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Curtis D. Mowry, Russell L. Jarek, Jessica Román-Kustas, Amber C. Telles, Adam S. Pimentel
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Series: ASM Handbook
Volume: 5B
Publisher: ASM International
Published: 30 September 2015
DOI: 10.31399/asm.hb.v05b.a0006061
EISBN: 978-1-62708-172-6
... assessment and determining selling cost. coating corrosion cost analysis industrial paints surface area ESTIMATING PAINTING PROJECT COSTS usually makes one think of contractors providing formal bids in order to be awarded contract work. Engineers, consultants, structure owners, and project...
Abstract
This article provides an insight into the cost estimation of painting projects for both contractors and others. The cost estimating methods include benchmarking, unit price estimating, developed pricing, market pricing, and critical path scheduling. The first step in developing an accurate estimate for an industrial painting contract is determining the scope of work. The article describes the method of calculating quantities of materials and labor, surface area takeoff, and equipment costs. It concludes by listing the forgotten costs and presenting information on coating condition assessment and determining selling cost.
Book: Corrosion: Materials
Series: ASM Handbook
Volume: 13B
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v13b.a0003968
EISBN: 978-1-62708-183-2
... 3 , 4 ) paved the way for systematic analysis of the cost of corrosion in the USA. He divided the cost of corrosion into direct losses resulting from the use of special alloys and replacement of corroded equipment, and indirect losses due to shutdown, overdesign, loss of product and efficiency...
Abstract
This article analyzes the estimates of the cost of corrosion, made in various countries at various times. The data are extrapolated to a 2004 base and then projected to the global economy. The chronological order of the countries are the United States of America, the United Kingdom, Australia, Japan, Canada, Germany, Poland, South Africa, Czechoslovakia, Belgium, Netherlands, Sweden, Finland, the Union of Soviet Socialist Republics, Kuwait, India, and the Basque Region.
Series: ASM Handbook
Volume: 4B
Publisher: ASM International
Published: 30 September 2014
DOI: 10.31399/asm.hb.v04b.a0005943
EISBN: 978-1-62708-166-5
... general and administrative costs. The article discusses the techniques involved in allocating costs to the group of equipment, and presents a description on the cost analysis of endothermic gas. cost analysis endothermic generators heat treatment quenchants Although heat...
Abstract
This article presents a simple cost/pricing system that is reasonably accurate and could easily be recalculated if the yearly cost of any of the basic cost components change. Using the example of a commercial heat treating facility, the operational details are categorized as atmosphere processes, induction processes, aluminum processes, high-heat processes, and secondary processes. For the purpose of calculating the heat treatment processing cost per hour and the selling price for a piece of equipment, the costs are separated into direct costs, allocated costs, capitalized cost, and general and administrative costs. The article discusses the techniques involved in allocating costs to the group of equipment, and presents a description on the cost analysis of endothermic gas.
Series: ASM Desk Editions
Publisher: ASM International
Published: 01 December 1998
DOI: 10.31399/asm.hb.mhde2.a0003087
EISBN: 978-1-62708-199-3
... processing, product design, cost analysis, manufacturing, recyclability, and performance. concurrent engineering design considerations material selection materials engineer ENGINEERING DESIGN can be defined as the creation of a product that satisfies a certain need. A good design should result...
Abstract
Engineering design should result in a product that performs its function efficiently and economically within the prevailing legal, social, safety, and reliability requirements. This introductory article discusses some key considerations in design, material selection, and manufacturing that a materials engineer should take into account to satisfy such requirements. It includes a brief section on concurrent engineering, which companies use to ensure that all needed input is obtained and addressed concurrently throughout the product lifecycle, including material selection and processing, product design, cost analysis, manufacturing, recyclability, and performance.
Series: ASM Desk Editions
Publisher: ASM International
Published: 01 December 1998
DOI: 10.31399/asm.hb.mhde2.a0003223
EISBN: 978-1-62708-199-3
... discusses the concept of life-cycle analysis (LCA), a quantitative accounting of the environmental and economic costs of using a given material and the energy required to make, distribute, operate, and eventually dispose of the host product and its constituent materials. An important but often overlooked...
Abstract
Product design greatly influences the recycling and reuse of manufacturing materials. This article presents a design for recycling strategy based on ease of disassembly, minimizing process scrap, using readily recyclable materials, and labelling or otherwise identifying parts. It also discusses the concept of life-cycle analysis (LCA), a quantitative accounting of the environmental and economic costs of using a given material and the energy required to make, distribute, operate, and eventually dispose of the host product and its constituent materials. An important but often overlooked step in the LCA process is to identify potential improvement pathways.
