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Series: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006868
EISBN: 978-1-62708-395-9
... process and find potential problems before investing in tooling. Perform Prototyping and Testing Every development project is different, but most will benefit from some sort of prototyping, either for visual verification or for functional testing, many times both. Rapid prototyping has...
Abstract
This article presents the benefits of selecting plastics for products to be manufactured. It discusses the four key considerations for plastic part design: material, process, tooling, and design. The article provides a detailed discussion of the development sequence for plastic parts. The basis for the development sequence is twofold: first, to create the best solution for the application, and second, to minimize potential project risks through careful and thoughtful work habits.
Book Chapter
Polymer Processing—An Introduction
Available to PurchaseSeries: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006864
EISBN: 978-1-62708-395-9
... angle of the screw is also larger in the second stage to create a more rapid forward movement of the polymer melt than in the first stage. This creates a zero-pressure region in the extraction zone. The barrel has a vent port above the extraction zone so that volatiles can escape and are not forced...
Abstract
This article discusses technologies focused on processing plastic materials or producing direct tools used in plastics processing. The article focuses on extrusion and injection molding, covering applications, materials and their properties, equipment, processing details, part design guidelines, and special processes. It also covers the functions of the extruder, webline handling, mixing and compounding operations, and process troubleshooting. Thermoforming and mold design are covered. Various other technologies for polymer processing covered in this article are blow molding, rotational molding, compression molding, transfer molding, hand lay-up process, casting, and additive manufacturing.
Book Chapter
Failures Related to Metal Additive Manufacturing
Available to PurchaseSeries: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006838
EISBN: 978-1-62708-329-4
... MANUFACTURING (AM) refers to a group of free-form fabrication technologies that incrementally build up a solid part by computer-controlled deposition of material from a digital solid model. The technology is an outgrowth and broadening of rapid prototyping methods that were developed in the 1980s to accelerate...
Abstract
This article provides an overview of metal additive manufacturing (AM) processes and describes sources of failures in metal AM parts. It focuses on metal AM product failures and potential solutions related to design considerations, metallurgical characteristics, production considerations, and quality assurance. The emphasis is on the design and metallurgical aspects for the two main types of metal AM processes: powder-bed fusion (PBF) and directed-energy deposition (DED). The article also describes the processes involved in binder jet sintering, provides information on the design and fabrication sources of failure, addresses the key factors in production and quality control, and explains failure analysis of AM parts.
Book Chapter
Metallurgical Evaluation of a Five Inch Cylindrical Induction Melter
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.steel.c9001598
EISBN: 978-1-62708-232-7
... of the research program that was undertaken to design and build a remote vitrification system. The CIM is prototypic of the production system and was undergoing final, non-radioactive performance testing when the melter drain tube developed a leak. An autopsy of the CIM vessel was performed to: 1) identify...
Abstract
The metallurgical condition of a cylindrical induction melter (CIM) vessel was evaluated after approximately 375 h of operation over a two-year span at temperatures between 1400 to 1500 deg C. Wall thinning and significant grain growth was observed in the lower portion of the conical section and the drain tube. No through-wall penetrations were found in the cylindrical and conical sections of the CIM vessel and only one leak site was identified in the drain tube. Failure of the drain tube was associated with localized overheating and creep. The observed degradation resulted from cumulative service at elevated temperature. A recommendation was made to implement a support for the conical section of the CIM and to increase the wall thickness of the drain tube. Thus, the possibility of drain tube misalignment in the induction coils and localized over heating will be minimized. In addition, the use of grain stabilized Pt/Rh alloy should be evaluated as a method to prevent grain growth.
Book Chapter
Designing with Plastics
Available to PurchaseSeries: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006927
EISBN: 978-1-62708-395-9
... in restrictions in the flow of the material within the mold. As a general design rule, part complexity should be minimized, and wall thicknesses should be as uniform as possible. Common tooling for these parts will be soft flexible molds, cast from a master part (sometimes made by rapid prototyping or additive...
Abstract
This article provides background information needed by design engineers to create part designs optimized for plastics and plastic manufacturing processes. It describes the four essential elements of plastic part development, namely, material, process, tooling, and design, and provides general design rules for the plastic forming processes covered. It also discusses the steps involved in design validation and verification.
Book Chapter
Characterization of Plastics in Failure Analysis
Available to PurchaseSeries: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003525
EISBN: 978-1-62708-180-1
... the heat of fusion obtained during an initial analysis of the sample with the results generated during the second run, after slow cooling. The level of crystallinity is important, because it impacts the mechanical, physical, and chemical resistance properties of the molded article. In general, rapid...
