Metallurgical failure analysis : techniques and case studies / Kannadi Palankeezhe Balan.

Format:

Book

Author/Creator:

Balan, Kannadi Palankeezhe, author.

Language:

English

Subjects (All):

Metals--Fracture.

Metals.

Failure analysis (Engineering).

Physical Description:

1 online resource (281 pages) : illustrations (some color)

Place of Publication:

Amsterdam, Netherlands : Elsevier, 2018.

Summary:

Metallurgical Failure Analysis: Techniques and Case Studies explores how components fail and what measures should be taken to avoid future failures. The book introduces the subject of failure analysis; covers the fundamentals and methodology of failure analysis, including fracture and fractography of metals and alloys and the tools and techniques used in a failure investigation; examines 37 case studies on high performance engineering components; features experimental results comprised of visual-, fractographic-, or metallographic- examination, hardness measurements and chemical analysis; includes illustrations and evidence obtained through test results to enhance understanding; and suggests suitable remedial measures when possible.The various case studies are classified according to the major causes of failures. The case studies pertain to: Improper Material Selection, Manufacturing Defects, Casting Defects, Overload, Fatigue, Corrosion Induced Failures, Hydrogen Embrittlement and Stress Corrosion Cracking, Wear and Elevated Temperature Failures. The book contains information gathered over three decades of the author's experience handling a variety of failure cases and will go a long way toward inspiring practicing failure analysts. The book is designed for scientists, metallurgists, engineers, quality control inspectors, professors and students alike.- Explores the fundamentals and methodology of failure analysis- Examines the major causes of component failures- Teaches a systematic approach to investigation to determine the cause of a failure- Features 37 case studies on high performance engineering components

Contents:

