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Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001035
EISBN: 978-1-62708-214-3
... of the failed axle did not, at this juncture, rule out or support either of the accident causation scenarios. However, it did give rise to an additional experiment. It was hypothesized that the material in the core of the axle was strain-rate sensitive. If this was so, and the failure of the core occurred...
Abstract
Following an accident in which a light pickup truck left the road and overturned, one of the rear axles, made of approximately 0.30C steel, was found to be fractured adjacent to the bearing lock nut. A keyway was present in the failed area, as were threads for the lock nut. Fracture surfaces of the failed axle and exemplar fractures obtained from simulation tests were studied using scanning electron microscope. The examination showed that the outer perimeter fracture in the axle was very flat and composed of cleavage and that the interior portion was composed of both cleavage and dimples. No evidence of prior cracking was found. The exemplar specimens from the simulation impact testing failed in a manner consistent with that observed in the axle. The examination confirmed that the failure was a one-time impact overload fracture and not the result of any prior crack in the material, indicating that the axle failure did not initiate the accident.
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in Oxidation Cracking and Residual Creep Life of an Incoloy 800H Bottom Manifold in a Steam Reformer at 800 °C
> ASM Failure Analysis Case Histories: Chemical Processing Equipment
Published: 01 June 2019
Fig. 7 Results of the accelerated creep testing. The secondary strain rate is plotted as a function of temperature.
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in Stress Corrosion Cracking of 4340 Steel in Aircraft Ignition Starter Residues
> ASM Failure Analysis Case Histories: Air and Spacecraft
Published: 01 June 2019
Fig. 5 Graph of %RA/%RA(oil) vs. Nominal Strain Rate for the Tests Conducted in the Residue Paste.
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in Superplastic HSLA Steels: Microstructure and Failure
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 5 Influence of strain rate on yield stress ( a ) and super-index m ( b ) in superplastic behavior at 800 °C
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in Metallurgical Failure Analysis of a Propane Tank Boiling Liquid Expanding Vapor Explosion (BLEVE)
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 13 Normal strain rate ultimate tensile strength (UTS) and stress-rupture strengths at various temperatures (as percentage of normal strain rate UTS at room temperature). (Data from Ref 1 and 14)
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in Mechanisms and Appearances of Ductile and Brittle Fracture in Metals
> Failure Analysis and Prevention
Published: 01 January 2002
Fig. 39 Temperature dependence of the strain-rate sensitivity of pure aluminum and alloy 2024. Note 2024-O becoming negative near room temperature. Source: Ref 63
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Published: 01 January 2002
Fig. 15 Effect of strain rate on ductile-to-brittle transition temperature in body-centered cubic metals
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in Fatigue Failure of Extrusion Dies: Effect of Process Parameters and Design Features on Die Life
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 5 Flow curves of Al-6063 at different temperatures and strain rates used in the simulation
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Series: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006919
EISBN: 978-1-62708-395-9
... Abstract This article reviews the impact response of plastic components and the various methods used to evaluate it.. It describes the effects of loading rate on polymer deformation and the influence of temperature and strain rate on failure mode. It discusses the advantages and limitations...
Abstract
This article reviews the impact response of plastic components and the various methods used to evaluate it.. It describes the effects of loading rate on polymer deformation and the influence of temperature and strain rate on failure mode. It discusses the advantages and limitations of standard impact tests, the use of puncture tests for assessing material behavior under extreme strain, and the application of fracture mechanics for analyzing impact failures. It also develops and demonstrates the theory involved in the design and analysis of thin-walled, injection-molded plastic components.
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001788
EISBN: 978-1-62708-241-9
... conditions/die configurations Morrow’s stress-life approach Morrow’s strain-life approach Temperature ( T ), °C 300 1490 0.00424 1730 751300 Strain rate: 1 s –1 420 862 0.00273 2318011 307807041 Fillet radius: 2 mm 540 620 0.00179 46042609 5.8e11 Bearing length: 8 mm...
Abstract
Several failed dies were analyzed and the results were used to evaluate fatigue damage models that have been developed to predict die life and aid in design and process optimization. The dies used in the investigation were made of H13 steels and fractured during the hot extrusion of Al-6063 billet material. They were examined to identify critical fatigue failure locations, determine corresponding stresses and strains, and uncover correlations with process parameters, design features, and life cycle data. The fatigue damage models are based on Morrow’s stress and strain-life models for flat extrusion die and account for bearing length, fillet radius, temperature, and strain rate. They were shown to provide useful information for the analysis and prevention of die failures.