Abstract
This article reviews the analytical techniques most commonly used in plastic component failure analysis. These include the Fourier transform infrared spectroscopy, differential scanning calorimetry, thermogravimetric analysis, thermomechanical analysis, and dynamic mechanical analysis. The descriptions of the analytical techniques are supplemented by a series of case studies that include pertinent visual examination results and the corresponding images that aid in the characterization of the failures. The article describes the methods used for determining the molecular weight of a plastic resin. It explains the use of mechanical testing in failure analysis and also describes the considerations in the selection and use of test methods.
Book Chapter
Engineering Design Process Investigation in a Failure Analysis
Available to PurchaseSeries: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006815
EISBN: 978-1-62708-329-4
... platform with a bar, torsion spring, hold-down bar, and trigger plate), could possibly be conceptualized “on a napkin” and developed with just a few prototypes. A working prototype or a simple freehand sketch with annotations may suffice to convey the design to a production shop. Other than tinkering...
Abstract
The intent of this article is to assist the failure analyst in understanding the underlying engineering design process embodied in a failed component or system. It begins with a description of the mode of failure. This is followed by a section providing information on the root cause of failure. Next, the article discusses the steps involved in the engineering design process and explains the importance of considering the engineering design process. Information on failure modes and effects analysis is also provided. The article ends with a discussion on the consequence of management actions on failures.
Book
Series: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.9781627083959
EISBN: 978-1-62708-395-9
Book Chapter
Avoiding Plastic Product Failure by Proper Plastic Selection and Design
Available to PurchaseSeries: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006912
EISBN: 978-1-62708-395-9
... constructed from plywood, steel, and a phenolic bezel. Courtesy of dtopal/Shutterstock. Royalty-free stock photo ID: 8554489 Although this rapid growth is based on the benefits these materials offer, plastic products have been controversial since their introduction into the marketplace. During...
Abstract
Plastic product failures are directly attributed to one of the following four reasons: omission of a critical performance requirement, improper materials specification, design error, and processing/manufacturing error. Therefore, product failures can be minimized or eliminated if all of these parameters are comprehensively examined during the design process. This article focuses on all of these factors, except processing-related failures, which are outside the design and engineering domain. It is dedicated to the identification and avoidance of common problems associated with the selection and designing of plastic parts. The article provides information on the material-related design criteria that depend on the applications, environmental conditions of use, and performance requirements. It discusses physical properties of plastics based on their relevance to real-world environmental conditions. The most-common design problems related to design considerations are also covered.
Book Chapter
Design-Related Failures of Plastic Parts
Available to PurchaseSeries: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006938
EISBN: 978-1-62708-395-9
... these neighboring parts. This phenomenon, known as coefficient of thermal expansion (CTE) mismatch, can introduce important stresses to an assembly. The design envelope may also include transient temperature effects in scenarios in which relatively rapid heating or cooling may be anticipated. Such transient...
Abstract
A design may be improvable without presenting an unacceptable risk related to safety or performance. However, design-related failures can result from an oversight in performing one of the major design activities or from a failure to balance the competing demands inherent to part design. This article focuses on design-related failures in products utilizing polymeric materials, and reviews important considerations of the design envelope of plastic parts. The article provides a non-exhaustive list and descriptions of design tools that can support the design process and the prevention of design-related failures. It also discusses the most common causes of design-related failures of plastic parts. The article can assist in both failure analysis and in the prevention of failures in which design may be a contributing factor or a root cause.
Series: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006942
EISBN: 978-1-62708-395-9
... analysis Objective type Possible rationale Product life cycle stage Product development Market demands Prototyping Product improvement Warranty costs Ongoing Assignment of responsibility Financial/physical damage or injury reparations After subject event Prevention of recurrence...
Abstract
Failure analysis is the process used to determine the cause of a failure. There is no definitive method for performing a failure analysis, and the method chosen is dependent upon the type of failure, the availability of background information, the tools available to perform the analysis, and the skills of the analyst. The information outlined in this article focuses on the general methodology while allowing for case-specific techniques to be utilized along the way. It covers the causes of failure, why a failure analysis is performed, the failure analysis process, the planning of failure analysis investigation, recommendations to prevent the need for a failure analysis, the implementation of product reviews, and forensic standards.
Book Chapter
Failure Analysis of Welded Structures
Available to PurchaseSeries: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006814
EISBN: 978-1-62708-329-4
... often be built and tested as prototypes before designs are finalized. While not minimizing the importance of the mechanical engineer’s weldments, the failure of a single weldment will rarely have the same consequences as the failure of a structure, such as a bridge. Because structural failures often...
