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pitting failure
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Image
Published: 15 January 2021
Fig. 5 Subsurface-initiated contact fatigue failure by (a) pitting and (b) spalling on a bearing raceway. Reprinted from Ref 16 with permission from Wiley
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Book: Fatigue and Fracture
Series: ASM Handbook
Volume: 19
Publisher: ASM International
Published: 01 January 1996
DOI: 10.31399/asm.hb.v19.a0002375
EISBN: 978-1-62708-193-1
... the equations for determining surface durability and life of gears. It tabulates the situations and concepts of pitting failures in gears. The article analyzes some of the more common flaws that affect the life of gear teeth. It reviews the components in the design and structure of each gear and/or gear train...
Abstract
This article summarizes the various kinds of gear wear, including fatigue, impact fracture, wear, and stress rupture, describes how gear life in service is estimated. It presents the rules concerning lubricants in designing gearing and analyzing failures of gears. The article presents the equations for determining surface durability and life of gears. It tabulates the situations and concepts of pitting failures in gears. The article analyzes some of the more common flaws that affect the life of gear teeth. It reviews the components in the design and structure of each gear and/or gear train that must be considered in conjunction with the teeth.
Image
Published: 01 January 2002
Fig. 10 Spring failure originating at a sharp-edged pitted area. Arrows indicate the location of the sharp-edged areas. 28×
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Image
Published: 01 January 2006
Fig. 4 Pit-initiated in-service failure of a landing gear due to dynamic stresses. The collapse of the high-strength 300M steel main landing gear load barrel was due to severe all-around pitting.
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Image
in Failure Analysis of Heat Exchangers
> Analysis and Prevention of Component and Equipment Failures
Published: 30 August 2021
Series: ASM Handbook
Volume: 8
Publisher: ASM International
Published: 01 January 2000
DOI: 10.31399/asm.hb.v08.a0003327
EISBN: 978-1-62708-176-4
... Abstract Mechanical tests are performed to evaluate the durability of gears under load. Gear tooth failures occur in two distinct regions, namely, the tooth flank and the root fillet. This article describes the common failure modes such as scoring, wear, and pitting, on tooth flanks. Failures...
Abstract
Mechanical tests are performed to evaluate the durability of gears under load. Gear tooth failures occur in two distinct regions, namely, the tooth flank and the root fillet. This article describes the common failure modes such as scoring, wear, and pitting, on tooth flanks. Failures in root fillets are primarily due to bending fatigue but can be precipitated by sudden overloading (impact). The article presents contact stress computations for gear tooth flank and bending stress computations for root fillets. Specimen characterization is a critical part of any fatigue test program because it enables meaningful interpretation of the results. The article describes four areas of the characterizations: dimensional, surface finish/texture, metallurgical, and residual stress. The rolling contact fatigue test, single-tooth fatigue test, single-tooth single-overload test, and single-tooth impact test are some of the gear action simulating tests discussed in the article.
Book Chapter
Series: ASM Handbook
Volume: 18
Publisher: ASM International
Published: 31 December 2017
DOI: 10.31399/asm.hb.v18.a0006358
EISBN: 978-1-62708-192-4
... of the gear unit—that is, the pitch diameter, gear ratio, and the face width—often must involve consideration of the Hertzian conditions necessary to avoid pitting failure of the gear face within the design life. Several types of pitting are recognized with regard to gear surface fatigue failures...
Abstract
This article discusses the physical signs of rolling-contact wear (RCW). It lists the major considerations in gear design and describes the mechanisms of RCW. The article provides a guide to rolling-contact fatigue (RCF) testing methods. It explains the steps involved in the processes of RCF and RCW.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001817
EISBN: 978-1-62708-180-1
... biological material or chemicals that can generate or decompose into ammonia. Hydrostatic-testing procedures that permit water to become stagnant in the tubes can result in serious pitting and SCC. Failure to remove shop-hydrostatic-test water that contained contaminants has caused tubing failures...
Abstract
This article describes the characteristics of tubing of heat exchangers with respect to general corrosion, stress-corrosion cracking, selective leaching, and oxygen-cell attack, with examples. It illustrates the examination of failed parts of heat exchangers by using sample selection, visual examination, microscopic examination, chemical analysis, and mechanical tests. The article explains corrosion fatigue of tubing of heat exchangers caused by aggressive environment and cyclic stress. It also discusses the effects of design, welding practices, and elevated temperatures on the failures of heat exchangers.
