Handbook of Case Histories in Failure Analysis, Vol. 1

Contains 115 never-before published case studies conducted by experts around the world.
 

TRANSPORTATION COMPONENTS

Aircraft
Aircraft Landing Gear Fracture
Analysis of Wing Main Spar Cracking
Cracking of Aluminum Alloy Aircraft Undercarriage Forgings
Engine Accessory Angle Drive Gear Failure
Failure of a Helicopter Main Rotor Blade
Fatigue Fracture of a Cl30 Aircraft Main Landing Gear Wheel
Flange
Hydrogen-Assisted Fracture of a 17-4PH Airplane Wing Component
Main Rotor Yoke Cracking
Mode III Fatigue Crack Growth Following the Curvature of the Heat
Affected Zone of a Type 321 Stainless Steel Spot Weld
Premature Torquing Failure of Cast A356 Aluminum Actuators
Stress-Corrosion Cracking of a High-Strength Steel Frame
in a Fighter Aircraft

Aerospace Components
Degradation of a Main Combustion Chamber Liner on a Space Shuttle
Main Engine
Failure of a Stirling Engine Heat Pipe
Fatigue Failure of Regenerator Screens in a High-Frequency
Stirling Engine

Ground Transportation Components
Bacteria-Induced Corrosion of a Stainless Steel Chemical Trailer
Barrel
Effect of Strain Rate on the Failure Mode of a Rear Axle
Examination of Broken Lamp Filaments Following a Rear-End
Vehicular Collision
Failure of Wrist Pins in an Automotive Engine
Fatigue Failure of a 1000 mm (40 in.) Diam Trailer Wheel at the
Bolt Holes
Fatigue Failure of a Steering Spindle on a Tricycle Agricultural Field Chemical Applicator
Fatigue Failure of an Axle From a Prototype Urban Transit Vehicle
Fatigue Failure of Welded Truck Cross Members
Fatigue Fracture of a Stainless Steel Leaf Spring

PROCESS EQUIPMENT

Heat Exchangers
Embrittlement of a 76 mm (3 in.) Stainless Steel Pipe and Liner From a Hydrogen Plant Quench Pot Vessel
Failure Analysis of Admiralty Brass Condenser Tubes
Failure of Brass Heat Exchanger Tubes
Heat Exchanger Corrosion in a Chlorinated Solvent Incinerator
Intergranular Corrosion in an E-Brite Clad Ferralium Tube
Sheet in Nitric Acid Service
Stress-Corrosion Cracking of Stainless Steel Heat Exchanger
Tubes in a Fertilizer Plant

Pressure Vessels
Corrosion and Cracking of the Internal Surfaces of a Black Liquor
Digester
Corrosion Fatigue and Subsequent Rupture of a Yankee Dryer Roll on
a Modified Paper Machine
Corrosion Fatigue Cracking of a Steam Generator Vessel From a
Pressurized Water Reactor
Fatigue Cracking in a Stainless Steel Welded Exhaust Hose
Assembly
Hydrotest Failure of a Carbon Steel Pressure Vessel
Stress-Corrosion Fracture in Silver Solid-State Bonds of Uranium

Pipes and Pipelines
Catastrophic Failure of a 1830 mm (72 in.) Diam Spiral-Welded
Water Line
Failure Analysis of the Moderator Branch Pipe of a
Pressured Hot Water Reactor
Failure of a Brass Pipe Nipple
Failure of a High-Pressure Water-Line Plug in a Fire
Sprinkler System
Field Replication of Stress-Corrosion Cracking in a Type 316
Stainless Steel Pressure Vessel
Intergranular Corrosion/Cracking of a Stainless Steel Pipe
Reducer Section in Bleached Pulp Stock Service
Intergranular Stress-Corrosion Cracking of Carbon Steel Pipe
Welds In a Kamyr Continuous Digester Equalizer Line
Internal Cracks in Cast Steel With 9% Nickel for Cryogenic
Applications
Pitting Corrosion of Stainless Steel by Potable Municipal Water
in an Organic Chemical Plant
Rapid Pitting Failure of Type 304 Stainless Steel Pipework
Single-Phase Erosion Corrosion of a 460 mm (18 in.) Diam
Feedwater Line Break
Stress-Corrosion Cracking of a Teflon-Lined Steel Pipe in
Sulfuric Acid Service
Stress-Corrosion Cracking of C-Mn Steel in a C02 Absorber
in a Chemical Plant

Tanks
Corrosion Failure of Stainless Steel Tanks
Failure of a Type 317L Stainless Steel Clad Bottom Cone of an
Acid Sulfite Pulping Batch Digester
Unexpected Corrosion of Type 316L Stainless Steel
Neutralization Tanks

