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designing for repairability
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Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.scm.t52870517
EISBN: 978-1-62708-314-0
... in the repair manual must be followed to the letter. A repair that is done incorrectly can often result in a second, more extensive and complicated repair. Information on the design of bolted repairs is given in Ref 2 , while Ref 3 covers bonded repair designs. Detailed procedures for many composite...
Book Chapter
Book: Systems Failure Analysis
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2009
DOI: 10.31399/asm.tb.sfa.t52780189
EISBN: 978-1-62708-268-6
... efficacy. Evaluate other potential failure causes as corrective action candidates, and incorporate preventive actions where it makes sense to do so. Incorporate failure analysis findings into a failure analysis library, design and process guidelines, and troubleshooting and repair documents...
Abstract
At the conclusion of a systems failure analysis, the people involved should have a much more in-depth understanding of how the system is supposed to work. The analysis should help understand shortfalls in the design, production, testing, and use of the system. The failure analysis team will have identified other potential failure causes and actions required to preclude future failures. This is valuable knowledge, and it should not be set aside or ignored when the failure analysis team concludes its activities. This chapter is a brief account of the creation of failure analysis libraries, of process guidelines based on previous failure analyses, and of troubleshooting and repair guidelines. Also provided is a listing of the various steps that should be included in a failure analysis procedure.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2012
DOI: 10.31399/asm.tb.ffub.t53610303
EISBN: 978-1-62708-303-4
... to sustain defects or cracks safely, until such time that action is (or can be) taken to eliminate the cracks by repair or by replacing the cracked structure or component . In the design stage, one still has the option to select a more crack-resistant material or improve the structural design to ensure...
Abstract
Fracture control can be defined as a concerted effort to maintain operating safety without catastrophic failure by fracture. It requires an understanding of how cracks affect structural integrity and strength and the time that a crack can grow before it exceeds permissible size. The chapter describes some of methods used to determine maximum permissible crack size and predict growth rates. It explains how the information can then be used to control fractures through periodic inspection, fail-safe features, mandated retirement, and proof testing. It presents a number of fracture control plans optimized for different circumstances, examines the damage tolerance requirements used by different industries, and discusses various approaches for fatigue design.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 July 1997
DOI: 10.31399/asm.tb.wip.t65930179
EISBN: 978-1-62708-359-1
... require samples of some of the base metal from the workpiece to be repaired. Nature of Failure When designing and producing a successful repair, it is often necessary to assess the reasons that a repair is required. Failures can be grouped into four major categories: Base-metal defects...
Abstract
This article describes the repair of weld defects and failed structures. It provides information on three factors that must first be considered before attempting a repair, namely material weldability, nature of the failure that prompted the repair, and involvement of any code requirements. The article discusses the processes involved in welding process selection and the methods of preparing base metal for repair welding. It presents the guidelines for weld repairs of various ferrous (carbon steels, cast irons, and stainless steels) and nonferrous (for example, titanium) base metals.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 June 2016
DOI: 10.31399/asm.tb.hpcspa.t54460227
EISBN: 978-1-62708-285-3
... spray repairs. The requirements and specifcations were presented in the Materials Joint Test Protocol (JTP) ( Ref 9.11 , 9.14 – 9.16 ). The JTP comprises mechanical, physical, and chemical tests designed specifically for the repair of the magnesium transmission housings. The cold spray process...
Abstract
High-pressure cold spray repair process has been used on a number of different applications in the defense industry. This chapter describes various applications for cold spray systems that have operating pressures greater than 2.4 MPa (350 psi) and operating temperatures greater than 500 deg C (930 deg F).
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 1995
DOI: 10.31399/asm.tb.sch6.t68200164
EISBN: 978-1-62708-354-6
... high production runs are required, the foam patterns are produced in specially designed tools, Figure 12-6 . The full mold process for producing steel castings has not been fully developed at this time. Fig. 12-6 Tools for foam patterns Pattern Repairs Polyester putties are used...
Abstract
Pattern equipment is the tooling utilized to form the mold cavity of a casting. This chapter first discusses the following factors that should be considered for determining the type of pattern equipment: number of castings to be produced, mold processes to be employed, dimensional tolerances required, casting design, and pattern cost. It also discusses the factors that should be considered when engineering a pattern. The chapter then presents the types of materials used for pattern construction. It provides an overview of patternmaker's shrinkage allowance. Finally, the chapter presents the factors that govern the space requirements for pattern storage.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2005
DOI: 10.31399/asm.tb.faesmch.t51270059
EISBN: 978-1-62708-301-0
... Abstract This chapter discusses some of the ways that the lessons learned from failures have benefitted society, leading to improved product designs, better materials, safer industrial processes, and more robust codes and standards. It also provides several examples of how the technology...