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
... prominence. The intent is to provide not only products and systems that garner high customer satisfaction but also increase productivity, reduce costs, and meet delivery requirements. In general, high quality refers to products and systems manufactured to higher standards, in response to higher...
Abstract
This article briefly introduces the concepts of failure analysis, including root-cause analysis (RCA), and the role of failure analysis as a general engineering tool for enhancing product quality and failure prevention. It initially provides definitions of failure on several different levels, followed by a discussion on the role of failure analysis and the appreciation of quality assurance and user expectations. Systematic analysis of equipment failures reveals physical root causes that fall into one of four fundamental categories: design, manufacturing/installation, service, and material, which are discussed in the following sections along with examples. The tools available for failure analysis are then covered. Further, the article describes the categories of mode of failure: distortion or undesired deformation, fracture, corrosion, and wear. It provides information on the processes involved in RCA and the charting methods that may be useful in RCA and ends with a description of various factors associated with failure prevention.
Series: ASM Handbook
Volume: 5B
Publisher: ASM International
Published: 30 September 2015
DOI: 10.31399/asm.hb.v05b.a0006071
EISBN: 978-1-62708-172-6
... been addressed. Because of their key performance properties, ease of use, and cost advantages, alkyd coatings are re-emerging as a significant player in the protective coating market. Alkyd resins are classified as polyesters because the molecular backbone of the polymeric structure forming the resin...
Abstract
An alkyd is an ester-based polymer derived from the polycondensation reaction of polyhydric alcohol and polybasic acid. This article provides useful information on the chemistry, production, coating formulations, modification, commercial products, and application methods of alkyd resins. It also provides a section on drying oil, which is used in the manufacture of resins. The article describes the three categories of metals that have been used in drier compounds: primary driers (active or oxidation driers), secondary driers (through-driers), and auxiliary driers. It also provides information on the oil length of an alkyd resin and on solvents, which play a critical role in the formulation and use of the coating. The article concludes with a description of the concerns that a user, specifier, or applicator should be aware of when using alkyd coatings.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006764
EISBN: 978-1-62708-295-2
... Visual observation of the test object surface to evaluate dimensions, color, and presence of surface discontinuities Postmanufacturing inspections, in-service inspections looking for dimensional anomalies, color variation, cracks, pits, etc. Only sensitive to surface flaws Low cost, intuitive. May be...
Abstract
Nondestructive testing (NDT), also known as nondestructive evaluation (NDE), includes various techniques to characterize materials without damage. This article focuses on the typical NDE techniques that may be considered when conducting a failure investigation. The article begins with discussion about the concept of the probability of detection (POD), on which the statistical reliability of crack detection is based. The coverage includes the various methods of surface inspection, including visual-examination tools, scanning technology in dimensional metrology, and the common methods of detecting surface discontinuities by magnetic-particle inspection, liquid penetrant inspection, and eddy-current testing. The major NDE methods for internal (volumetric) inspection in failure analysis also are described.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006784
EISBN: 978-1-62708-295-2
... analysis practitioner or for someone who is contemplating procurement of a cost-effective failure analysis of commodity-grade components suspected of hydrogen embrittlement. Some prevention strategies for design and manufacturing problem-induced hydrogen embrittlement are also provided. failure...
Abstract
Hydrogen damage is a term used to designate a number of processes in metals by which the load-carrying capacity of the metal is reduced due to the presence of hydrogen. This article introduces the general forms of hydrogen damage and provides an overview of the different types of hydrogen damage in all the major commercial alloy systems. It covers the broader topic of hydrogen damage, which can be quite complex and technical in nature. The article focuses on failure analysis where hydrogen embrittlement of a steel component is suspected. It provides practical advice for the failure analysis practitioner or for someone who is contemplating procurement of a cost-effective failure analysis of commodity-grade components suspected of hydrogen embrittlement. Some prevention strategies for design and manufacturing problem-induced hydrogen embrittlement are also provided.
Series: ASM Handbook
Volume: 17
Publisher: ASM International
Published: 01 August 2018
DOI: 10.31399/asm.hb.v17.a0006451
EISBN: 978-1-62708-190-0
... larger imaging arrays, and with the development of lower-cost uncooled IR detectors, it is becoming easier for researchers and practitioners outside of the experimental mechanics field to capitalize on this powerful technique and use it in a wider range of engineering applications...
