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Definition of Failure
When a part or device can no longer perform its intended function, the part has failed.
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Spring 2014
MSE 624 Failure Analysis Time: Tues 7:00 9:45 pm, room JD 3504 Instructor: Dr. Behzad Bavarian Office: JD 3513, Tel: 818-667-3917, Office Hour: T 6:00 7:00 pm Email: bavarian@csun.edu Website: http://www.csun.edu/~bavarian/mse_624.htm
Course Description: An introductory course in failure analysis using basic materials properties and engineering principles for understanding the causes of failures and methods of preventing future failures by applying the lessons learned in the process of studying failures. A number of real-life case studies will be used to reinforce topics discussed in the lectures.
Grading Policy: Mid-term Term Paper/ Oral Presentation, (Pert, paper Due by May 6, 2014) Homework (6 assignments) Final Exam
Grading System: A through F with Plus/Minus Grading Homework format: Short report (~3-4 pages on the subject including the list of references)
Failure means nonperformance of something required or expected Failure means cessation of normal operation and breakdown.
Failure ?
How do cracks that lead to failure form? How is fracture resistance quantified? How do the fracture resistances of the different material classes compare? How do we estimate the stress to fracture? How do loading rate, loading history, and temperature affect the failure behavior of materials?
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Fracture mechanisms
Ductile fracture
Accompanied by significant plastic deformation Brittle fracture Little or no plastic deformation Catastrophic
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Classification:
Brittle
%AR or %EL
Ductile fracture is
usually more desirable than brittle fracture!
Large
Moderate
Small
Brittle: No warning
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Ductile failure:
Pipe Failures
Brittle failure:
-- many pieces -- small deformations
Figures from V.J. Colangelo and F.A. Heiser, Analysis of Metallurgical Failures (2nd ed.), Fig. 4.1(a) and (b), p. 66 John Wiley and Sons, Inc., 1987. Used with permission.
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50 50mm mm
100 mm
From V.J. Colangelo and F.A. Heiser, Analysis of Metallurgical Failures (2nd ed.), Fig. 11.28, p. 294, John Wiley and Sons, Inc., 1987. (Orig. source: P. Thornton, J. Mater. Sci., Vol. 6, 1971, pp. 347-56.) Fracture surface of tire cord wire loaded in tension. Courtesy of F. Roehrig, CC Technologies, Dublin, OH. Used with permission. 28
cup-and-cone fracture
brittle fracture
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Brittle Failure
Arrows indicate point at which failure originated
Transgranular Brittle Fracture Surfaces (through grains) 304 S. Steel (between grains) Intergranular
(metal)
Reprinted w/permission from "Metals Handbook", Reprinted w/ permission 9th ed, Fig. 633, p. 650. from "Metals Handbook", Copyright 1985, ASM 9th ed, Fig. 650, p. 357. International, Materials Copyright 1985, ASM Park, OH. (Micrograph by International, Materials J.R. Keiser and A.R. Park, OH. (Micrograph by Olsen, Oak Ridge D.R. Diercks, Argonne National Lab.) National Lab.)
4 mm
160 mm
Polypropylene (polymer)
Reprinted w/ permission from R.W. Hertzberg, "Defor-mation and Fracture Mechanics of Engineering Materials", (4th ed.) Fig. 7.35(d), p. 303, John Wiley and Sons, Inc., 1996.
Al Oxide (ceramic)
Reprinted w/ permission from "Failure Analysis of Brittle Materials", p. 78. Copyright 1990, The American Ceramic Society, Westerville, OH. (Micrograph by R.M. Gruver and H. Kirchner.)
3 mm
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1 mm
(Orig. source: K. Friedrick, Fracture 1977, Vol. 3, ICF4, Waterloo, CA, 1977, p. 1119.)
Origin point Initial region (mirror) is flat and smooth After reaches critical velocity crack branches mist hackle
Adapted from Figs. 9.14 & 9.15, Callister & Rethwisch 4e.
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fibrillar bridges
microvoids
crack
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Reprinted w/ permission from R.W. Hertzberg, "Deformation and Fracture Mechanics of Engineering Materials", (4th ed.) Fig. 7.1(a), p. 262, John Wiley and Sons, Inc., 1996. (Orig. source: Dr. Robert D. Ballard, The Discovery of the Titanic.)
Reprinted w/ permission from R.W. Hertzberg, "Deformation and Fracture Mechanics of Engineering Materials", (4th ed.) Fig. 7.1(b), p. 262, John Wiley and Sons, Inc., 1996. (Orig. source: Earl R. Parker, "Behavior of Engineering Structures", Nat. Acad. Sci., Nat. Res. Council, John Wiley and Sons, Inc., NY, 1957.)
Problem: Steels were used having DBTTs just below room temperature.