Front Cover

Metallurgical Failure Analysis: Techniques and Case Studies

Copyright

Dedication

Contents

Preface

Acknowledgments

Part One: Fundamentals and Methodology

Chapter One: Introduction

Chapter Two: Fracture

2.1. Ductile and Brittle Fractures

2.2. Fractography of Ductile and Brittle Fractures

2.3. Fatigue Fracture

2.4. Fractography of Fatigue Fracture

Chapter Three: Tools and Techniques

3.1. Acquisition of Background Data

3.2. Selection of Samples

3.3. Photographic Records

3.4. Preliminary Examination

3.5. Nondestructive Testing

3.6. Chemical Analysis

3.7. Fractography, Energy Dispersive Analysis by X-Ray (EDAX), and Microscopy using Scanning Electron Microscope (SEM)

3.7.1. Principle of SEM

3.7.2. Fractography

3.7.3. EDAX

3.7.4. Microscopy

3.8. Optical Microscopy

3.9. Electron Probe Micro Analysis (EPMA)

3.10. X-ray Diffraction

3.11. Evaluation of Mechanical Properties

3.11.1. Hardness

3.11.2. Tensile Properties

3.11.3. Impact Toughness

Part Two: Case Studies

Chapter Four: Material Selections

4.1. Case Study: Failure of Hip-Joint Prosthesis

4.1.1. Background

4.1.2. Experimental Results

4.1.3. Chemical Analysis (Wt.%)

4.1.4. Discussion

4.1.5. Conclusion

4.1.6. Remedial Measures

4.1.7. Reference

4.2. Case Study: Failure of Firing Pin of 120mm Low Range Mortar

4.2.1. Background

4.2.2. Experimental Results

4.2.3. Chemical Analysis (Wt.%)

4.2.4. Discussion

4.2.5. Conclusion

4.2.6. Remedy

4.2.7. Reference

4.3. Case Study: Failure of Shaft of a Gearbox

4.3.1. Background

4.3.2. Experimental Results

4.3.3. Chemical Analysis (Wt.%)

4.3.4. Discussion

4.3.5. Conclusion

4.3.6. Remedial Measures

4.3.7. Reference

4.4. Case Study: Failure of 7.62mm Cartridge Cases.

4.4.1. Background

4.4.2. Experimental Results

4.4.3. Discussion

4.4.4. Conclusion

4.5. Case Study: Failure of Fin Mounting Nuts

4.5.1. Background

4.5.2. Experimental Results

4.5.3. Chemical Analysis (Wt.%)

4.5.4. Discussion

4.5.5. Conclusion

Chapter Five: Manufacturing Defects

5.1. Case Study: Failure of Track Pins of Track Link

5.1.1. Background

5.1.2. Experimental Results

5.1.3. Chemical Analysis (Wt.%)

5.1.4. Discussion

5.1.5. Conclusion

5.1.6. Recommendations

5.2. Case Study: Failure of Track Shoe of an Infantry Combat Vehicle

5.2.1. Background

5.2.2. Experimental Results

5.2.3. Chemical Analysis (Wt.%)

5.2.4. Discussion

5.2.5. Conclusion

5.3. Case Study: Failure of Control Lever of Fuel-Metering Unit of an Aeroengine

5.3.1. Background

5.3.2. Experimental Results

5.3.3. Chemical Analysis (Wt.%)

5.3.4. Discussion

5.3.5. Conclusion

5.3.6. References

5.4. Case Study: Failure of Drill Rods for Mining

5.4.1. Background

5.4.2. Experimental Results

5.4.3. Chemical Analysis (Wt.%)

5.4.4. Discussion

5.4.5. Conclusion

5.4.6. Recommendation

5.5. Case Study: Failure of Lifting Lugs of a Missile

5.5.1. Background

5.5.2. Experimental Results

5.5.3. Discussion

5.5.4. Conclusion

5.6. Case Study: Failure of Breech Block of Light Machine Gun

5.6.1. Background

5.6.2. Experimental Results

5.6.3. Chemical Analysis (Wt. %)

5.6.4. Discussion

5.6.5. Conclusion

5.6.6. Recommendation

5.7. Case Study: Failure of Titanium Sponge Cutting Ring

5.7.1. Background

5.7.2. Experimental Results

5.7.3. Chemical Analysis (Wt. %)

5.7.4. Discussion

5.7.5. Conclusion

5.7.6. Remedial Measures

5.8. Case Study: Failure of Combustion Chamber Outer Casing of an Aeroengine

5.8.1. Background

5.8.2. Experimental Results.

5.8.3. Chemical Analysis (Wt.%)

5.8.4. Discussion

5.8.5. Conclusion

5.8.6. Reference

Chapter Six: Casting Defects in Iron and Steel

6.1. Case Study: Failure of Exhaust Outer Cone of an Aeroengine

6.1.1. Background

6.1.2. Experimental Results

6.1.3. Chemical Analysis of the Flange (Wt. %)

6.1.4. Discussion

6.1.5. Conclusion

6.1.6. Recommendations

6.2. Case Study: Failure of Sealing Rings of Centrifugal Breather of an Aeroengine

6.2.1. Background

6.2.2. Experimental Results

6.2.3. Chemical Analysis (Wt. %)

6.2.4. Discussion

6.2.5. Conclusion

6.2.6. Reference

6.3. Case Study: Failure of Grinding Roll of a Bowl Mill

6.3.1. Background

6.3.2. Experimental Results

6.3.3. Chemical Analysis (Wt.%)

6.3.4. Discussion

6.3.5. Conclusion

6.3.6. Recommendation

Chapter Seven: Overload

7.1. Case Study: Failure of Mounting Bolt of Emergency Changeover Valve

7.1.1. Background

7.1.2. Experimental Results

7.1.3. Chemical Analysis (Wt.%)

7.1.4. Discussion

7.1.5. Conclusion