Series: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006944
EISBN: 978-1-62708-395-9
... Abstract The discussion on the fracture of solid materials, both metals and polymers, customarily begins with a presentation of the stress-strain behavior and of how various conditions such as temperature and strain-rate affect the mechanisms of deformation and fracture. This article describes...
Abstract
The discussion on the fracture of solid materials, both metals and polymers, customarily begins with a presentation of the stress-strain behavior and of how various conditions such as temperature and strain-rate affect the mechanisms of deformation and fracture. This article describes crazing and fracture in polymeric materials, with a review of the behavior of the elastic modulus as a function of temperature or time parameters, emphasizing the importance of the viscoelastic nature of their deformation and fracture. The discussion covers the behavior of polymers under stress, provides information on ductile and brittle behaviors, and describes craze initiation in polymers and crack formation and fracture by crazing. Macroscopic permanent deformation of polymeric materials caused by shear-yielding and crazing, which eventually can result in fracture and failure, is also covered.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.homegoods.c0090457
EISBN: 978-1-62708-222-8
... resulting from a relatively high strain rate event and/or significant stress concentration. A relatively sharp corner formed by a retaining tab on the older design was shown to be a primary cause of the failures. Design Injection moldings Latches Stress concentration Polyacetal Brittle fracture...
Abstract
Components of a latch assembly used in a consumer safety restraint exhibited a relatively high failure rate. The failures were occurring after installation but prior to actual field use when failure could result in severe injury. Cracking occurred within retaining tabs used to secure a metal slide on an older design, whereas newer components showed no signs of failure. The latch assembly components were injection molded from an unfilled commercial grade of a polyacetal copolymer. Investigation of failed parts (including visual inspection, a specially designed proof load test, 59x SEM images, micro-FTIR in the ATR mode, and DSC/TGA/MFR analysis) showed no evidence of contamination or degradation from the molding process. The conclusion was that the parts failed via brittle fracture associated with stress overload. The stress overload was accompanied by severe apparent embrittlement resulting from a relatively high strain rate event and/or significant stress concentration. A relatively sharp corner formed by a retaining tab on the older design was shown to be a primary cause of the failures.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c9001687
EISBN: 978-1-62708-220-4
... properties. Grain boundary sliding and dislocation motion were enhanced, causing a local increase in the steady state strain rate and the premature failure of the tube. Grain boundary sliding Plastic deformation Spalling Voids HK UNS J94224 Creep fracture/stress rupture The petrochemical...
Abstract
Microstructural examinations on transverse cross sections of a steam reformer tube, showed the presence of large macrovoids elongated in the radial direction and emanating from the internal surface of the tube. The macrovoids were located at the interdendritic regions, and were partially filled by a Mn-Fe bearing chromium oxide film. The areas adjacent to the oxide film were chemically depleted in C, Cr and Mn and rich in Fe and Ni. Associated with this depletion were a large concentration of microvoids. It was suggested that the dissolution of carbides in areas surrounding the macrovoids and the concentration of stresses at their tips, caused extensive localized plastic deformation which led to the formation of microvoids and subsequently to the spalling of the oxide film. The non-protective character of the film induced a progressive deterioration of the grain boundaries properties. Grain boundary sliding and dislocation motion were enhanced, causing a local increase in the steady state strain rate and the premature failure of the tube.
Book Chapter
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001816
EISBN: 978-1-62708-241-9
...Tests conducted at 800 °C using different strain rates Table 1 Tests conducted at 800 °C using different strain rates L 0 (mm) V t (mm/min) σ y (MPa) A (%) ε ̇ s − 1 Log ε ̇ Log (σ y ) Non-superplastic tests 57 5 70.0 >109.2...
Abstract
This paper describes the superplastic characteristics of shipbuilding steel deformed at 800 °C and a strain rate less than 0.001/s. After the superplastic deformation, the steel presents mixed fractures: by decohesion of the hard (pearlite and carbides) and ductile (ferrite) phases and by intergranular sliding of ferrite/ferrite and ferrite/pearlite, just as it occurs in stage III creep behavior. The behavior is confirmed through the Ashby-Verrall model, according to which the dislocation creep (power-law creep) and diffusion creep (linear-viscous creep) occur simultaneously.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c9001560
EISBN: 978-1-62708-217-4
... failure mechanism ( 1 , 2 ). Fig. 1 Overall View of a Failed Breech Chamber. This paper describes the results of constant extension rate tests (CERT) carried out at slow strain rates to determine the susceptibility of 4340 steel to stress corrosion cracking in an environment consisting...
