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Failure mechanisms and analysis
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Book Chapter
Gray Cast Irons
Available to PurchaseBook: Atlas of Fractographs
Series: ASM Handbook
Volume: 12A
Publisher: ASM International
Published: 30 June 2025
DOI: 10.31399/asm.hb.v12a.a0007063
EISBN: 978-1-62708-500-7
Abstract
This article presents fractographs that show evidence of overload and fatigue in gray cast irons. The overload failure section illustrates a fractured motor housing, valve body, and bracket with microvoid coalescence (dimpled rupture) in the metal matrix between graphite flakes. The fractographs of fatigue failures illustrate a gearbox housing with fatigue striations and pearlitic microstructure.
Book Chapter
Ductile Cast Irons
Available to PurchaseBook: Atlas of Fractographs
Series: ASM Handbook
Volume: 12A
Publisher: ASM International
Published: 30 June 2025
DOI: 10.31399/asm.hb.v12a.a0007064
EISBN: 978-1-62708-500-7
Abstract
This article presents fractographs of overload fractures in a ductile cast iron piston, tensile test bar, differential case, brake caliper, compressor crankshaft, and pivot arm. SEM images show such features as dimpled rupture at the thin metallic matrix ligatures between the graphite nodules, bull's-eye ferrite and pearlite microstructure, loose graphite nodules and dimpled rupture morphology transitioning to cleavage, cleavage morphology with river lines, and ratchet marks and beach marks.
Book Chapter
White Cast Irons
Available to PurchaseBook: Atlas of Fractographs
Series: ASM Handbook
Volume: 12A
Publisher: ASM International
Published: 30 June 2025
DOI: 10.31399/asm.hb.v12a.a0007065
EISBN: 978-1-62708-500-7
Abstract
This article presents fractographs that show evidence of overload in white cast irons. Images illustrate brittle fracture with cleavage facets and fracture at carbide boundaries, as well as cracks caused by shear stress and the tensile stress due to rebounding.
Book Chapter
Malleable Cast Irons
Available to PurchaseBook: Atlas of Fractographs
Series: ASM Handbook
Volume: 12A
Publisher: ASM International
Published: 30 June 2025
DOI: 10.31399/asm.hb.v12a.a0007066
EISBN: 978-1-62708-500-7
Abstract
This article presents fractographs that show evidence of overload in a ferritic malleable cast iron. The images illustrate crack initiation and propagation, as well as regions of dimpled rupture.
Book Chapter
Pure Irons
Available to PurchaseBook: Atlas of Fractographs
Series: ASM Handbook
Volume: 12A
Publisher: ASM International
Published: 30 June 2025
DOI: 10.31399/asm.hb.v12a.a0007067
EISBN: 978-1-62708-500-7
Abstract
This article presents fractographs of pure irons that show evidence of overload, fatigue, and embrittlement. Woody fracture, microvoid coalescence, cleavage, and stress rupture are seen in the overload failure images. A large inclusion is seen in the fatigue fractograph. Embrittlement images show an impact fracture with intergranular rupture and transcrystalline cleavage.
Book
Series: ASM Handbook
Volume: 12A
Publisher: ASM International
Published: 30 June 2025
DOI: 10.31399/asm.hb.v12a.9781627085007
EISBN: 978-1-62708-500-7
Book Chapter
Corrosion Failures of Industrial Refractories and Technical Ceramics
Available to PurchaseBook: Corrosion: Materials
Series: ASM Handbook
Volume: 13B
Publisher: ASM International
Published: 31 January 2025
DOI: 10.31399/asm.hb.v13b.a0007042
EISBN: 978-1-62708-183-2
Abstract
This article provides a discussion on the corrosion of industrial refractory materials and technical ceramics. These materials, which are used to minimize heat losses and provide a barrier between the vessel and its contents, are utilized in the metallurgical, chemical process, power generation, automotive, and aerospace industries. The article covers the fundamental principles of chemical corrosion of refractories and ceramics, and the use of thermodynamic calculations and kinetic models to evaluate the probability of the occurrence of corrosion-causing chemical reactions. It describes the corrosion resistance characteristics of specific classes of refractories and structural ceramics. The article also examines the prevention strategies that minimize corrosion failures of both classes of materials.
