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Book Chapter
Aspects of a Failure Investigation
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 August 2005
DOI: 10.31399/asm.tb.horfi.t51180061
EISBN: 978-1-62708-256-3
.... statistics failure investigation data collection failure database maintenance company-related failures material failure root cause analysis problem-solving process Firestone 500 steel-belted tire data analysis IMPORTANT ASPECTS of failure investigation addressed in this chapter include...
Abstract
Statistics, data analysis, root cause analysis, and problem-solving processes play a key role in failure investigations. This chapter explains how to collect failure investigation data, how to build and maintain a database for company-related failures, and how to use corresponding statistics including type of failure, material, and root cause. It describes the purpose and benefits of conducting a root cause analysis and the factors, namely relative failure importance and company value, that determine when an investigation should be performed. The chapter also discusses the four-step problem-solving process as it applies to failure investigation, how to assemble an investigation team, and the details of organization and planning. It concludes with a case history of the Firestone 500 steel-belted tire failure, stressing the importance of a systematic approach to failure investigations.
Book Chapter
The Effects and Economic Impact of Corrosion
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 January 2000
DOI: 10.31399/asm.tb.cub.t66910001
EISBN: 978-1-62708-250-1
... one of its many direct and indirect consequences. Some consequences are economic, and cause the following: Replacement of corroded equipment Overdesign to allow for corrosion Preventive maintenance, for example, painting Shutdown of equipment due to corrosion failure Contamination...
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
Pedigree Analysis
Available to PurchaseBook: Systems Failure Analysis
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2009
DOI: 10.31399/asm.tb.sfa.t52780075
EISBN: 978-1-62708-268-6
.... This is especially true in highly regulated industries, such as aerospace, defense, biomedical, cosmetics, and food manufacturers. These records are retained in the organization’s quality-assurance files and database. The failure analysis team should review these records for nonconformances, and the team should do...
Abstract
A product pedigree describes its design and how it was built and shows that it was built in accordance with the drawings and other documentation defining the product configuration. Evaluating the pedigree of a failed product can help to rule in or rule out hypothesized failure causes. This chapter describes various areas that can be examined by the failure analysis team to assess the pedigree of the failed system. If the failure analysis team suspects product pedigree anomalies it should confirm conformance through independent means.
Book Chapter
Failure Analysis Laboratory Management Principles and Practices
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2019
DOI: 10.31399/asm.tb.mfadr7.t91110032
EISBN: 978-1-62708-247-1
... Abstract The management of a failure analysis (FA) laboratory requires a broad range of activities to optimize the efficiency of the operation. The purpose of this article is to stimulate readers to consider the various aspects of FA laboratory operations and their respective business...
Abstract
The management of a failure analysis (FA) laboratory requires a broad range of activities to optimize the efficiency of the operation. The purpose of this article is to stimulate readers to consider the various aspects of FA laboratory operations and their respective business management requirements. The various aspects include: staffing, laboratory organization, lab design and operations, strategic development, financial management, and metrics and measurements. References for further reading and examples of resource materials are also included.
Book Chapter
Techniques of Failure Analysis
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 30 November 2013
DOI: 10.31399/asm.tb.uhcf3.t53630001
EISBN: 978-1-62708-270-9
... normal maintenance with the recommended materials? This is particularly important when lubricants are involved in the failure, because use of improper lubricants can be extremely damaging to certain mechanisms, as well as to the seals and gaskets that are intended to keep them from leaking. What...
Abstract
Failure analysis is a systematic investigative procedure using the scientific method to identify the causes of a failure. This chapter begins by exploring what failure analysis is followed by a section describing the sequence of stages in the investigation and analysis of failure and the three principles that must be carefully followed during the analysis. It then provides information on the normal location of fracture and concludes with a list of questions to ask about fractures.
Book Chapter
Inspection, Data Collection, and Management
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 December 2015
DOI: 10.31399/asm.tb.cpi2.t55030360
EISBN: 978-1-62708-282-2
... of catastrophic plant failure were much reduced due to better materials, tighter control of design, improved fabrication quality assurance, appropriate maintenance, valid inspections, better plant process control, and so forth. This improved track record and the continued drive for improved profitability turned...
Abstract
This chapter concentrates almost exclusively on inspection techniques related to pressure vessels and pipework. The discussion covers the general aspects associated with inspection and the key factors relevant to it. In addition, the chapter addresses processes involved in data collection and management, namely data acquisition, reporting, trending, reviewing, and auditing. Capabilities and limitations of in-service inspection techniques are discussed in the Appendix to this chapter.
