SWI 3.2
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M.S.Rogers
TECHNOLOGY
SWI 3.2
Introduction:
Fatigue and brittle fractures are the two most
important forms of service failure in welded
structures
Fatigue fractures account for more than 90% of all
service failures
Brittle fractures although rare in occurrence are usually
catastrophic in economic terms and may cause loss in
life
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M.S.Rogers
TECHNOLOGY
SWI 3.2
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M.S.Rogers
TECHNOLOGY
SWI 3.2
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M.S.Rogers
TECHNOLOGY
SWI 3.2
Points of initiation
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TECHNOLOGY
SWI 3.2
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Ductile fracture
Beach Marks
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TECHNOLOGY
SWI 3.2
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M.S.Rogers
TECHNOLOGY
SWI 3.2
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M.S.Rogers
TECHNOLOGY
SWI 3.2
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M.S.Rogers
TECHNOLOGY
SWI 3.2
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M.S.Rogers
TECHNOLOGY
SWI 3.2
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M.S.Rogers
TECHNOLOGY
SWI 3.2
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M.S.Rogers
TECHNOLOGY
SWI 3.2
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M.S.Rogers
TECHNOLOGY
SWI 3.2
Ductile
Fracture
A. Initiation point
B. Initiation point
C. Initiation point
D. Initiation point
E. Initiation point
F. Initiation point
G. Initiation point
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B
E
G
H
H
G
A
B
A. Shear lips
B. Initiation points/weld
toe undercut
C. Weld spatter
D. Fatigue fracture surface
E. Ductile fracture surface
F. Weld undercut
G. Poor weld craters
H. Possible beach marks
Name:
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Copyright 2003 TWI Ltd
Date: 13/06/03
TECHNOLOGY
SWI 3.2
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Ductile Fracture
M.S.Rogers
TECHNOLOGY
SWI 3.2
D
H
B
Date: 13/06/03
TECHNOLOGY
SWI 3.2
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Ductile
Fracture
A. Slag inclusion
B. Slag inclusion
C. Slag inclusion
D. Shear lip
E.
Slag inclusion
F.
Shear lip
G. Fatigue fracture
H. Ductile fracture
Note: Reduction in area
M.S.Rogers
SWI 3.2
TECHNOLOGY
F
D
C
A. Fatigue fracture
surface
B. Shear lips
C. Reduced area
D. Ductile fracture surface
E. Weld defects (slag
inclusions)
F. Beach markings
Date: 13/06/03
TECHNOLOGY
SWI 3.2
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Ductile
Fracture
A.
Gas pore/initiation
point
B.
Beach mark
C.
Ductile fracture
D.
Fatigue fracture
E.
Shear lip
F.
Shear lip
G.
Shear lip
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SWI 3.2
TECHNOLOGY
A. Gas pore
B. Beach mark
Name:
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Copyright 2003 TWI Ltd
Date: 13/06/03
TECHNOLOGY
SWI 3.2
Brittle
Fracture
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M.S.Rogers
SWI 3.2
TECHNOLOGY
Name:
Mark
Rogers
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Sep
02
Copyright 2003 TWI Ltd
Date: 13/06/03
TECHNOLOGY
SWI 3.2
Brittle Fracture
Note: Patterned/chevron fracture surface - Brittle
fracture.
Note: Small shear lips along both plate surfaces.
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Sep 02
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M.S.Rogers
SWI 3.2
TECHNOLOGY
B. Brittle fracture
surface/chevron pattern
C. Initiation point
A
DIRECTION OF PROPERGATION
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Date: 13/06/03
TECHNOLOGY
SWI 3.2
A.
B.
C. Brittle fracture
Note: Very little reduction in area
and no evidence of shear lips
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M.S.Rogers
TECHNOLOGY
SWI 3.2
A. Machined notch,
initiation point
A
B
Conclusion: The CTOD sample failed from a purposely initiated fatigue crack
The primary mode of failure is a fatigue fracture (B) this is evident by the smooth fracture
surface, which initiated from a machined notch (A). The secondary mode of failure is a
brittle fracture (C) this is evident by the crystalline fracture surface with very little
evidence of plastic deformation (very little reduction in area) and no evidence of shear lips
Name: Mark Rogers
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Date: 13/06/03
TECHNOLOGY
SWI 3.2
A.
B.
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M.S.Rogers
TECHNOLOGY
SWI 3.2
A. Machined notch,
initiation point
A
Conclusion: The CTOD sample failed from a purposely initiated fatigue crack
The primary mode of failure is a fatigue fracture (B) this is evident by the smooth fracture
surface, which initiated from a machined notch (A). The secondary mode of failure is a
ductile fracture (D) this is evident by the fibrous appearance of the fracture surface with
evidence of plastic deformation, a large reduction in area and shear lips (C).
Name: Mark Rogers
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Sep 02
Copyright 2003 TWI Ltd
Date: 13/06/03
TECHNOLOGY
SWI 3.2
D
A
G
F
B
Ductile / Brittle
Fracture
F. Ductile fracture
A. Cracks / forging bursts.
G. Brittle fracture
B. Cracks / forging bursts.
C. Cracks / forging bursts
D. Initiation point / threat tip
E. Fatigue fracture
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M.S.Rogers
TECHNOLOGY
SWI 3.2
A
E
B
A. Cracks/forging bursts
B. Fatigue fracture surface
C. Ductile fracture surface
D. Brittle fracture surface
E. Initiation point
A
A
Name:
Mark
Rogers
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Sep
02
Copyright 2003 TWI Ltd
Date: 13/06/03
TECHNOLOGY
SWI 3.2
F
C
Ductile Fracture
D
B
SWI 3.2
TECHNOLOGY
Date: 13/06/03