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 that occur in service due to stresses caused by externally applied loads. The purpose of this article is to enable a failure analyst to identify the causative factors that lead to welded connection failure and to identify the corrective actions needed to overcome such failures in the future. Additionally, the reader will learn from the mistakes of others and use principles that will avoid the occurrence of similar failures in the future. The topics covered include failure analysis fundamentals, welded connections failure analysis, welded connections and discontinuities, and fatigue. In addition, several case studies that demonstrate how a holistic approach to failure analysis is necessary are presented.
Book Chapter
Failure Analysis and Life Assessment of Structural Components and Equipment
Available to PurchaseSeries: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003512
EISBN: 978-1-62708-180-1
... for such a claim. Such bases are usually provided by analyses and by accelerated testing in the laboratory and with prototype and model testing. As part of the life assessment process, it is important to understand how a structural component—whether a pressure vessel, shaft, or structural member—is designed...
Abstract
This article provides an overview of the structural design process and discusses the life-limiting factors, including material defects, fabrication practices, and stress. It details the role of a failure investigator in performing nondestructive inspection. The article provides information on fatigue life assessment, elevated-temperature life assessment, and fitness-for-service life assessment.
Book Chapter
Fracture of Plastics
Available to PurchaseSeries: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003541
EISBN: 978-1-62708-180-1
... are usually diagnosed early in the development of a product, such as during prototype testing. Ductile fractures can also result from other causes, such as excessive creep deformation or inadvertent exposure to elevated temperatures, which can substantially reduce yield strength. Brittle Fractures...
Abstract
This article reviews the mechanical behavior and fracture characteristics that discriminate structural polymers from metals. It provides information on deformation, fracture, and crack propagation as well as the fractography involving the examination and interpretation of fracture surfaces, to determine the cause of failure. The fracture modes such as ductile fractures and brittle fractures are reviewed. The article also presents a detailed account of various fracture surface features. It concludes with several cases of field failure in various polymers that illustrate the applicability of available analytical tools in conjunction with an understanding of failure mechanisms.
Series: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006865
EISBN: 978-1-62708-395-9
... but also surpassed even the yield and tensile strengths of the material. Problems of underdesign or overloading are usually diagnosed early in the development of a product, such as during prototype testing. Ductile fractures can also result from other causes, such as excessive creep deformation...
Abstract
This article reviews the mechanical behavior and fracture characteristics that discriminate structural polymers from metals, including plastic deformation. It provides overviews of crack propagation and fractography. The article presents the distinction between ductile and brittle fracture modes. Several case studies of field failure in various polymers are also presented to illustrate the applicability of available analytical tools in conjunction with an understanding of failure mechanisms.
Book Chapter
Failure Prevention through Life Assessment of Structural Components and Equipment
Available to PurchaseSeries: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006802
EISBN: 978-1-62708-329-4
... years. This is not to say that some maintenance is not necessary. However, to assert to a customer that a component has a 40 year design life, it is necessary to develop a basis for such a claim. Such bases are usually provided by analyses and by accelerated testing in the laboratory and with prototype...
Abstract
Life assessment of structural components is used to avoid catastrophic failures and to maintain safe and reliable functioning of equipment. The failure investigator's input is essential for the meaningful life assessment of structural components. This article provides an overview of the structural design process, the failure analysis process, the failure investigator's role, and how failure analysis of structural components integrates into the determination of remaining life, fitness-for-service, and other life assessment concerns. The topics discussed include industry perspectives on failure and life assessment of components, structural design philosophies, the role of the failure analyst in life assessment, and the role of nondestructive inspection. They also cover fatigue life assessment, elevated-temperature life assessment, fitness-for-service life assessment, brittle fracture assessments, corrosion assessments, and blast, fire, and heat damage assessments.
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 parts. It discusses the overall concept of design and describes the role of the materials engineer in the design and materials selection process. The article highlights the significance of materials selection in both the prevention and analysis of failures.
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006800
EISBN: 978-1-62708-329-4
Abstract
Materials selection is closely related to the objectives of failure analysis and prevention. This article briefly reviews the general aspects of materials selection as a concern in both proactive failure prevention during design and as a possible root cause of failed parts. Coverage is more conceptual, with general discussions on the following topics: design and failure prevention, materials selection in design, materials selection for failure prevention, and materials selection and failure analysis. Because materials selection is just one part of the design process, the overall concept of design is discussed. The article also describes the role of the materials engineer in the design and materials selection process. It provides information on the significance of materials selection in both the prevention and analysis of failures.