7.2. Case Study: Failure of Steam Pipe in Unit-VI of a Thermal Power Station

7.2.1. Background

7.2.2. Experimental Results

7.2.3. Chemical Analysis (Wt.%)

7.2.4. Mechanical Properties

7.2.5. Discussion

7.2.6. Conclusion

7.2.7. References

7.3. Case Study: Failure of Body of Saddle Assembly

7.3.1. Background

7.3.2. Experimental Results

7.3.3. Chemical Analysis (Wt.%)

7.3.4. Discussion

7.3.5. Conclusion

7.4. Case Study: Failure of Boiler Tube of a Thermal Power Station

7.4.1. Background

7.4.2. Experimental Results

7.4.3. Chemical Analysis (Wt.%)

7.4.4. Discussion

7.4.5. Conclusion

Chapter Eight: Fatigue

8.1. Case study: Failure of Wheel Hub of an Aircraft

8.1.1. Background

8.1.2. Experimental Results

8.1.3. Chemical Analysis (Wt.%).

8.1.4. Discussion

8.1.5. Conclusion

8.2. Case study: Failure of Bolts of Flapjack Mounting Bracket of an Aircraft

8.2.1. Background

8.2.2. Experimental Results

8.2.3. Chemical Analysis (Wt.%)

8.2.4. Discussion

8.2.5. Conclusion

8.3. Case Study: Failure of Compressor Rotor Blades of an Aeroengine

8.3.1. Background

8.3.2. Experimental Results

8.3.3. Chemical Analysis (Wt.%)

8.3.4. Discussion

8.3.5. Conclusion

8.4. Case Study: Failure of Bearing Cage of an Aeroengine

8.4.1. Background

8.4.2. Experimental Results

8.4.3. Chemical Analysis (Wt.%)

8.4.4. Discussion

8.4.5. Conclusion

Chapter Nine: Corrosion

9.1. Case Study: Failure of Nipple of Fuel Pipe Line

9.1.1. Background

9.1.2. Experimental Results

9.1.3. Chemical Analysis (Wt.%)

9.1.4. Discussion

9.1.5. Conclusion

9.2. Case Study: Failure of Condenser Tubes of Thermal Power Station

9.2.1. Background

9.2.2. Experimental Results

9.2.3. Chemical Analysis (Wt.%)

9.2.4. Discussion

9.2.5. Conclusion

9.3. Case Study: Failure of High Pressure Air and Hydraulic Pipes

9.3.1. Background

9.3.2. Experimental Results

9.3.3. Chemical Analysis (Wt.%)

9.3.4. Discussion

9.3.5. Conclusion

9.3.6. Recommendation

9.4. Case Study: Failure of Detonator of Grenade

9.4.1. Background

9.4.2. Experimental Results

9.4.3. Chemical Analysis (Wt.%)

9.4.4. Discussion

9.4.5. Conclusion

Chapter Ten: Hydrogen Embrittlement and Stress Corrosion Cracking

10.1. Case Study: Failure of Fin Mounting Screws of an Aero weapon

10.1.1. Background

10.1.2. Experimental Results

10.1.3. Chemical Analysis (Wt.%)

10.1.4. Discussion

10.1.5. Conclusion

10.2. Case Study: Failure of Differential Valve Cover of Fuel Metering Unit

10.2.1. Background

10.2.2. Experimental Results.

10.2.3. Chemical Analysis (Wt.%)

10.2.4. Discussion

10.2.5. Conclusion

10.2.6. Reference

10.3. Case Study: Failure of Lever Assembly of Main Under Carriage of an Aircraft

10.3.1. Background

10.3.2. Experimental Results

10.3.3. Chemical Analysis (Wt.%)

10.3.4. Discussion

10.3.5. Conclusion

10.3.6. Reference

10.4. Case Study: Failure of Cartridge Seat Ejection Secondary of an Aircraft

10.4.1. Background

10.4.2. Experimental Results

10.4.3. Chemical Analysis (Wt.%)

10.4.4. Discussion

10.4.5. Conclusion

10.4.6. Recommendations

10.4.7. References

Chapter Eleven: Wear

11.1. Case Study: Failure of Interrotor Bearing of An Aeroengine

11.1.1. Background

11.1.2. Experimental Results

11.1.3. Chemical Analysis (Wt.%)

11.1.4. Discussion

11.1.5. Conclusion

11.2. Case Study: Failure of Low Temperature Super Heater Tube of a Thermal Power Station

11.2.1. Background

11.2.2. Experimental Results

11.2.3. Chemical Analysis (Wt.%)

11.2.4. Discussion

11.2.5. Conclusion

11.3. Case Study: Failure of Main Landing Gear Assembly of an Aircraft

11.3.1. Background

11.3.2. Experimental Results

11.3.3. Chemical Analysis (Wt.%)

11.3.4. Discussion

11.3.5. Conclusion

11.4. Case Study: Failure of Coupling Shaft and Bevel Gear of an Aeroengine

11.4.1. Background

11.4.2. Experimental Results

11.4.3. Chemical Analysis (Wt.%)

11.4.4. Discussion

11.4.5. Conclusion

Chapter Twelve: Elevated Temperature Failures

12.1. Case Study: Failure of a Bolt of Nozzle Guide Vane of an Aeroengine

12.1.1. Background

12.1.2. Experimental Results

12.1.3. Chemical Analysis (Wt.%)

12.1.4. Discussion

12.1.5. Conclusion

12.1.6. Reference

12.2. Case Study: Failure of Vanes of Front Nozzle Diaphragm Assembly of an Aeroengine

12.2.1. Background.

12.2.2. Experimental Results.

Notes:

Includes bibliographical references and index.

Description based on online resource; title from PDF title page (EBC, viewed February 1, 2018).

ISBN:

9780128143377

0128143371