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microstructural analysis
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Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.omfrc.t53030211
EISBN: 978-1-62708-349-2
... section. Phase contrast, 40× objective Fig. 12.9 Transmitted-light microscopy of the natural fiber composite ultrathin section. Hoffman modulation contrast, 40× objective Abstract Microstructural analysis of the composite matrix is necessary to understand the performance of the part...
Abstract
Microstructural analysis of the composite matrix is necessary to understand the performance of the part and its long-term durability. This chapter focuses on the microstructural analysis of engineering thermoplastic-matrix composites and the influence of cooling rate and nucleation on the formation of spherulites in high-temperature thermoplastic-matrix carbon-fiber-reinforced composites. It also describes the microstructural analysis of a bio-based thermosetting-matrix natural fiber composite system.
Image
Published: 01 December 2000
Fig. 5.64 Typical microstructure of experimental gears. Microstructure analysis: the microstructure consists of ferrite and pearlite. There is no evidence of banding. Section location: gear hub. Process: 100×, etched 3% nital
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Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2005
DOI: 10.31399/asm.tb.faesmch.t51270141
EISBN: 978-1-62708-301-0
...-defined chevron marks along the fracture surface that end in a shear lip on the convex side. Further examination using a SEM shows that the failure was due to overload. Based on these observations and the results of tensile testing and microstructural analysis, investigators concluded that a sudden impact...
Abstract
A compressor blade made of titanium alloy fractured during an engine test. The material and processing conditions of the blade were found to be satisfactory, turning the focus of the investigation to operating anomalies and human error. A photograph of the failed blade shows well-defined chevron marks along the fracture surface that end in a shear lip on the convex side. Further examination using a SEM shows that the failure was due to overload. Based on these observations and the results of tensile testing and microstructural analysis, investigators concluded that a sudden impact load on the concave side of the blade caused it to fracture.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2005
DOI: 10.31399/asm.tb.faesmch.t51270191
EISBN: 978-1-62708-301-0
... Abstract This report describes the failure of a gas turbine in a combined-cycle power plant and the examination and tests that were conducted to determine the cause. Based on microstructural analysis, hardness measurements, and tensile tests, the failure was attributed to inadequate clearances...
Abstract
This report describes the failure of a gas turbine in a combined-cycle power plant and the examination and tests that were conducted to determine the cause. Based on microstructural analysis, hardness measurements, and tensile tests, the failure was attributed to inadequate clearances in the seal land region between two stages in the compressor section of the rotor. The report also recommends changes to remediate the problem.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2005
DOI: 10.31399/asm.tb.faesmch.t51270165
EISBN: 978-1-62708-301-0
... and progressed circumferentially outward. Based on these observations and the results of SEM fractography and microstructural analysis, the fatigue cracking can be traced to insufficient fillet radius at the transition zone. crack initiation fatigue failure pressure impulse testing SEM fractography...
Abstract
Two filtration components installed on a developmental aircraft cracked during pressure impulse testing. Both parts were made from an aluminum alloy, solutionized and aged, and cracked due to fatigue. In both cases, the crack initiated at a transition region on an inner surface and progressed circumferentially outward. Based on these observations and the results of SEM fractography and microstructural analysis, the fatigue cracking can be traced to insufficient fillet radius at the transition zone.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2005
DOI: 10.31399/asm.tb.faesmch.t51270133
EISBN: 978-1-62708-301-0
... Abstract A second-stage compressor blade in an aircraft engine fractured after 21 h of service. The remaining portion of the blade was removed and examined as were several adjacent blades. Based on the results of SEM fractography, microstructural analysis, and hardness testing, the blade failed...
Abstract
A second-stage compressor blade in an aircraft engine fractured after 21 h of service. The remaining portion of the blade was removed and examined as were several adjacent blades. Based on the results of SEM fractography, microstructural analysis, and hardness testing, the blade failed due to stress-corrosion cracking combined with the effects of inadequate tempering.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2005
DOI: 10.31399/asm.tb.faesmch.t51270031
EISBN: 978-1-62708-301-0
... Abstract This chapter discusses some of the more advanced methods and procedures used in failure analysis, including in-service material sampling, in situ microstructure analysis, and a form of punch testing that can determine the fracture toughness of any material from a tiny specimen...
Abstract
This chapter discusses some of the more advanced methods and procedures used in failure analysis, including in-service material sampling, in situ microstructure analysis, and a form of punch testing that can determine the fracture toughness of any material from a tiny specimen. The chapter also covers quantitative fractography, fracture surface topography analysis, and the use of oxide dating as well as fault tree and failure modes and effects analysis (FMEA) and computational techniques.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 January 2015
DOI: 10.31399/asm.tb.spsp2.t54410001
EISBN: 978-1-62708-265-5
... International® All rights reserved asminternational.org Introduction Purpose of Text, Microstructure and Analysis, Steel Definitions, and Specifications Purpose of This Book THE PURPOSE OF THIS BOOK is to describe the physical metallurgy, i.e., the processing-structure-p roperty relationships, of steels...