Book Chapter
Process Control, Product Quality, and Product Launch Process
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 January 2022
DOI: 10.31399/asm.tb.isceg.t59320323
EISBN: 978-1-62708-332-4
... material control; process control of sand preparation and system maintenance; metallic charge materials; product quality control; and melting, metallurgical, and mechanical testing. casting mechanical testing melting metallurgical testing process control product launch process product quality...
Abstract
This chapter provides an overview of key elements in controlling the casting process, systems to confirm the quality of outgoing components, and the steps needed to launch a novel product. The discussion also provides information on process control tools and techniques; incoming material control; process control of sand preparation and system maintenance; metallic charge materials; product quality control; and melting, metallurgical, and mechanical testing.
Book Chapter
General Design Guidelines
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 December 2003
DOI: 10.31399/asm.tb.cfap.t69780051
EISBN: 978-1-62708-281-5
... or replacing a product formerly made of another material, have four major concerns ( Ref 1 ): Designing products that can be built as easily and economically as possible Ensuring product reliability Simplifying product maintenance and extending product life Ensuring timely delivery of materials...
Abstract
To ensure the proper application of plastics, one must keep in mind three factors that determine the appropriate end-use: material selection, processing, and design. This article begins by providing information on various factors pertinent to the anticipated use conditions of the article to be designed. This is followed by a discussion on several stages necessary to define the geometry of plastic parts. Details on the strength of and cost estimation for plastic parts are then provided. The article ends with a section providing information on the structure, properties, processing, and end-use applications of plastics.
Book Chapter
A Few Pitfalls and More Useful Tools
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 August 2005
DOI: 10.31399/asm.tb.horfi.t51180127
EISBN: 978-1-62708-256-3
... or as an individual. The Combing Process is a failure mode and effects analysis (FMEA)-based tool for rapidly identifying your “significant few” chronic failures in hours or days. It proposes to be an approach that goes to the hands-on operating and maintenance people for information, rather than relying...
Abstract
This chapter describes some common pitfalls encountered in failure investigations and provides guidance to help engineers recognize processes and “quick fixes” that companies often try to substitute for failure analysis. It discusses three important skills and characteristics that a professional engineer must improve to conduct an effective and successful failure investigation, namely technical skills, communication skills, and technical integrity. The chapter also provides information on the additional basic tools available for failure investigation and root cause determination: the Kepner-Tregoe structured problem-solving method, PROACT software for root cause analysis developed by the Reliability Center, Inc., and other processes and methods developed by the Failsafe Network, Inc., and Shainin LLC.
Book Chapter
Corrosion Control by Materials Selection
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 January 2000
DOI: 10.31399/asm.tb.cub.t66910331
EISBN: 978-1-62708-250-1
... consequences of failure) Availability and delivery time Need for further testing Material costs Fabrication costs Maintenance and inspection costs Return or investment analysis Information necessary for estimating corrosion performance Table 2 Information necessary...
Abstract
The challenge of materials selection is to achieve adequate performance at the lowest possible cost. Corrosion resistance is not the only property to be considered in making materials selections. Typical requirements and some of the procedures involved in making a selection and some of the factors that must be considered when determining the corrosion performance of a given material are listed in this chapter. The various steps that might be included in a materials selection process are then examined. These include a review of operating conditions and design, the selection of candidate materials, the in-depth evaluation of each candidate material, fabrication requirements, follow-up monitoring, and final materials selection. Material considerations such as cost, materials properties, and processing and fabrication requirements are subsequently covered. Finally, the chapter provides information on materials selection under general corrosion conditions and under conditions of localized corrosion forms such as pitting, crevice corrosion, and stress-corrosion cracking.
Book Chapter
Life Prediction for Boiler Components
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 December 1989
DOI: 10.31399/asm.tb.dmlahtc.t60490183
EISBN: 978-1-62708-340-9
... States and in most other countries in the world ( Ref 1 and 2 ). In the United States alone, the cost penalty due to these failures is estimated to be in excess of 5 billion dollars per year in replacement power and maintenance costs. The failure mechanisms in boiler tubes, and their characteristics...
Abstract
This chapter covers the failure modes and mechanisms associated with boiler components and the tools and techniques used to assess damages and predict remaining component life. It begins with a review of the design and operation of a utility boiler and the materials used in construction. It then describes the various causes of failure in boiler tubes, headers, and steam pipes, explaining how and why they occur, how they are diagnosed, and how to mitigate their effects. The final and by far largest section in the chapter is a tutorial on damage and life assessment techniques for boiler components and assemblies. It demonstrates the use of various methods, including analytical techniques that estimate life expenditure based on operating history, component geometry, and material properties; predictive methods based on the extrapolation of failure statistics; methods that predict life based on dimensional measurements; methods based on metallographic studies; methods based on temperature estimates; and a method for estimating remaining life under creep conditions based on stress-rupture testing of service-exposed material samples. The chapter also discusses the use of fracture mechanics and presents a number of cases in which life assessments are made based on the integration of several methods.