Auxiliary Components
Brittle Fracture of a Cast Iron Valve in Oleum and Sulfuric
Acid Service
Environmental Cracking of a Low-Alloy Steel Welded Impeller
Cover From a Centrifugal Unit
Excessive Wear of Plain Carbon Steel Sprockets in a Chemical
Plant Producing Fibers
Failure of a Yoke Body of Master Slave Manipulator Due to
Casting Defect
Fatigue Failure of Stainless Steel Wires in a Electrostatic
Precipitator at a Paper Plant


ROTATING EQUIPMENT

Bearings and Gears
Electrostatic Discharge Attack on a Thrust Bearing Face
in a Power Turbine
Fatigue Failure of a Carburized Steel Gear From a Helicopter
Transmission
Gear Failure of a Pressurized Heavy-Water Reactor Refueling
Machine

Blades, Disks, and Rotors
Condition Assessment and Improvement of a Steam Turbine Rotor
Failure of a Steam Turbine Due to a Design Flaw
Fatigue Fracture of Aircraft Engine Compressor Disks
Flow-Induced Vibration Fatigue of Stainless Steel Impeller Blades
in a Circulating Water Pump

Impellers
Corrosion Failure of Four Pump Impellers
Failure of a Boiler Feed Pump Second-Stage Impeller
Hot Cracking of a Pump Impeller From a Nuclear Plant
Intergranular Cracking and Failure of Stainless Steel Vanes
from a Closed, Riveted Impeller
Repeated Failure of Rubber Slurry Pump Impellers and Liners in
a Flue Gas Desulfurization Plant

Shafts and Housings
Failure of a Carrier Shaft
Failure of a Cast Steel Crosshead
Failure of a Flexible Pump Connector
Fracture of a Turbine Impeller Shaft
Surface Damage on a Transfer Gear Shaft

FASTENERS

Cracking of an Alloy Steel Solt
Environmentally-Induced Fracture of Type 410 Martensic Stainless
Steel Self-Drilling Tapping Screws
Failure of a 20 Ton Polar Crane Motor by Bolt Fatigue
Failure of a Stud From a Boiler Manhole
Fatigue Failure of 316L Stainless Steel Screws Employed
for Surgical Implanting
Fatigue Failure of Six Cap Screws From a Hydraulic Coupling
Fracture of Alloy Steel Cap Screws in a Refrigeration Compressor
Fractures of Hot Dip Galvanized Steel Anchor Bolts in Chemical
Plant Construction Project
Hydrogen Embrittlement Failure of Socket Head Cap Screws
Liquid Metal Embrittlement of Flange Connector Studs in Contact
With Cadmium
Stress-Corrosion Cracking of a Ship Propeller Tap Bolt

HIGH-TEMPERATURE FAILURES

Failure of a Heat-Resistant Sinter Belt
Failure of a Tied Universal Expansion Joint
Furnace Element Tube Failures
Gaseous Corrosion of a Heat-Resistant Alloy (Metal Dusting)
High-Temperature Failure by Perforation of Incoloy 800H
Pigtails in Reformer Furnaces
Hot Corrosion of Stainless Steel Grate Bars in Taconite Indurators
Thermal Fatigue of an Austenitic Stainless Steel Tube

MISCELLANEOUS

Structural Components

Brittle Fracture of the Tension Flange of a Steel Box-Girder
Bridge
Failure of an I-Beam
Hydrogen Induced Cracking of Welded Truss Gusset Plates

Oil and Gas Production Components

Brittle Fracture of a Marine Riser Clamp
Failure of 9 % Ni Steel Production Tubing
Failure of Grade J-55 Electric Resistance Welded Production
Tubing
Hydrogen Embrittlement of P-110 Couplings for Mating 180 mm
(7 in.) Casing in Oilfield Production

Springs
Failure of Stainless Steel Springs Used in an Oil Ring Lip Seal
Stress-Corrosion Cracking Caused by Residual Stresses in Chromium-
Silicon Alloy Steel Helical Compression Springs

Tools
Failure of an ASTM A681-89 H13 Die Segment for Die Casting of
Aluminum
Service Failure of a Die Insert Made From AISI D2 Tool Steel
Sledgehammer Chipping Failure

Valves
lntergranular Corrosion Failure in Zn-Al Alloy Solenoid Valve
Seats

Electrical Equipment

Failure Fracture of Aluminum Wires in High-Voltage Electrical
Cables in Alaska
Failure of an Aluminum Connector in a Electrical Transmission Cable

Nonmetallic Materials

Delayed Fracture of Tempered Glass Panels Due to Nickel
Sulfide Inclusions
Failure of Two Plastic Toilet-Tank Floats


General
Fracture of Steam Pipes Removed From Service
Failure of a Cast Steel Crane Bolster
Failure of a Seat on a School Playground Swing Set 443-444
Failure of Hot-Rolled Steel Bars
Failure of Pendent Sprinkler Heads
Failure of the Bond Between a Cobalt Alloy Prosthetic Casting
and a Sintered Porous Coating
Tensile Failure of a Hoist Chain Link

Index