Book
Series: ASM Handbook
Volume: 12
Publisher: ASM International
Published: 01 June 2024
DOI: 10.31399/asm.hb.v12.9781627083874
EISBN: 978-1-62708-387-4
Book Chapter
The Role of Fractography in Metallurgical Failure Analysis
Available to PurchaseBook: Fractography
Series: ASM Handbook
Volume: 12
Publisher: ASM International
Published: 01 June 2024
DOI: 10.31399/asm.hb.v12.a0007038
EISBN: 978-1-62708-387-4
Abstract
Many metal failures involve fracture, and fractography is an essential activity in many, if not most, failure analysis (FA) investigations. This article introduces and illustrates the role of fractography in an FA investigation. Basic guidelines are briefly presented for investigating a failure and how fractography helps the FA investigator determine evidence. Examples are given throughout this article on how the examination of fracture surfaces discerns various sources of crack initiation and mechanisms of crack growth. The procedures for analyzing fractures also include several steps and techniques that involve photographic documentation, proper specimen handling, and visual or microscopic examination. The article also briefly describes the use of metallography in fracture analysis along with case studies as illustrative examples of various fracture mechanisms and modes.
Book Chapter
Introduction to Types and Appearances of Fracture
Available to PurchaseBook: Fractography
Series: ASM Handbook
Volume: 12
Publisher: ASM International
Published: 01 June 2024
DOI: 10.31399/asm.hb.v12.a0006842
EISBN: 978-1-62708-387-4
Abstract
This article addresses macroscale fracture appearances, microscale fracture-surface appearances or morphologies, fracture mechanisms, and those factors that influence fractures and fracture appearances. Some of the macroscopic and microscopic features identified by the failure analyst to evaluate the fracture surfaces of metals and plastics are described and compared.
Book Chapter
Visual Examination, Downselection, and Field Photography
Available to PurchaseBook: Fractography
Series: ASM Handbook
Volume: 12
Publisher: ASM International
Published: 01 June 2024
DOI: 10.31399/asm.hb.v12.a0006844
EISBN: 978-1-62708-387-4
Abstract
With regard to documentation and photography of a catastrophic event, the field investigator's duties are fundamentally different from those of the laboratory-based analyst, even though both share the same goals. This article presents a case study on documentation considerations during the field investigation. It provides a detailed discussion on the general procedure to downselect from a multicomponent assemblage to a set of potential primary failed components. The article describes visual examination in macrofractography.
Book: Fractography
Series: ASM Handbook
Volume: 12
Publisher: ASM International
Published: 01 June 2024
DOI: 10.31399/asm.hb.v12.a0006845
EISBN: 978-1-62708-387-4
Abstract
Fracture surfaces can provide an important and indispensable record of many factors in simple or complex failures. Visual examination of fracture surfaces can reveal the type and direction of loading, with fracture-surface features often providing definitive evidence of torsion, tension, bending, and compressive loads. This article discusses tools and techniques of visual examination and characteristic features of fracture features. A brief review of ductile and brittle fracture-surface features is provided. The article also describes macroscopic features that can be used to identify fracture-initiation sites, locations of final overload, and the directions of crack propagation. In addition, the use of these features to characterize loading at the time of failure is also described.
Book: Fractography
Series: ASM Handbook
Volume: 12
Publisher: ASM International
Published: 01 June 2024
DOI: 10.31399/asm.hb.v12.a0006847
EISBN: 978-1-62708-387-4
Abstract
The introduction of focused ion beam (FIB) microscopy in the 1990s added the capability of studying fracture surfaces in the third dimension and making site-specific and stress-free transmission electron microscope (TEM) specimens in situ. This article reviews the methods for preparing replicas and the site-specific FIB thin-foil preparation technique. It provides an overview of FIB-TEM specimen preparation.
Book Chapter
Quantitative Fractography Applications for Fatigue Fracture Surfaces
Available to PurchaseBook: Fractography
Series: ASM Handbook
Volume: 12
Publisher: ASM International
Published: 01 June 2024
DOI: 10.31399/asm.hb.v12.a0006848
EISBN: 978-1-62708-387-4
Abstract
Quantitative fractography (QF) is the examination and characterization of fracture surfaces of failed or broken-open components and specimens. This article provides examples of the application of QF to evaluate real-life fatigue failures and also a comprehensive guideline chart for detecting and measuring fatigue striations and progression markings, with examples.