Abstract
Thermoelastic stress analysis (TSA) an increasingly popular infrared (IR)-based technique for measuring stress on the surface of a part subjected to time-varying loads. This article begins by providing a theoretical and historical background of thermoelastic stress analysis. It then describes infrared detectors, such as quantum detectors and thermal/nonquantum detectors, for thermoelastic stress analysis. The article discusses the theoretical aspects for producing thermoelastic stress analysis data and the applications amenable to thermoelastic stress analysis. It concludes with information on the qualitative applications of thermoelastic stress analysis.
Series: ASM Handbook
Volume: 5B
Publisher: ASM International
Published: 30 September 2015
DOI: 10.31399/asm.hb.v05b.a0006043
EISBN: 978-1-62708-172-6
... a syringe. Sampling for solvent entrapment should be coordinated with the laboratory based on the laboratory's analytical capabilities. Coating failures often lead to costly remediation. The cost of such remediation may hinge on the results of a failure analysis investigation, and, in...
Abstract
This article discusses the standard conduct of coating failure investigation. As each failure is different, a specific coating failure may require increased emphasis on a given step, or additional work and/or steps may be required. This article covers the following topics: obtaining and analyzing background information, preliminary determination of site conditions, inspection equipment requirements, coating failure site investigation, sampling techniques, sample chain of custody, coordination with the coatings laboratory, report preparation, and sample retention.
Book Chapter
Series: ASM Desk Editions
Publisher: ASM International
Published: 01 December 1998
DOI: 10.31399/asm.hb.mhde2.a0003134
EISBN: 978-1-62708-199-3
... method of producing internal cavities. There is no general rule for choosing between cored and coreless designs. A cost analysis will determine which is the more economical method of producing the castings, although frequently the choice can be decided by experience. For example, costs were compared...
Abstract
Copper alloy castings are used in applications that require superior corrosion resistance, high thermal or electrical conductivity, good bearing surface qualities, or other special properties. Discussing the types and compositions of copper alloy used for casting, this article describes the major factors considered in alloy selection for casting, including raw material cost, castability, machinability, and the bearing and wear properties. It also provides information on the cost of the final product.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006770
EISBN: 978-1-62708-295-2
..., and, as always, the skill of the operator. Recent advances in energy-dispersive x-ray technology have resulted in instrumentation that provides higher count rates and analytical results comparable to the best x-ray wavelength-dispersive systems of the past at only a fraction of the cost. In addition...
Abstract
X-ray spectroscopy is generally accepted as the most useful ancillary technique that can be added to any scanning electron microscope (SEM), even to the point of being considered a necessity by most operators. While “stand-alone” x-ray detection systems are used less frequently in failure analysis than the more exact instrumentation employed in SEMs, the technology is advancing and is worthy of note due to its capability for nondestructive analysis and application in the field. This article begins with information on the basis of the x-ray signal. This is followed by information on the operating principles and applications of detectors for x-ray spectroscopy, namely energy-dispersive spectrometers, wavelength-dispersive spectrometers, and handheld x-ray fluorescence systems. The processes involved in x-ray analysis in the SEM and handheld x-ray fluorescence analysis are then covered. The article ends with a discussion on the applications of x-ray spectroscopy in failure analysis.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006782
EISBN: 978-1-62708-295-2
... in global savings of 15 to 35% of the damage costs, or 375 to 875 billion U.S. dollars. The articles in this Section are devoted to the identification and analysis of corrosion-related failures, the categorization of corrosion failures by form and mechanism, and the...
Abstract
Corrosion is the deterioration of a material by a reaction of that material with its environment. The realization that corrosion control can be profitable has been acknowledged repeatedly by industry, typically following costly business interruptions. This article describes the electrochemical nature of corrosion and provides the typical analysis of environmental- and corrosion-related failures. It presents common methods of testing of laboratory corrosion and discusses the processes involved in the prevention of environmental- and corrosion-related failures of metals and nonmetals.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006769
EISBN: 978-1-62708-295-2
... to be examined and the necessity for (or elimination of) sample-preparation equipment. For example, in failure analysis investigations, parts are often submitted that contain residual oil or grease or are covered with nonconductive corrosion products. For cases such as these, the additional cost of a...
Abstract
The scanning electron microscope (SEM) is one of the most versatile instruments for investigating the microscopic features of most solid materials. The SEM provides the user with an unparalleled ability to observe and quantify the surface of a sample. This article discusses the development of SEM technology and operating principles of basic systems of SEM. The basic systems covered include the electron optical column, signal detection and display equipment, and the vacuum system. The processes involved in the preparation of samples for observation using an SEM are described, and the application of SEM in fractography is discussed. The article covers the failure mechanisms of ductile failure, brittle failure, mixed-mode failure, and fatigue failure. Lastly, image dependence on microscope type and operating parameters is also discussed.