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Fatigue failure
crack origin
Adapted from Fig. 9.28, Callister & Rethwisch 4e. (Fig. 9.28 is from D.J. Wulpi, Understanding How Components Fail, American Society for Metals, Materials Park, OH, 1985.)
From V.J. Colangelo and F.A. Heiser, Analysis of Metallurgical Failures (2nd ed.), Fig. 4.32, p. 87, John Wiley and Sons, Inc., 1987. (Orig. source: Pergamon Press, Inc.) 44
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2. Preliminary Examinations.
* Most important part of failure analysis. * Visual inspection of all parts. * Detailed photography of all parts. * Study of the fractures.
3. Nondestructive Inspections.
* Magnetic particle inspection. * Liquid penetrant inspection. * Electromagnetic inspection. * Ultrasonic inspection. * Radiography. * Residual stress analysis.
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4. Mechanical Testing.
* Hardness testing. * Tensile testing. * Shear testing. * Impact testing. * Fatigue testing. * Fracture mechanics testing.
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6. Macroscopic Examinations
* Use low power stereo-microscopes. * Determine Origin of failure. * Determine direction of crack growth: Chevron patterns, beach marks etc... * Determine ductile or brittle fracture. * Locate other cracks.
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7. Microscopic Examinations
* Light microscopes: shallow depth of field. * Transmission Electron Microscopes (TEM): sample preparation problems. * Scanning Electron Microscopes ( SEM): conductivity problems. coating and replication techniques.
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8. Metallographic Examination
* Class of Material: Cast or Wrought * General Microstructure. * Crack Path: Transgranular and/or Intergranular * Heat Treatment Problems: Decarburization, Alpha-Case, etc.
9. Failure Modes
* Ductile: Plastic Deformation Equiaxed or Shear Dimples Dull, Gray and usually Transgranular. * Brittle: No Macroscopic Plastic Deformation Cleavage, Intergranular or Striations Difficult to diagnose.
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Modes of Fracture
* Monotonic Overload Brittle Ductile * Sub-Critical Crack Growth Static Loads Dynamic Loads
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Mechanisms of Fracture
* Overload - Fracture with application of load. Ductile or Brittle * Crack Growth - Under Load Over Time. Fatigue Stress Corrosion Cracking Hydrogen Embrittlement Creep
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14. Recommendations
* Should lead to prevention of future failures. * Should lead to product improvements. * Do not rush to change material or process specifications without complete analysis of possible interaction with other parts of the system.
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The purpose of identifying all solutions to a problem is to prevent recurrence at lowest cost in the simplest way. If there are alternatives that are equally effective, then the simplest or lowest cost approach is preferred. Root causes identified depend on the way in which the problem or event is defined. Effective problem statements and event descriptions (as failures, for example) are helpful, or even required. To be effective, the analysis should establish a sequence of events or timeline to understand the relationships between contributory (causal) factors, root cause(s) and the defined problem or event to prevent in the future. Root cause analysis can help to transform a reactive culture (that reacts to problems) into a forward-looking culture that solves problems before they occur or escalate. More importantly, it reduces the frequency of problems occurring over time within the environment where the RCA process is used. RCA is a threat to many cultures and environments. Threats to cultures often meet with resistance. There may be other forms of management support required to achieve RCA effectiveness and success. For example, a "non-punitory" policy towards problem identifiers may be required.
The 6 Ms (used in manufacturing) Machine (technology) Method (process) Material (Includes Raw Material, Consumables and Information.) Man Power (physical work)/Mind Power (brain work): Kaizens, Suggestions Measurement (Inspection) Milieu/Mother Nature (Environment)
The 8 Ps (used in service industry) Product=Service Price Place Promotion/Entertainment People(key person) Process Physical Evidence Productivity & Quality
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A bit of Philosophy
A part is a collection of defects An acceptable part is one with irrelevant defects A scrap has defects that are critical to the application
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Electromagnetic Energies
Electrical Energies Magnetic Energies Optical Energies Infra-Red Energies Ultra-Violet Energies X-Ray Energies Gamma Ray Energies
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Geometric Properties
Dimensions Porosity Discontinuities Cracks
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Mechanical Properties
Stress Strain Hardness Modulus of Elasticity
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Thermal Properties
Thermal Conductivity Thermal Expansion Thermal Stress Thermoelectric Properties
(Thermocouples)
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Physical Properties
Density Composition Grain Size Grain Orientation Index of Refraction Coefficient of Friction
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Magneto-electric Transducers
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Thermoelectric Transducers
thermocouples
Liquid Crystals
change in color with temperature, cholesteric
Potentiometers
displacement, velocity, acceleration, liquid level
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Photoconductive Cells
semiconductors
Capacitance Transducers
C = 0.225 K*A/d
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Variable inductance transducers Variable reluctance transducers Magneto striction transducers Variable transformer transducers Differential transformer transducers
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Display Systems
Galvanometers Electronic Voltmeters Oscilloscopes Digital Indicators Chart Recorders
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