Series: ASM Handbook
Volume: 13A
Publisher: ASM International
Published: 01 January 2003
DOI: 10.31399/asm.hb.v13a.a0003641
EISBN: 978-1-62708-182-5
... Table 4 Main probability distributions observed in corrosion testing Probability distribution Corrosion phenomenon Normal Pitting potential Log normal Stress-corrosion cracking (SCC) failure time Poisson Two-dimensional distribution of pits Exponential Pit induction time SCC...
Abstract
This article details factors that have been used for evaluating the susceptibility of alloys to stress-corrosion cracking. Many considerations impacting the validity and accuracy of information gathered from laboratory testing programs are reviewed. The article highlights the main characteristics of probability distributions, such as normal distribution, log-normal distribution, exponential distribution, Poisson distribution, and extreme-value distribution. It also provides information on the statistical concepts to produce effective test programs.
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006813
EISBN: 978-1-62708-329-4
... generate or decompose into ammonia. Hydrostatic testing procedures that permit water to become stagnant in the tubes can result in serious pitting and SCC. Failure to remove shop hydrostatic testing water that contained contaminants has caused tubing failures to occur before startup. The water used...
Abstract
Heat exchangers are devices used to transfer thermal energy between two or more fluids, between a solid surface and a fluid, or between a solid particulate and a fluid at different temperatures. This article first addresses the causes of failures in heat exchangers. It then provides a description of heat-transfer surface area, discussing the design of the tubular heat exchanger. Next, the article discusses the processes involved in the examination of failed parts. Finally, it describes the most important types of corrosion, including uniform, galvanic, pitting, stress, and erosion corrosion.
Book Chapter
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003548
EISBN: 978-1-62708-180-1
... examination revealed pitting corrosion on the inner surface of the spar cavity. Fig. 6 Fatigue cracking of a helicopter tail rotor blade. (a) Scanning electron micrograph of the blade showing lead wool ballast in contact with the 2014-T652 aluminum spar bore cavity wall at the failure origin ∼13×. (b...
Abstract
This article addresses the forms of corrosion that contribute directly to the failure of metal parts or that render them susceptible to failure by some other mechanism. It describes the mechanisms of corrosive attack for specific forms of corrosion such as galvanic corrosion, uniform corrosion, pitting and crevice corrosion, intergranular corrosion, and velocity-affected corrosion. The article contains a table that lists combinations of alloys and environments subjected to selective leaching and the elements removed by leaching.
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
... Abstract Because of the tough engineering environment of the railroad industry, fatigue is a primary mode of failure. The increased competitiveness in the industry has led to increased loads, reducing the safety factor with respect to fatigue life. Therefore, the existence of corrosion pitting...
Abstract
Because of the tough engineering environment of the railroad industry, fatigue is a primary mode of failure. The increased competitiveness in the industry has led to increased loads, reducing the safety factor with respect to fatigue life. Therefore, the existence of corrosion pitting 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 equipment.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001815
EISBN: 978-1-62708-180-1
... modes, which together account for more than half the failures studied, are tooth-bending fatigue, tooth-bending impact, and abrasive tooth wear. Failure modes of gears Table 1 Failure modes of gears Failure mode Type of failure Fatigue Tooth bending, surface contact (pitting...
Abstract
Gears can fail in many different ways, and except for an increase in noise level and vibration, there is often no indication of difficulty until total failure occurs. This article reviews the major types of gears and the basic principles of gear-tooth contact. It discusses the loading conditions and stresses that effect gear strength and durability. The article provides information on different gear materials, the common types and causes of gear failures, and the procedures employed to analyze them. Finally, it presents a chosen few examples to illustrate a systematic approach to the failure examination.
Image
Published: 01 January 2002
Fig. 6 Fatigue cracking of a helicopter tail rotor blade. (a) Scanning electron micrograph of the blade showing lead wool ballast in contact with the 2014-T652 aluminum spar bore cavity wall at the failure origin ∼13×. (b) Greater magnification (∼63×) in this same area shows the multiple pits
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Image
Published: 15 January 2021
shows the multiple pits and associated corrosion products at the failure origin. The beach marks are seen emanating from the pits, typical of fatigue failure mode. Source: Ref 6
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Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006783
EISBN: 978-1-62708-295-2
... examination revealed pitting corrosion on the inner surface of the spar cavity. Fig. 6 Fatigue cracking of a helicopter tail rotor blade. (a) Scanning electron micrograph of the blade showing lead wool ballast in contact with the 2014-T652 aluminum spar bore cavity wall at the failure origin. Original...