Abstract
Military aircraft use a cartridge ignition system for emergency engine starts. Analysis of premature failures of steel (AISI 4340) breech chambers in which the solid propellant cartridges were burned identified corrosion as one problem with an indication that stress-corrosion cracking may have occurred. A study was made for stress-corrosion cracking susceptibility of 4340 steel in a paste made of the residues collected from used breech chambers. The constant extension rate test (CERT) technique was employed and SCC susceptibility was demonstrated. The residues, which contained both combustion products from the cartridges and corrosion products from the chamber, were analyzed using elemental analysis and x-ray diffraction techniques. Electrochemical polarization techniques were also utilized to estimate corrosion rates.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001685
EISBN: 978-1-62708-235-8
... Studies were initiated to determine the effects of different levels of absorbed hydrogen and differences in the crosshead velocity (strain rate). Reference test material was prepared by solution heat treating in vacuum for 1h, whereas the low-hydrogen test group was solutionized for 8 h. Half...
Abstract
The U-0.8wt%Ti alloy is often used in weapon applications where high strength and fairly good ductility are necessary. Components are immersion quenched in water from the gamma phase to produce a martensitic structure that is amenable to aging. Undesirable conditions occur when a component occasionally cracks during the quenching process, and when tensile specimens fail prematurely during mechanical testing. These two failures prompted an investigative analysis and a series of studies to determine the causes of the cracking and erratic behavior observed in this alloy. Quench-related failures whereby components that cracked either during or immediately after the heat treatment/quenching operation were sectioned for metallographic examination of the microstructure to examine the degree of phase transformation. Examination of premature tensile specimen failures by scanning electron microscopy and X-ray imaging of fracture surfaces revealed pockets of inclusions at the crack origins. In addition, tests were conducted to evaluate the detrimental effects of internal hydrogen on ductility and crack initiation in this alloy.
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in Metallurgical Failure Analysis of a Propane Tank Boiling Liquid Expanding Vapor Explosion (BLEVE)
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 12 Ultimate tensile strengths (UTS) of various steels at high temperatures (high-strain-rate UTS at temperature as percentage of high-strain-rate UTS at room temperature). (Adapted from Ref 14)
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Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003538
EISBN: 978-1-62708-180-1
... intersecting the outside surface at an angle Fig. 38 Fractured 1020 steel showing an angled connection between a cup portion on one half of the fractured bar and a cup portion on the other half Fig. 39 Temperature dependence of the strain-rate sensitivity of pure aluminum and alloy 2024...
Abstract
This article provides a description of the microscale models and mechanisms for deformation and fracture. Macroscale and microscale appearances of ductile and brittle fracture are discussed for various specimen geometries and loading conditions. The article reviews the general geometric factors and materials aspects that influence the stress-strain behavior and fracture of ductile metals. It highlights fractures arising from manufacturing imperfections and stress raisers. The article presents a root cause failure analysis case history to illustrate some of the fractography concepts.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006775
EISBN: 978-1-62708-295-2
... that can cause specimen-scale shear banding is the combination of minimum strain hardening and negative strain-rate hardening. A second case in which the central fibrous zone is (apparently) absent has been reported in an HY-100 steel. Both cases are discussed in this article. When edge- or center...
Abstract
This article focuses on characterizing the fracture-surface appearance at the microscale and contains some discussion on both crack nucleation and propagation mechanisms that cause the fracture appearance. It begins with a discussion on microscale models and mechanisms for deformation and fracture. Next, the mechanisms of void nucleation and void coalescence are briefly described. Macroscale and microscale appearances of ductile and brittle fracture are then discussed for various specimen geometries (smooth cylindrical and prismatic) and loading conditions (e.g., tension compression, bending, torsion). Finally, the factors influencing the appearance of a fracture surface and various imperfections or stress raisers are described, followed by a root-cause failure analysis case history to illustrate some of these fractography concepts.
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in Elevated-Temperature Life Assessment
> Analysis and Prevention of Component and Equipment Failures
Published: 30 August 2021
Fig. 20 (a) Typical uniaxial creep strain versus time curve. (b) Natural logarithm of strain rate versus strain
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