Abstract
This chapter discusses some of the ways that the lessons learned from failures have benefitted society, leading to improved product designs, better materials, safer industrial processes, and more robust codes and standards. It also provides several examples of how the technology and procedures associated with aviation security have been upgraded in the wake of air disasters.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2000
DOI: 10.31399/asm.tb.ttg2.t61120039
EISBN: 978-1-62708-269-3
... as completely as possible. (Weld repair, if it is required at all, should be limited as far as possible to noncritical areas.) Unnecessary tooling complexity should be avoided. The casting envelope should be designed for smooth transitions between thick and thin areas, to contain generous radii...
Abstract
Titanium castings are used in a wide range of aerospace, chemical process, marine, biomedical, and automotive applications. This chapter provides an overview of titanium casting and associated processes and how they compare with other manufacturing methods. It also discusses the role heat treating and its effect on the tensile properties of different titanium alloys.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.scm.t52870489
EISBN: 978-1-62708-314-0
... resistance but high in cost and damage tolerance/repairability. The second design is a titanium structure fabricated using superplastic forming/diffusion bonding. Its stiffness is better than that of the aluminum structure, but it is heavier and the nonrecurring tooling cost is high. However, it has...
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 June 2010
DOI: 10.31399/asm.tb.hss.t52790229
EISBN: 978-1-62708-356-0
...-hand equipment. The cars are even lighter than when originally built, because of the elimination of individual generators for heating, cooling, and lighting in each car, but still approximately 15% heavier than cars made today with computer-assisted designs that reduce section thickness...
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.tb.ssde.t52310213
EISBN: 978-1-62708-286-0
... to which this is objectionable is a function of design, and tolerances can be held tightly at a cost. Width tolerance is normally +1/16 in./–0 in 48 in., while length is held to +1/8 in./–0 in 10 ft or less. Maximum camber is 3/32 in. in 8 ft. Closer tolerances can be negotiated. Maintenance and Repair...
Abstract
This chapter deals with the technology of stainless steel as it pertains to its proper use in architecture, art, and construction. It begins with an overview of the corrosion resistance of stainless steel, providing guidelines for balancing corrosion resistance, processing characteristics, and economy. This is followed by sections describing the influence of surface finish on corrosion resistance of stainless steel and reviewing some of the factors pertinent to balancing service environment, design requirements, and maintenance considerations. The chapter then discusses the various factors pertinent to important considerations in buildings, namely surface finish aesthetics, flatness, maintenance, repair, fabrication, and service considerations. It ends with a section providing information on concrete reinforcing bar.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 March 2006
DOI: 10.31399/asm.tb.fdsm.t69870267
EISBN: 978-1-62708-344-7
... of assembly damage and operating overload, the importance of surface cleanliness and finish, and the role of inspection, testing, replacement, and repair in safe-life and fail-safe designs. Examples highlighting the benefits and potential pitfalls of proof loading tests are included as well. References...
Abstract
This chapter is largely a compendium of best practices and procedures for minimizing the effects of fatigue. It explains how to make products more resistant to fatigue by choosing the right materials and manufacturing processes, avoiding geometries and features that concentrate strains, preventing or removing surface damage, and by inducing compressive mean stresses that prolong fatigue life. It also discusses the use of property conditioning and restoration treatments, the benefits of interference fits and processes such as coaxing, the effects of assembly damage and operating overload, the importance of surface cleanliness and finish, and the role of inspection, testing, replacement, and repair in safe-life and fail-safe designs. Examples highlighting the benefits and potential pitfalls of proof loading tests are included as well.
Book Chapter
Book: Systems Failure Analysis
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2009
DOI: 10.31399/asm.tb.sfa.t52780183
EISBN: 978-1-62708-268-6
... Abstract Corrective action means the implementation or modification of things designed to eliminate or reduce failure causes. This chapter addresses developing potential solutions and selecting the best solution. It discusses the special operations that should be used only as temporary...
Abstract
Corrective action means the implementation or modification of things designed to eliminate or reduce failure causes. This chapter addresses developing potential solutions and selecting the best solution. It discusses the special operations that should be used only as temporary or interim corrective actions to overcome design, process, and other failure causes. The chapter concludes by describing the process of corrective action implementation.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 1995
DOI: 10.31399/asm.tb.sch6.t68200220
EISBN: 978-1-62708-354-6
... in the subsequent production castings. Full scale destructive tests are sometimes performed in pilot castings to evaluate the casting design. If needed, design changes can be made by the casting purchaser before proceeding with production of the order. Inspection, Upgrading and Repair A series of quality...