Book Chapter
Series: ASM Handbook
Volume: 10
Publisher: ASM International
Published: 15 December 2019
DOI: 10.31399/asm.hb.v10.a0006663
EISBN: 978-1-62708-213-6
... relate to the factors of analysis speed, m / z resolution, size, and cost discussed previously. For a particular application, these factors are not equally weighted, and there is significant overlap among the capabilities of the different analyzer types. The systems covered here do not use separation...
Abstract
Gas analysis by mass spectrometry, or gas mass spectrometry, is a general technique using a family of instrumentation that creates a charged ion from a gas phase chemical species and measures the mass-to-charge ratio. This article covers gas analysis applications that do not use chromatographic separation to physically isolate components of the sample prior to analysis. It is intended to provide an understanding of gas analysis instrumentation and terminology that will help make informed decisions in choosing an instrument and methodology appropriate for the data needed. Mass-analyzer technologies for gas mass spectrometry, namely quadrupole mass filters, magnetic sector mass filters, and time-of-flight mass analyzers are covered. Common factors to consider in choosing an analyzer for static or continuous gas measurement are also described. In addition, the article presents some examples of applications of gas mass spectrometry.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006754
EISBN: 978-1-62708-295-2
... inconvenience, to a massive catastrophic event. Methodologies are designed to match the complexity of the investigation to the costs of the failure, whether human or material. This means choosing multiple test locations or exemplar specimens, as appropriate. Failure analysis is an iterative and creative...
Abstract
Failure analysis is a process that is performed in order to determine the causes or factors that have led to an undesired loss of functionality. This article is intended to demonstrate proper approaches to failure analysis work. The goal of the proper approach is to allow the most useful and relevant information to be obtained. The discussion covers the principles and approaches in failure analysis work, objectives and scopes of failure analysis, the planning stages for failure analysis, the preparation of a protocol for a failure analysis, practices used by failure analysts, and procedures of failure analysis.
Book: Surface Engineering
Series: ASM Handbook
Volume: 5
Publisher: ASM International
Published: 01 January 1994
DOI: 10.31399/asm.hb.v05.a0001322
EISBN: 978-1-62708-170-2
... Abstract Environmental and worker health regulations have increased the costs associated with cadmium coating application and cadmium-beating waste disposal, thus creating economic incentives for industrial users to seek cadmium plating replacements. This article presents a cadmium replacement...
Abstract
Environmental and worker health regulations have increased the costs associated with cadmium coating application and cadmium-beating waste disposal, thus creating economic incentives for industrial users to seek cadmium plating replacements. This article presents a cadmium replacement identification matrix that includes information on the specifications, corrosion control performance, environment-assisted cracking, coating lubricity, environmental and worker health regulations, and cost and performance factors for various replacement processes.
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005343
EISBN: 978-1-62708-187-0
... variety of factors that include the material available for evaluation, the timing for completion of the evaluation, and, of course, cost considerations. Under ideal conditions, there would be several samples to investigate, several weeks for the examination and testing, and no limit to the cost. In...
Abstract
This article reviews the failure analysis process with specific reference to the considerations that should be addressed when a casting has failed. It describes the failure analysis methodology for three failed cast components: an aluminum bracket, a bronze suction roll, and a steel automotive spindle. The article discusses failure analysis investigation by obtaining casting background information, planning the evaluation and selecting the appropriate casting for analysis, conducting a preliminary examination, conducting the proper material evaluations, and thoroughly evaluating the test data. It concludes with information on case studies that show how the methodology is adapted for differing materials, failure mechanisms, and failure circumstances.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006773
EISBN: 978-1-62708-295-2
... speed have continued to reduce computational costs, where personal computers (PCs) with very efficient and strong computing-powered central processing units and enormous amounts of dedicated memory are quite readily available at a fraction of the cost compared to that around 2000. Currently, FEA...
Abstract
When complex designs, transient loadings, and nonlinear material behavior must be evaluated, computer-based techniques are used. This is where the finite-element analysis (FEA) is most applicable and provides considerable assistance in design analysis as well as failure analysis. This article provides a general view on the applicability of finite-element modeling in conducting analyses of failed components. It highlights the uses of finite-element modeling in the area of failure analysis and design, with emphasis on structural analysis. The discussion covers the general development and both general- and special-purpose applications of FEA. The special-purpose applications of FEA covered are piping and pressure vessel analysis, impact analysis, and microelectronic and microelectromechanical systems analysis. The article provides case histories that involved the use of FEA in failure analysis.