Failure Analysis Case Studies II A Sourcebook of Case Studies Selected from the Pages of Engineering Failure Analysis 1997 1999 Volume 2 1st Edition by Jones ISBN 0080439594 978-0080439594

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ISBN 10: 0080439594
ISBN 13: 978-0080439594
Author: Jones

The first book of Failure Analysis Case Studies selected from volumes 1, 2 and 3 of the journal Engineering Failure Analysis was published by Elsevier Science in September 1998. The book has proved to be a sought-after and widely used source of reference material to help people avoid or analyse engineering failures, design and manufacture for greater safety and economy, and assess operating, maintenance and fitness-for-purpose procedures. In the last three years, Engineering Failure Analysis has continued to build on its early success as an essential medium for the publication of failure analysis cases studies and papers on the structure, properties and behaviour of engineering materials as applied to real problems in structures, components and design.Failure Analysis Case Studies II comprises 40 case studies describing the analysis of real engineering failures which have been selected from volumes 4, 5 and 6 of Engineering Failure Analysis. The case studies have been arranged in sections according to the specific type of failure mechanism involved. The failure mechanisms covered are overload, creep, brittle fracture, fatigue, environmental attack, environmentally assisted cracking and bearing failures. The book constitutes a reference set of real failure investigations which should be useful to professionals and students in most branches of engineering.

Failure Analysis Case Studies II A Sourcebook of Case Studies Selected from the Pages of Engineering Failure Analysis 1997 1999 Volume 2 1st Table of contents:

Chapter 1: BURSTING OF A SILO

Abstract

1 INTRODUCTION

2 INVESTIGATIONS AND TESTS PERFORMED

3 NUMERICAL EVALUATIONS

4 CONCLUSIONS

Chapter 2: SHEAR FAILURE OF A ROAD-VEHICLE STEERING SHAFT

1 BACKGROUND

2 METALLURGY OF THE SHAFT

3 ESTIMATING THE FAILURE TORQUE

4 ESTIMATING THE APPLIED FORCE

5 CONCLUSIONS

Chapter 3: BREAKUP OF THE FIREWALL BETWEEN THE B AND C MODULES OF THE PIPER ALPHA PLATFORM—I. ANALYSIS BY HAND CALCULATION

Abstract

1 INTRODUCTION

2 STRUCTURE OF THE B/C FIREWALL

3 OVERPRESSURE LOADING OF B/C FIREWALL BY AN EXPLOSION IN MODULE C

4 APPROACH TO STRUCTURAL ANALYSIS

5 LOCAL STRENGTH OF FIREWALL

6 GLOBAL STRENGTH OF SEGMENTS OF FIREWALL

7 DYNAMIC RESPONSE: ELASTIC MODEL

8 DYNAMIC RESPONSE: ELASTIC-PLASTIC MODEL

9 ALTERNATIVE FAILURE MECHANISMS

10 RESPONSE OF C/D AND A/B FIREWALLS

11 CONCLUSIONS

APPENDIX

Chapter 4: FAILURE OF A FLEXIBLE PIPE WITH A CONCRETE LINER

Abstract

1 INTRODUCTION

2 DESIGN, CONSTRUCTION AND SITE CONDITIONS

3 OBSERVATION OF PIPE FAILURE

4 GENERAL DESIGN PERSPECTIVE AND PURPOSE OF INVESTIGATION

6 INTERPRETATION AND ANALYSIS OF FAILURE

7 STRUCTURAL STABILITY OF PIPELINE

8 CONCLUSIONS

Chapter 5: Torsional failure of a wire rope mooring line during installation in deep water

Abstract

1 Introduction

2 Background

3 The selection of rope construction

4 The torsional response of wire rope

5 Sensitivity of wire rope to torsional distortion

6 Torsional characteristics of chain

7 Interactions in installed mooring systems

8 Problems encountered during installation

9 Steps to avoid induced torsion

10 Conclusions and recommendations

Creep failures

Chapter 6: TYPE III CREEP CRACKING AT MAIN STEAM LINE WELDS

Abstract

1 INTRODUCTION

2 INITIAL DISCOVERY OF CRACKING

3 EXAMINATIONS AT OTHER SITES

4 EXAMINATIONS OF THE SCRAPPED TEE, AND OF THE REDUCERS AND THEIR WELDS

5 DISCUSSION

6 CONCLUSIONS

Chapter 7: CREEP FAILURE OF A SPRAY DRIER

Abstract

1 BACKGROUND

2 INSPECTION

3 STRESS ANALYSIS AND ASSESSMENT

4 CONCLUSIONS

Chapter 8: Catastrophic failure of a polypropylene tank Part I: primary investigation

Abstract

1 Introduction

2 The accident

3 Fractography

4 Re-examination of the failed tank

5 Mechanical testing of welds and panels

6 Inspection of the welding method

7 Materials analysis programme

8 Discussion

Acknowledgements

Chapter 9: Catastrophic failure of a polypropylene tank Part II: comparison of the DVS 2205 code of practice and the design of the failed tank