Abstract
This chapter provides perspective on the physical dimensions associated with the microstructure of steel and the instruments that reveal grain size, morphology, phase distributions, crystal defects, and chemical composition, from which properties and behaviors derive. The chapter also reviews the definitions and classifications used to identify and differentiate commercial steels, including the AISI/SAE and UNS designation systems.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2005
DOI: 10.31399/asm.tb.faesmch.t51270067
EISBN: 978-1-62708-301-0
... measurements. fatigue fracture fractography microstructural analysis turbine blades Summary A low-pressure turbine rotor blade failed in service, causing extensive damage to the engine. The blade failed by stress rupture followed by fatigue due to high operating temperature. Background...
Abstract
A low-pressure turbine rotor blade failed in service, causing extensive engine damage. A section of the blade broke off around 25 mm from the root platform, producing a flat fracture surface that appeared smooth on one end and grainy elsewhere. Based on their examination, investigators concluded that the nickel-base superalloy blade was exposed to high temperatures and stresses, initiating a crack that propagated under cyclic loading. This chapter provides a summary of the investigation and the insights acquired using scanning electron fractography, metallography, and hardness measurements.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2005
DOI: 10.31399/asm.tb.faesmch.t51270087
EISBN: 978-1-62708-301-0
... images of the microstructure and fracture surfaces and explains what some of the details reveal about the failure. fatigue crack metallography microstructural analysis SEM fractography turbine blades Summary A blade from the last turbine stage of an aircraft engine failed in service...
Abstract
A turbine blade in an aircraft engine failed, fracturing at the root above the fir tree region. Fractography indicated that a fatigue crack initiated at the trailing edge of the blade and the final fracture occurred when the crack reached critical length. Although the exact cause of crack initiation could not be established, material defects, improper root loading, and high operating temperatures were ruled out. This chapter describes how investigators came to their conclusions and what they learned through visual and SEM examination and qualitative elemental analysis. It includes images of the microstructure and fracture surfaces and explains what some of the details reveal about the failure.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2005
DOI: 10.31399/asm.tb.faesmch.t51270126
EISBN: 978-1-62708-301-0
... microstructural analysis visual examination Summary A four-engine aircraft made a test flight after a number of rectifications and ground runs. After becoming airborne, a fire warning came on for one of the engines. Even after a three-engine landing, the fire warning continued. On strip examination...
Abstract
A test flight was cut short after a fire warning came on indicating a problem with one of the four engines on an aircraft. A visual examination following the precautionary landing revealed several burned hoses, a melted bolt, and fuel leaking from the base of the main burner. The fuel nozzle was also damaged, and based on its microstructure, came very close to melting. Investigators determined that the burner was mounted backwards, facing the compressor rather than the turbine. They also recommended a redesign to prevent the fuel nozzle from being reversed.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2005
DOI: 10.31399/asm.tb.faesmch.t51270130
EISBN: 978-1-62708-301-0
.... The bolts were removed and analyzed to determine the mode and cause of failure. Based on the results of macroscopy, scanning electron fractography, metallographic examination, and chemical analysis, the failures were caused by stress corrosion cracking, and in one case, overtightening. microstructural...
Abstract
An aircraft crashed following the loss of yaw control in full airborne flight. The subsequent discovery of broken shutter bolts in the rear pitch reaction control valve led to an inspection campaign that found bolt failures of a similar nature in valves on several other aircraft. The bolts were removed and analyzed to determine the mode and cause of failure. Based on the results of macroscopy, scanning electron fractography, metallographic examination, and chemical analysis, the failures were caused by stress corrosion cracking, and in one case, overtightening.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2005
DOI: 10.31399/asm.tb.faesmch.t51270095
EISBN: 978-1-62708-301-0
... to overheating, possibly as a result of misalignment compounded by insufficient lubrication and high speeds. aircraft engine bearings high-temperature wear microstructural analysis visual examination Summary In an aircraft engine, two center support ball bearings failed. In one, the inner ring...
