SME 4133 Failure of Engineering Components and Structures

Classification of the causes of failure

Faulty design considerations/

misapplication of materials
Ductile failure excessive Severe stress raiser inherent
deformation (elastic or plastic), in design.
tearing or shear fracture).
Inadequate stress analysis
Brittle fracture from flaws and
critical stress raisers. Mistake in designing on
basis of static tensile
Fatigue failure due to time- properties only
varying load, thermal cycling,
corrosion fatigue.
High-temperature failure creep,
oxidation, local melting, warping.
Static delayed fracture hydrogen
embrittlement,
SME 4133 Failure of Engineering Components and Structures

Classification of the causes of failure

Faulty processing
Flaws due to faulty composition
wrong material, inclusions,
embrittling impurities.
Defects originating in ingot
making and casting porosity, non-
metallic inclusions, segregation.
Defects due to working laps,
seams, hot-short splits, excess local
deformation
Irregularities / mistakes due to
machining, grinding or stamping
burns, tearing, cracks.
Welding defects voids, undercuts,
residual stresses, HAZ, lack of
penetration.
Abnormalities due to heat treatment
grain growth, precipitation, excessive
retained austenite, decarburization.
Flaws due to case hardening
intergranular carbides, soft core.
Defects due to surface treatment
plating, chemical diffusion, hydrogen
embrittlement.
Parting-line failure in forging - due
to poor transverse properties.
Careless assembly mismatch of
mating parts, residual stress, gouges.
SME 4133 Failure of Engineering Components and Structures
Classification of the causes of failure
Deterioration in service
Overload / unforeseen loading Radiation damage -
conditions decontamination may destroy
evidence for the cause of failure.
Wear erosion, galling,
seizing, cavitation. Accidental condition abnormal
operating temperature, severe
Corrosion chemical attack,
vibration, impact, thermal shock.
stress corrosion, dezincification.
Inadequate / misdirected
maintenance or improper repair
welding, grinding, cold
straightening.
Disintegration by chemical
attack, attack by liquid metals or
plating at elevated temperature
SME 4133 Failure of Engineering Components and Structures

Steps in Performing Failure Analysis

Description of the failure situation

Background information, history of
usage, design of component. Metallographic examination to help
establish such facts as whether the part
Visual inspection DO NOT damage
has correct heat treatment.
the fracture surface.
Determine properties to establish
Mechanical design analysis (stress
properties pertinent to the design.
analysis) to establish the cause of
failure. Was the part of sufficient size? Failure simulation - to establish
response of identical component under
Chemical design analysis to establish
exact condition of loading, numerical
the suitability of the material wrt
simulation.
corrosion resistance.
Formulation of conclusions, Report
Fractography examine fracture
writing (may include recommendations)
surface to establish the mechanism of
fracture.