Abstract

1 Introduction

2 Design methodology of DVS 2205

3 Application to the failed tank

4 DVS 2205 and consultant engineer’s calculations

5 Extra bending strains

6 Conclusions

Acknowledgements

Appendix 1

Appendix 2

Appendix 3

Brittle fracture

Chapter 10: INVESTIGATION OF THE MV KURDISTAN CASUALTY

Abstract

1 BACKGROUND

2 PRELIMINARY INSPECTION OF THE VESSEL AT St JOHN DRY DOCK—16 & 17 APRIL 1979

3 DISCUSSION OF THE RESULTS OF THE FAILURE INVESTIGATION

4 CONCLUSIONS

Chapter 11: INVESTIGATION OF FAILED ACTUATOR PISTON RODS

Abstract

1 INTRODUCTION

2 BACKGROUND

3 INVESTIGATION

4 DISCUSSION

5 CONCLUSIONS

6 RECOMMENDATIONS

7 SUMMARY

Chapter 12: PREMATURE FAILURE OF PRESTRESSED STEEL BARS

Abstract

1 INTRODUCTION

2 CASE STUDY: FAILURE OF PRESTRESSED BARS

3 DESIGN IMPLICATIONS

Fatigue

Chapter 13: CATASTROPHIC FAILURE OF A RAISE BORING MACHINE DURING UNDERGROUND REAMING OPERATIONS

Abstract

1 INTRODUCTION

2 REAMING PRINCIPLES

3 BACKGROUND

4 SITE VISIT

5 EXAMINATION OF THE FRACTURED BOLTS

6 METALLURGICAL EXAMINATION

7 DISCUSSION

8 CONCLUSIONS

9 RECOMMENDATIONS

10 FINAL NOTE

Chapter 14: Premature fracture of a composite nylon radiator

Abstract

1 Introduction

2 Survey of failed whole radiator

3 Microscopic examination

4 Mechanical tests on tank material

5 Discussion

6 Conclusions

Acknowledgements

Chapter 15: FATIGUE FAILURE OF THE DE HAVILLAND COMET I

Abstract

1 HISTORICAL BACKGROUND

2 THE INVESTIGATION

3 ANALYSIS OF THE FAILURE

4 CONCLUSIONS

Chapter 16: LOW-CYCLE FATIGUE OF TITANIUM 6A1–4V SURGICAL TOOLS

Abstract

1 INTRODUCTION

2 INVESTIGATION METHOD

3 RESULTS

4 DISCUSSION

5 Conclusion

Chapter 17: FAILURE ANALYSIS AND EXPERIMENTAL STRESS ANALYSIS OF A THREADED ROTATING SHAFT

Abstract

1 INTRODUCTION

2 EXPERIMENTAL DETAILS

3 RESULTS

4 DISCUSSION

5 CONCLUSIONS

Chapter 18: AN INVESTIGATION OF THE FAILURE OF LOW PRESSURE STEAM TURBINE BLADES

Abstract

1 INTRODUCTION

2 EXPERIMENTAL DETAILS

3 RESULTS

4 DISCUSSION

5 CONCLUSIONS

Chapter 19: VIBRATION-INDUCED FATIGUE FAILURE OF AN IMPULSE LINE

Abstract

1 BACKGROUND

3 FINITE ELEMENT ANALYSIS

4 Conclusions And Recommendations

Chapter 20: MALFUNCTIONS OF A STEAM TURBINE MECHANICAL CONTROL SYSTEM

Abstract

1 INTRODUCTION

2 MECHANICAL CONSIDERATIONS

3 FAILURE CONSIDERATIONS

4 FATIGUE CRACK GROWTH ASSESSMENT

5 DISCUSSION AND RECOMMENDATIONS

Chapter 21: FATIGUE FAILURE OF HOLD-DOWN BOLTS FOR A HYDRAULIC CYLINDER GLAND

Abstract

1 INTRODUCTION

2 METALLOGRAPHIC EXAMINATION

3 STRESS ACTING ON THE BOLTS

4 REMEDIAL MEASURES

Chapter 22: ANALYSIS OF A VEHICLE WHEEL SHAFT FAILURE

Abstract

1 INTRODUCTION

2 THE WHEEL SHAFT DESIGN

3 ASSESSING THE FAILURE

4 SHAFT ANALYSIS

5 DISCUSSION OF FINDINGS

6 PROPOSED DESIGN MODIFICATIONS

7 CONCLUSIONS

Chapter 23: Fatigue failure analysis of a leg press exercise machine

Abstract

1 Background

2 Fatigue failure

3 Design implications

Chapter 24: Failure analysis of rubber fuel pipes in aero-engines

Abstract

1 Introduction

2 Visual inspection of hosepipes

3 Dissection of hosepipes

4 Fracture analysis of layers

5 Analysis of hosepipe bursting failures

6 Conclusions

Environmental attack

Chapter 25: FAILURE OF AUSTENITIC STAINLESS STEEL COMPONENTS USED IN NITROGEN OXIDE PLANT

Abstract

1 INTRODUCTION

2 CASE STUDY I: FAILURE OF PIPE-TO-FLANGE JOINT