Abstract
A pair of bearings mounted side by side in an aircraft engine failed in service. Photographs show that the inner rings were either broken or deformed, the balls were worn and flattened, and the cages severely damaged. The bearing races were damaged as well, but only on one side indicating a directional thrust. In addition to their examination, investigators also conducted metallographic studies and hardness tests, which indicated that the balls and inner rings reached temperatures above 825 °C (1520 °F). Based on their findings, investigators concluded that the bearings failed due to overheating, possibly as a result of misalignment compounded by insufficient lubrication and high speeds.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 July 1997
DOI: 10.31399/asm.tb.wip.t65930039
EISBN: 978-1-62708-359-1
... characterization of a sectioned weld, including features such as number of passes; weld bead size, shape, and homogeneity; and the orientation of beads in a multipass weld. Macroscopic characterization is followed by microstructural analysis, including microsegregation, grain size and structure, the phase makeup...
Abstract
This article reviews nondestructive and destructive test methods used to characterize welds. The first process of characterization discussed involves information that may be obtained by direct visual inspection and measurement of the weld. An overview of nondestructive evaluation is included that encompasses techniques used to characterize the locations and structure of internal and surface defects, including radiography, ultrasonic testing, and liquid penetrant inspection. The next group of characterization procedures discussed is destructive tests, requiring the removal of specimens from the weld. The third component of weld characterization is the measurement of mechanical and corrosion properties. Following the discussion on the characterization procedures, the second part of this article provides examples of how two particular welds were characterized according to these procedures.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2005
DOI: 10.31399/asm.tb.faesmch.t51270124
EISBN: 978-1-62708-301-0
... that a considerable amount of rubbing occurred after the shaft broke. SEM fractography revealed deformation marks and elongated dimples, typical of shear overloads, along with other details. Based on their analysis, investigators concluded that the cardan shaft failed under torsional overload. They also cited a need...
Abstract
A cardon shaft operating in an aircraft engine failed and was taken out and analyzed to determine the cause. A photograph of the broken shaft in the as-received condition shows the location and orientation of the fracture. The fracture surface appeared smooth, indicating that a considerable amount of rubbing occurred after the shaft broke. SEM fractography revealed deformation marks and elongated dimples, typical of shear overloads, along with other details. Based on their analysis, investigators concluded that the cardan shaft failed under torsional overload. They also cited a need for a more detailed examination of the driven end of the shaft.
Image
Published: 01 September 2008
Fig. 17 Examples of failures in an 8%Cr-0.8%C tool steel, caused by an incorrect heat treating procedure. (a) Punches and (b) their microstructures. (c) Cutting blade and (d) the microstructure observed in its failure analysis. The primary cause of failure is low-temperature tempering and high
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Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.fibtca.t52430149
EISBN: 978-1-62708-253-2
... crystal structure followed by hematite and magnetite layers. Chemical analysis confirmed the MOC of the tube as SA 213 T91 steel. The microstructure was tempered martensite, with normal tensile and hardness values. However, the thickness of the internal scale, which was in the range of 160 µm...
Abstract
Boiler tubes operating at high temperatures under significant pressure are vulnerable to stress rupture failures. This chapter examines the cause, effect, and appearance of such failures. It discusses the conditions and mechanisms that either lead to or are associated with stress rupture, including overheating, high-temperature creep, graphitization, and dissimilar metal welds. It explains how to determine which mechanisms are in play by interpreting fracture patterns and microstructural details. It also describes the investigation of several carbon and low-alloy steel tubes that failed due to stress rupture.
Image
Published: 01 August 2018
Fig. 17.22 Schematic microstructural evolution of a gray cast iron during solidification superimposed on a thermal analysis curve. Some undercooling below the eutectic temperature is needed for nucleation to start. Eutectic solidification happens essentially at constant temperature
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Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 March 2002
DOI: 10.31399/asm.tb.mgppis.t60400149
EISBN: 978-1-62708-258-7
... it employs light as the source of illumination of the specimen. These microscopes are commonly called “optical” microscopes, but in this book the authors identify the microscope by the type of illumination used. The first stage in any metallographic analysis involves the observation of the microstructure...
Abstract
Several specialized instruments are available for the metallographer to use as tools to gather key information on the characteristics of the microstructure being analyzed. These include microscopes that use electrons as a source of illumination instead of light and x-ray diffraction equipment. This chapter describes how these instruments can be used to gather important information about a microstructure. The instruments covered include image analyzers, transmission electron microscopes, scanning electron microscopes, electron probe microanalyzers, scanning transmission electron microscopes, x-ray diffractometers, microhardness testers, and hot microhardness testers. A list of other instruments that are usually located in a research laboratory or specialized testing laboratory is also provided.
Image
Published: 01 September 2008
Fig. 38 Examples of undesirable microstructures encountered on the surface of nitrided tools. For both cases, the core microstructures are correct, indicating proper hardening and tempering procedures. (a) Surface and (b) core microstructure of a nitrided forging tool, showing
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