material defects, manufacturing/installation defects, and service life anomalies, with examples. The article describes several common charting methods that may be useful in performing an RCA. It also discusses other failure analysis tools, including review of all sources of input...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c0090994
EISBN: 978-1-62708-225-9
... failed during installation due to the presence of preexisting defects. Crack surfaces were found to be corroded and phosphate coated, indicating that the cracks occurred during manufacture. Installation, which presumably entailed some axial extension, resulted in ductile overload failure at the crack...
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001074
EISBN: 978-1-62708-214-3
... in casting geometry, indicating the use of improper risering and contour design. Because nondestructive quality control inspection had not been carried out, the defect had gone undetected during the manufacturing stage. Remedial Action The site of the abrupt change in the cross section of the casting...
Series: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006870
EISBN: 978-1-62708-395-9
.... Manufacturing Defects Figure 8 shows a failed O-ring. The key question with this rubber article was whether the failure was due to a manufacturing defect or to damage upon installation. The initial view in Fig. 8 clearly shows an initiation point that originated in the area close to the outer diameter...
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001845
EISBN: 978-1-62708-241-9
.... The investigation results suggest that the root cause of failure was a forging lap that occurred during manufacturing. Precracks induced by the forging defect and the influence of preload stress (due to bolt torque) caused the premature failure. cable clamps brittle fracture forging overlap copper alloy...
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001302
EISBN: 978-1-62708-215-0
... Abstract To forged AISI 4140 steel trailer kingpins fractured after 4 to 6 months of service. Fractographic and metallographic examination revealed that cracks were present in the spool-flange shoulder region of the defective kingpins prior to installation on the trailers. The cracks grew...
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001766
EISBN: 978-1-62708-241-9
.... Post-failure analysis revealed that the fracture was precipitated by a preexisting weld-related crack. Closed form and numerical stress analyses were also conducted, with the results indicating that the anchor was installed properly within the parameters intended by the manufacturer. mooring...
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006837
EISBN: 978-1-62708-329-4
... and manufacturing defects has become more important. This article presents case histories that are intended as an overview of the unique types of failures encountered in the freight railroad industry. The discussion covers failures of axle journals, bearings, wheels, couplers, rails and rail welds, and track...
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001842
EISBN: 978-1-62708-241-9
... balance weight blocks installed were outside the normal maximum accepted weight. The integrity of the manufactured condition of the roll was therefore brought into question. Figure 12 shows a basic model of the roll represented as a simply supported beam. The loads on the span of the beam that would...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c9001907
EISBN: 978-1-62708-217-4
... bolts Grain flow Carburizing Hy-Tuf UNS K325599 Heat treating related failures Metalworking related failures Stress-corrosion cracking Introduction Component: LAU-7 missile launcher attachment bolts Manufacturing defects: Machining rather than forging/inadvertent carburization...
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
... categories ( Ref 23 ): Design Manufacturing/installation Service Material An effective graphical representation of the impact of defects on the service life of a component or system is provided in the application-life diagram ( Fig. 4 ) ( Ref 24 , 25 ). The diagram is constructed...
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001343
EISBN: 978-1-62708-215-0
... interval between the installation of the pipe inside the reactor and the observation of leak was not known. Specimen Selection Leaking occurred in only one spot. The defective portion of the pipe was drilled out, and the pipe was repaired. The drilled-out piece was submitted for analysis. Visual...
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006814
EISBN: 978-1-62708-329-4
... Abstract Welded connections are a common location for failures for many reasons, as explained in this article. This article looks at such failures from a holistic perspective. It discusses the interaction of manufacturing-related cracking and service failures and primarily deals with failures...
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001114
EISBN: 978-1-62708-214-3
.... Contributing factors included the presence of a hard, brittle, heat-affected zone and weld defects at the handling pad eye. It was recommended that the replacement clamp be made from a material with good toughness and that any installation of attachments by welding be done according to qualified procedures...
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001761
EISBN: 978-1-62708-241-9
... 300,000 km when an engine overhaul was carried out as specified by the operation manual of the engine manufacturer. As indicated by the bus company, the crankshaft was disassembled and checked visually for defects and then ground to remove a thickness of 0.25 mm at the journals to restore surface...
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001113
EISBN: 978-1-62708-214-3
.... Brittle fracture Heat-affected zone Steel construction Weld defects Welded joints ASTM A36 Hydrogen damage and embrittlement Joining-related failures Background Six cracked A36 steel gusset plates that formed part of the roof trusses of a large manufacturing facility were discovered during...
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006758
EISBN: 978-1-62708-295-2
... render the component unusable. The results may also show whether issues such as corrosion, surface pitting, stress corrosion cracking or other manufacturing and in-service defects may be responsible for, or helped contribute to, the part’s condition. Overview The failure analyst should have...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c9001172
EISBN: 978-1-62708-220-4
.... Ammonia Chemical processing equipment Decarburization Surface defects Nickel steel St 55.25 Hydrogen damage and embrittlement Unalloyed steels and the pure nickel steels frequently used in the past for highly stressed forgings are attacked by hydrogen under high pressure. The attack causes...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.usage.c9001508
EISBN: 978-1-62708-236-5
.... A contributing factor was the length of time spent in the packaging, 21 years. Cracking (fracturing) Heat shields Residual stress Weld defects 321 UNS S32100 Stress-corrosion cracking The standard depot level maintenance of Pratt & Whitney/U.S. Navy J52-P-6, J52-P-8, and J52-P-408 gas...
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001087
EISBN: 978-1-62708-214-3
... to be the result of defective materials. The components examined were all within reasonable material tolerances. No evidence of defects was found, nor was there any of the usual evidence of rubber degradation: crazing, swelling, embrittlement, or softening. Caraful review of the installation history of the pumps...