3 CASE STUDY II: FAILURE OF SIGHT PORT FLANGE

Chapter 26: CORROSION OF CENTRAL HEATING SYSTEMS

Abstract

1 BACKGROUND

2 OXYGEN REDUCTION—BASIC MECHANISMS

3 OXYGEN REDUCTION—SOME COMPLICATIONS

4 REDUCTION OF HYDROGEN

5 USING INHIBITORS

6 CASE STUDY 1–RAPID RUSTING OF STEEL RADIATORS

7 CASE STUDY 2—HOLES IN ALUMINIUM HEAT-EXCHANGER TUBES

8 Case Study 3—External Corrosion of Steel Water Pipes

9 DESIGN IMPLICATIONS

Appendix A Pourbaix Diagrams

Chapter 27: CREVICE CORROSION OF 316L CAUSED BY CHLORIDE PARTITION IN WATER-BUTANONE MIXTURES

Abstract

1 BACKGROUND

2 THE MATERIALS

3 THE CORROSION

4 DISCUSSION

5 A DEMONSTRATION

6 CONCLUSION

Chapter 28: TYPE I PITTING OF COPPER TUBES FROM A WATER DISTRIBUTION SYSTEM

Abstract

1 INTRODUCTION

2 EXPERIMENTAL PROCEDURE

3 METALLOGRAPHY

4 TYPE I PITTING

5 CONCLUSIONS

Chapter 29: CORROSION OF FLEXIBLE WAVEGUIDES

Abstract

1 INVESTIGATION

2 FABRICATION PROCESS

3 ARCING INDUCED CHEMICAL REACTIONS

4 RECOMMENDATIONS

Chapter 30: Failure of automobile seat belts caused by polymer degradation

Abstract

1 Background

2 The seat belt mechanism and its failure

3 Degradation and failure of the release button

4 Short- and long-term industry solutions

5 Conclusions

Chapter 31: Oxidation failure of radiant heater tubes

Abstract

1 Introduction

2 Tests and results

3 Discussion

4 Conclusions

Acknowledgements

Environmentally assisted cracking

Chapter 32: SUSTAINED LOAD CRACK GROWTH LEADING TO FAILURE IN ALUMINIUM GAS CYLINDERS IN TRAFFIC

Abstract

1 INTRODUCTION

2 EXAMINATION OF TWO SEVERELY CRACKED CYLINDERS

3 MODELS OF CRACK GROWTH

4 LOCAL STRESS MODEL FOR CALCULATING CRACK GROWTH RATE

5 Results

6 DISCUSSION

7 CONCLUSIONS

Chapter 33: HYDROGEN-ASSISTED STRESS-CORROSION OF PRESTRESSING WIRES IN A MOTORWAY VIADUCT

Abstract

1 INTRODUCTION

2 EXPERIMENTAL INVESTIGATIONS AND DISCUSSION

3 CONCLUSION

Chapter 34: FAILURE ANALYSIS OF CARRIER CHAIN PINS

Abstract

1 INTRODUCTION

2 INVESTIGATION

3 DISCUSSION

4 CONCLUSIONS

Chapter 35: UNUSUAL CASES OF WELD-ASSOCIATED CRACKING EXPERIENCED IN A HIGH TEMPERATURE CATALYST REDUCTION REACTOR

Abstract

1 INTRODUCTION

2 CASE 1—EXAMINATION OF CRACKED NOZZLE C1

3 CASE 2—EXAMINATION OF CRACKS IN EXTERNAL SUPPORT RING

4 POSTSCRIPT

Chapter 36: HYDROGEN CRACKING OF FERRITIC STAINLESS STEEL THERMAL STORAGE TANKS

Abstract

1 INTRODUCTION

2 FAILURE OF THERMAL STORAGE TANK

3 EXPERIMENTAL METHODS

4 EXPERIMENTAL RESULTS AND DISCUSSIONS

5 CONCLUSION

Chapter 37: Hydrogen embrittlement failure of hot dip galvanised high tensile wires

Abstract

1 Introduction

2 Investigation

3 Experimental details

4 Results

5 Discussion

6 Concluding remarks

Acknowledgements

Bearing failures

Chapter 38: CONTACT FATIGUE IN ROLLING-ELEMENT BEARINGS

1 Introduction

2 ROLLING AND ROLLING-SLIDING CONTACT FATIGUE

3 FLAKING AND SPALLING

4 SUMMARY

Chapter 39: AN AIR CRASH DUE TO FATIGUE FAILURE OF A BALL BEARING

Abstract

1 INTRODUCTION

2 CMB ASSEMBLY

3 FRACTOGRAPHY OF THE CAGE FRACTURE STRUCTURE

4 POSSIBLE SEQUENCE OF FAILURE

5 CONCLUSION

Chapter 40: Failure analysis of a condensate pump shaft

Abstract

1 Introduction

2 Visual inspection after the failure

3 Destructive examination of the shaft

4 Destructive examination of the chromium-plated sleeve

5 Discussion

6 Conclusions

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