Book Chapter
Book: Systems Failure Analysis
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2009
DOI: 10.31399/asm.tb.sfa.t52780081
EISBN: 978-1-62708-268-6
... as is” or “repair” dispositions, the nonconforming items are deemed acceptable for use, but they do not conform to the engineering drawings. In effect, they are design changes not shown in the engineering drawings. For this reason, the failure analysis team should review all quality-assurance documentation...
Abstract
This chapter targets areas that determine if a change occurred and if the change induced the failure: change or what's different analysis. It describes the different sources of changes that induce process deficiencies: design, process, test and inspection, environmental, supplier lot, aging, and supplier changes. The chapter presents an example of a cluster bomb failure to explain how the failure analysis team found and corrected the failure cause.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 January 2000
DOI: 10.31399/asm.tb.cub.t66910001
EISBN: 978-1-62708-250-1
... The application of rational design principles can eliminate many corrosion problems and greatly reduce the time and cost associated with corrosion maintenance and repair. Corrosion often occurs in dead spaces or crevices where the corrosive medium becomes more corrosive. These areas can be eliminated or minimized...
Abstract
Corrosion can be defined as a chemical or electrochemical reaction between a material, usually a metal, and its environment that produces a deterioration of the material and its properties. This chapter describes the effects and economic impact of corrosion in major industrial plants. The emphasis in this chapter, as well as in other chapters in this book, is on aqueous corrosion, or corrosion in environments where water is present. The chapter describes the classification of various forms of corrosion based on the nature of the corrodent, mechanism of corrosion, and appearance of the corroded metal. It discusses five primary methods of corrosion control, namely, material selection, coatings, inhibitors, cathodic protection, and design. Examples of the opportunities in corrosion control and the means to implement a program to capitalize on those opportunities are presented in a table. The chapter concludes with varied sources of information pertaining to corrosion and corrosion prevention.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 March 2002
DOI: 10.31399/asm.tb.stg2.t61280323
EISBN: 978-1-62708-267-9
... of phases, and how these processes contribute to microstructural changes as a function of time, temperature, and applied stress. It also describes several failure examples and discusses related issues, including damage recovery, refurbishment, and repair. microstructure gas turbine components...
Abstract
This chapter discusses the failure of superalloy components in high-temperature applications where they are subject to the effects of microstructural changes, melting, and corrosion. It explains how overheating can deplete alloying elements and alter the composition and distribution of phases, and how these processes contribute to microstructural changes as a function of time, temperature, and applied stress. It also describes several failure examples and discusses related issues, including damage recovery, refurbishment, and repair.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 June 2016
DOI: 10.31399/asm.tb.hpcspa.t54460277
EISBN: 978-1-62708-285-3
... Abstract This chapter focuses on high-pressure cold spray applications pertaining to repair and refurbishment in the aerospace, oil and gas, and power-generation industries, the last specifically involving repair of gas turbine components. Advantages of cold spray coating in the repair...
Abstract
This chapter focuses on high-pressure cold spray applications pertaining to repair and refurbishment in the aerospace, oil and gas, and power-generation industries, the last specifically involving repair of gas turbine components. Advantages of cold spray coating in the repair and refurbishment of structural engineering components are also discussed.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 January 2017
DOI: 10.31399/asm.tb.sccmpe2.t55090349
EISBN: 978-1-62708-266-2
... from austenitic stainless steel have suffered from stress-corrosion cracking (SCC). This has resulted in loss of plant availability, increased cost of electrical energy, and increased exposure to radiation of skilled personnel involved in inspection and repair operations ( Ref 15.1 ). This chapter...
Abstract
This chapter examines the stress-corrosion cracking (SCC) failure of stainless steel pipe welds in boiling water reactor (BWR) service. It explains where most of the failures have occurred and provides relevant details about the materials of construction, fabrication techniques, environmental factors, and cracking characteristics. It includes a model that accounts for the primary factors involved in intergranular SCC, namely, tensile stresses above the yield stress of the base material, a sensitized microstructure, and reactor cooling water. The chapter also provides proven remedies and mitigation techniques corresponding to a wide range of issues related to stress, sensitization, and operating conditions.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2013
DOI: 10.31399/asm.tb.ahsssta.t53700215
EISBN: 978-1-62708-279-2
...-Strength Steel Applications: Design and Stamping Process Guidelines” ( Ref 14.2 ), was released in January 2010 by the Auto Steel Partnership (ASP). The WorldAutoSteel document is a leading information resource for people developing, making, and using AHSS. The document contains 338 pages and hundreds...
Abstract
This chapter briefly reviews the experience-based guidelines that were developed for forming and welding advanced high-strength steels (AHSS). It discusses the benefits of using HSS in car body structures and components that are analyzed by the performance indices developed for materials selection.