Professional Documents
Culture Documents
Failed Component(s)
1. Metallurgical Evaluation
Failed Component
Definitions
Failure: A term which infers that a component or assembly is in a state of damage that renders it no longer capable of reliably performing its intended function.
Failed Component
Definitions
Secondary Damage: Inadvertent changes to a component that may or may not affect functionality.
! Prior Damage: damage that may have contributed to the failure ! Consequential Damage: damage that resulted due to continued operation post failure ! Mechanical/Environmental Damage: subjected to the failed component
! Handling ! Cleaning ! Storage
Failed Component
General Failure Categories
Fracture (full section) Cracking (partial section) Distortion (bending, elongation, plastic collapse) Corrosion (pitting, through wall perforation) Wear (material wastage)
Metallurgical Evaluation
A. Examination and Testing
Primary Objectives:
1. Characterize Failure
Identify Failure Origin Characterize fracture textures
Metallurgical Evaluation
A. Examination and Testing
Primary Objectives:
Fracture Examples
Fracture Macro Textures:
! Ductile shear lip
Metallurgical Evaluation
A. Examination and Testing
1. Characterize Failure
Fracture Examples
Fracture Macro Textures:
! Chevron markings
Metallurgical Evaluation
A. Examination and Testing
1. Characterize Failure
Fracture Examples
Fracture Macro Textures:
! Ratchet markings ! Beach markings
1
10
Metallurgical Evaluation
A. Examination and Testing
1. Characterize Failure
Fracture Examples
Fracture Micro Textures:
! Intergranular
11
Metallurgical Evaluation
A. Examination and Testing
1. Characterize Failure
Fracture Examples
Fracture Micro Textures:
! Transgranular ! Dimple (MVC)
12
Metallurgical Evaluation
A. Examination and Testing
1. Characterize Failure
Fracture Examples
Fracture Micro Textures:
! Transgranular ! Cleavage
13
Metallurgical Evaluation
A. Examination and Testing
1. Characterize Failure
Fracture Examples
Fracture Micro Textures:
! Transgranular ! Striated ! Fibrous textured
14
Metallurgical Evaluation
A. Examination and Testing
Primary Objectives: 2. Characterize and categorize other forms of visual damage present.
Secondary cracks along component or adjacent to fracture Anomalies associated with the region of initiation or otherwise potentially contributory to the failure
15
Metallurgical Evaluation
A. Examination and Testing
Tools and Techniques: 1. 2. 3. Visual examination and NDE (by eye) Macroscopic examination (stereomicroscope) provides depth of field magnification to about 20X Microscopic examination
Fractures - examined by SEM to characterize fracture textures (20X to 3000X magnification) Prepared cross section - optical microscopy (no depth of field magnifications between 50 and 1000X)
! Characterize microstructure and damage/fracture profiles
16
Metallurgical Evaluation
A. Examination and Testing
Tools and Techniques:
4. Chemical Analysis
Generally for grade verification or impurity evaluation Examples:
! Stainless steel corrosion/oxidation resistance ! Alloy steel hardenability, temper embrittlement resistance, weldability
17
Metallurgical Evaluation
A. Examination and Testing
Tools and Techniques:
4. Chemical Analysis
Typical Methods Bulk Analysis
!Spark Emission !Wet Analysis
Microanalysis
!SEM EDX !XRF/XRD (non-metallic scales and friable substances)
18
Metallurgical Evaluation
A. Examination and Testing
Tools and Techniques:
5. Mechanical Testing
Generally for purposes of grade determination/verification, or estimation of component fracture properties Examples:
! Material strength and ductility ! Fatigue properties ! Fracture resistance
19
Metallurgical Evaluation
A. Examination and Testing
Tools and Techniques:
5. Mechanical Testing
Typical Methods
Hardness testing (micro and macro) Tensile testing (yield, ultimate, and elongation) Charpy V-notch impact testing (temperature transition, value conversion for Level 1 fracture mechanics assessment) Fatigue testing (axial or bending) Fracture toughness testing (CTOD)
20
Metallurgical Evaluation
B. Identification of Failure Mechanism(s)
Definition
Specific series of events that describe both how the damage was incurred and the resulting consequences.
Examples
Metal fatigue Stress corrosion cracking Hydrogen embrittlement Ductile or brittle fracture High temperature creep, oxidation, sulphidation
Ludwig & Associates Engineering Ltd.
21
22
23
24
25
26
27
28
29
30
General Approach
1. Assess for mechanical overload relative to rated capacity. 2. Assess for a critical manufacturing deficiency relative to component design. 3. Examine component design for deficiencies relative to intended service conditions.
31
Detailed Approach
1. Attain additional information and knowledge:
Attain background information regarding the failure and equipment Understand the mechanics of the equipment and the operating conditions
32
Detailed Approach
2. Application of Metallurgical Findings
Failure mechanism Failure origin Direction and mode of loading Condition of loading (single event or cyclic)
33
Detailed Approach
3. Perform a component stress assessment
A. Metallurgical Approach Estimate applied loading causing failure ! Ductile failure (yield, ultimate strength) ! Brittle failure from flaw precursor (fracture toughness) ! Fatigue failures (estimation of material endurance limit for conditions of loading based on microstructure, tensile strength, or fatigue test data)
Ludwig & Associates Engineering Ltd.
34
Detailed Approach
3. Perform a component stress assessment
B. Mechanical Approach Estimate nominal service stresses and critical failure loads ! Closed form analysis (moment, force balance) ! Finite element analysis ! Instrumented strain gauge analysis
35
36