Book Chapter
Microscale Fracture Surface Morphologies
Available to PurchaseBook: Fractography
Series: ASM Handbook
Volume: 12
Publisher: ASM International
Published: 01 June 2024
DOI: 10.31399/asm.hb.v12.a0006843
EISBN: 978-1-62708-387-4
Abstract
This article presents the concept of fracture mechanisms in general terms in order to impart a practical understanding as well as enable readers to develop the ability to identify the basic fracture mechanisms correctly based on microscope observations. The key microscopic features of fracture surfaces are described and illustrated for the important types of fracture mechanisms. It provides a detailed discussion on environmentally assisted crack initiation and growth.
Book Chapter
History of Fractography
Available to PurchaseBook: Fractography
Series: ASM Handbook
Volume: 12
Publisher: ASM International
Published: 01 June 2024
DOI: 10.31399/asm.hb.v12.a0006872
EISBN: 978-1-62708-387-4
Abstract
This article reviews the historical development of fractography, from the early studies of fracture appearance dating back to the sixteenth century, and including the development of microfractography in the middle of the 20th century, to the current state-of-the-art work in electron fractography and quantitative fractography.
Book Chapter
Macroscale Fracture Appearances
Available to PurchaseBook: Fractography
Series: ASM Handbook
Volume: 12
Publisher: ASM International
Published: 01 June 2024
DOI: 10.31399/asm.hb.v12.a0006873
EISBN: 978-1-62708-387-4
Abstract
This article provides practical guidance for interpreting macroscale fracture appearances. It focuses on metallic fracture features. The article covers the important distinctions between ductile and brittle fracture and the influence of the type of loading on the facture-surface orientation. It discusses both ductile fracture and brittle fracture macroscale features. Finally, it delves into fracture-initiation sites and metal-processing effects on fracture appearance, including castings, powder metals, additive manufacturing, and surface treatments.
Book: Fractography
Series: ASM Handbook
Volume: 12
Publisher: ASM International
Published: 01 June 2024
DOI: 10.31399/asm.hb.v12.a0006874
EISBN: 978-1-62708-387-4
Abstract
Identification of the fracture mechanism is one of the principal responsibilities of a failure analyst and is an important component of any root-cause analysis. This article explores the varied mechanisms responsible for metal fracture, particularly regarding fractography. The behavior of engineering materials at fracture is based on a large number of interrelated characteristics from the atomic level to the component level. These characteristics range from ductile to brittle at the microscale and macroscale levels. Fundamental relative ductility results from the type of electronic bonding, the crystal structure, and the broader long-range degree of order. It provides detailed discussion on ductile fracture, brittle fracture, mixed fracture, embrittlement, stress-corrosion cracking.
Book Chapter
Factors Influencing Fractures and Fracture Appearance
Available to PurchaseBook: Fractography
Series: ASM Handbook
Volume: 12
Publisher: ASM International
Published: 01 June 2024
DOI: 10.31399/asm.hb.v12.a0006946
EISBN: 978-1-62708-387-4
Abstract
This article describes the general factors that can influence fracture appearances. The focus is on the general practical relationships of fracture appearances, with factors presented in some broad categories, including: material conditions (e.g., crystal structure and microstructure); loading conditions (stress state, strain rate, and fatigue); manufacturing conditions (casting, metal-working, machining, heat treatment, etc.); and service and environmental factors (hydrogen embrittlement, stress corrosion, temperature, and corrosion fatigue).
Book Chapter
Photography of Fractured Parts and Fracture Surfaces
Available to PurchaseBook: Fractography
Series: ASM Handbook
Volume: 12
Publisher: ASM International
Published: 01 June 2024
DOI: 10.31399/asm.hb.v12.a0006846
EISBN: 978-1-62708-387-4
Abstract
This article provides a discussion on the following photographic equipment: point-and-shoot cameras, digital single-reflex cameras, stand-mounted digital zoom cameras, and digital microscope cameras. It presents two principal types of optical microscopes that are appropriate for visual examination of fractured parts: the stereomicroscope and the single-light-path digital microscope. The common features present on fracture surfaces are each considered separately, both in their significance and as photographic challenges. The article also presents a short note on low-magnification scanning electron microscopy and postcapture image processing.
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