Series: ASM Technical Books
Publisher: ASM International
Published: 30 November 2013
DOI: 10.31399/asm.tb.uhcf3.9781627082709
EISBN: 978-1-62708-270-9
Book Chapter
Defects Leading to Failure
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2012
DOI: 10.31399/asm.tb.ffub.t53610585
EISBN: 978-1-62708-303-4
... CATEGORIZING DEFECTS leading to failure vary among failure analysis practitioners, quality engineers, other engineers, and managers, as well as legal and insurance professionals. Grouping failure causes into a few fundamental categories is advantageous and informative because it defines which aspect...
Abstract
This appendix provides detailed information on design deficiencies, material and manufacturing defects, and service-life anomalies. It covers ingot-related defects, forging and sheet forming imperfections, casting defects, heat treating defects, and weld discontinuities. It shows how application life is affected by the severity of service conditions and discusses the consequences of using inappropriate materials.
Book Chapter
Package Innovation Roadmap
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2023
DOI: 10.31399/asm.tb.edfatr.t56090131
EISBN: 978-1-62708-462-8
... Abstract This chapter assesses the potential impact of neural networks on package-level failure analysis, the challenges presented by next-generation semiconductor packages, and the measures that can be taken to maximize FA equipment uptime and throughput. It presents examples showing how...
Abstract
This chapter assesses the potential impact of neural networks on package-level failure analysis, the challenges presented by next-generation semiconductor packages, and the measures that can be taken to maximize FA equipment uptime and throughput. It presents examples showing how neural networks have been trained to detect and classify PCB defects, improve signal-to-noise ratios in SEM images, recognize wafer failure patterns, and predict failure modes. It explains how new packaging strategies, particularly stacking and disintegration, complicate fault isolation and evaluates the ability of various imaging methods to locate defects in die stacks. It also presents best practices for sample preparation, inspection, and navigation and offers suggestions for improving the reliability and service life of tools.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 1989
DOI: 10.31399/asm.tb.dmlahtc.9781627083409
EISBN: 978-1-62708-340-9
Book Chapter
Life-Assessment Techniques for Combustion Turbines
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 December 1989
DOI: 10.31399/asm.tb.dmlahtc.t60490415
EISBN: 978-1-62708-340-9
... overhauls by negligent maintenance personnel. In order to withstand such damage and have tolerance to pre-existing or service-induced flaws, it is essential that blade materials have adequate impact toughness. Because impact toughness is subject to in-service degradation, periodic assessment...
Abstract
Combustion turbines consist of a compressor, a combustor, and a turbine. As commonly configured, the compressor and turbine mount on a single shaft that connects directly to a generator. This chapter reviews the materials of construction, damage mechanisms, and life-assessment techniques for nozzles and buckets. It also presents key information from a detailed review of the literature and the results of a survey on combustion-turbine material problems.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.fibtca.9781627082532
EISBN: 978-1-62708-253-2
Book Chapter
Extrusion Die and Tooling
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 30 April 2025
DOI: 10.31399/asm.tb.aet2.t59420107
EISBN: 978-1-62708-487-1
... design for a new product is developed based on previous experience and experimentation. Die design is influenced by many factors, including: Press procedure and maintenance Understanding of the section or profile geometry and its tolerances Alloy characteristics The skill...
Abstract
This chapter discusses many aspects of extrusion die and tooling, including the terminology and function of extrusion die and tooling, the types of dies, the fundamentals of die design, manufacturing, correction, material, and the surface treatments of die bearings and tribology in extrusion dies. It then presents the fundamentals and function of finite-element modeling simulation. The chapter describes the role of tribology and thermodynamics in the die bearing to control the flow and dimensional stability of extrusion exiting the die.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2023
DOI: 10.31399/asm.tb.edfatr.9781627084628
EISBN: 978-1-62708-462-8
Book Chapter
Composite Mechanical Properties
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.scm.t52870373
EISBN: 978-1-62708-314-0
... Interlaminar shear strength, ksi 10.9 8.70 13.4 13.1 Poisson’s ratio 0.28 0.34 0.25 0.27 The largest publicly accessible database for composite materials is the MIL-HNBK-17 series ( Ref 1 to 5 ). Volume 2 contains databases on polymer matrix systems, and Volumes 4 and 5 contain information...
Abstract
This chapter examines the static, fatigue, and damage tolerance properties of glass, aramid, and carbon fiber systems. It also explains how delaminations, voids, porosity, fiber distortion, and fastener hole defects affect impact resistance and strength.
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