Abstract
Corrosion is the electrochemical reaction of a material and its environment. This article addresses those forms of corrosion that contribute directly to the failure of metal parts or that render them susceptible to failure by some other mechanism. Various forms of corrosion covered are galvanic corrosion, uniform corrosion, pitting, crevice corrosion, intergranular corrosion, selective leaching, and velocity-affected corrosion. In particular, mechanisms of corrosive attack for specific forms of corrosion, as well as evaluation and factors contributing to these forms, are described. These reviews of corrosion forms and mechanisms are intended to assist the reader in developing an understanding of the underlying principles of corrosion; acquiring such an understanding is the first step in recognizing and analyzing corrosion-related failures and in formulating preventive measures.
Series: ASM Handbook
Volume: 13C
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v13c.a0004154
EISBN: 978-1-62708-184-9
... lay-up conditions. Further discussion of corrosion and failure mechanisms is provided in Ref 6 , 7 , 8 , 9 . One distinguishing feature of corrosion is its appearance. Metal loss may be uniform, so the surface appears smooth. Conversely, the surface may be gouged, scalloped, or pitted. Other...
Abstract
This article briefly describes water and steam chemistry, which influence the effect of corrosion in boilers. The appropriate control measures to prevent corrosion in boilers are also presented. The article provides a discussion on the common causes of fluid-side corrosion such as flow-accelerated corrosion, oxygen pitting, chelant corrosion, caustic corrosion, acid corrosion, organic corrosion, phosphate corrosion, hydrogen damage, and corrosion-assisted cracking.
Series: ASM Handbook
Volume: 13C
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v13c.a0004128
EISBN: 978-1-62708-184-9
... as analysis of failed aircraft parts ( Ref 23 ) have demonstrated that pits are sites for fatigue crack initiation. Documented cases of fatigue cracks initiating from corrosion pits in 7 xxx series alloys have also shown that crack growth was promoted by the environment until failure of the components...
Abstract
Corrosion, fatigue, and their synergistic interactions are among the principal causes of damage to aircraft structures. This article describes aircraft corrosion fatigue assessment in the context of different approaches used to manage aircraft structural integrity, schedule aircraft inspection intervals, and perform repair and maintenance of aircraft in service. It illustrates the types of corrosive attack observed in aircraft structures, including uniform, galvanic, pitting, filiform, fretting, intergranular, exfoliation corrosion, and stress-corrosion cracking. The article discusses geometric parameters such as pit dimensions, surface roughness, loss of metal thickness, and volume increase due to pillowing to quantitatively characterize the types of corrosion. It also explains the two most common fatigue life assessment methods used in the military aerospace industry: fatigue crack initiation and crack growth analysis.
Book Chapter
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003507
EISBN: 978-1-62708-180-1
... Abstract This article describes the general root causes of failure associated with wrought metals and metalworking. This includes a brief review of the discontinuities or imperfections that may be the common sources of failure-inducing defects in bulk working of wrought products. The article...
Abstract
This article describes the general root causes of failure associated with wrought metals and metalworking. This includes a brief review of the discontinuities or imperfections that may be the common sources of failure-inducing defects in bulk working of wrought products. The article discusses the types of imperfections that can be traced to the original ingot product. These include chemical segregation; ingot pipe, porosity, and centerline shrinkage; high hydrogen content; nonmetallic inclusions; unmelted electrodes and shelf; and cracks, laminations, seams, pits, blisters, and scabs. The article provides a discussion on the imperfections found in steel forgings. The problems encountered in sheet metal forming are also discussed. The article concludes with information on the causes of failure in cold formed parts.
Image
Published: 01 January 2005
originating from the inside of the bellows. Analysis showed iron-rich brown products with high chloride and sulfur content. The failures were attributed to pitting corrosion with extreme undercutting, probably resulting from changes in location of the hoses during storage and use. Bleach, used to deodorize
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