Archives du mot-clef case study

Failure analysis of the pulleys during the press-fit assembling process

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A new case studie in engineering  failure analysis published on SienceDirect.com. The present article highlights failure investigation of the pulleys during a press-fit assembling process. Pulleys are used to transmit power between rotational mechanical elements.  It was found that cooperative influence of higher carbon content with combination of elongated sulphides is reason for pulleys cracking. Steel cleanliness and homogeneous structure is an important factor for users of steel. The success of production process is connected with the optimal quality of steel.

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STATISTICAL TOOLS APPLIED FOR THE REDUCTION OF THE DEFECT RATE OF COFFEE DEGASSING VALVES

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This work takes inspiration from an industrial problem: a company that assembles valve components, supplied by different manufacturers, observed a high level of defect rate, affecting its valve production. An integrated approach, consisting in the adoption of quality charts, in an experimental campaign for the dimensional analysis of the mating parts and in the statistical processing of the data, was necessary to tackle the question.

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Failure Analysis of a Helical Compression Spring for a Heavy Vehicle’s Suspension System

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An interesting  paper in « Case study in Engineering Failure Analysis » published on ScienceDirect.com. This paper analyzed why a compression coil spring fractured at the transition position from the bearing coil to the first active coil in service, while the nominal stress here should always be much less than that at the inside coil position of a fully active coil. Visual observations indicated that a wear scar was formed on the first active coil and the fracture surface showed radiating ridges emanating from the wear scar. Scanning electron microscopy examination showed crescent shaped region and beach marks, typical of fatigue failure. ZnCaph phosphate layer and painting around the contact zone were worn out due to contact and friction and resulted in corrosion and corrosion pits induced local stress concentration. Stress analysis indicated severe stress singularities at the edges of the contact zone, which facilitated cycle slip and fatigue crack nucleation. Recommendations were also made for improving the fatigue performance of the suspension springs.

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Observing early stage rail axle bearing damage

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Railway bearingA paper presented   at the Sixth International Conference of Engineering Failure Analysis on July 2014 in Lisbon – Protugal. This paper brings out the detail of investigation carried out on failing  rail axle bearing.

A novel condition monitoring system has for the first time enabled reliable extraction from service and detailed forensic examination of failing rail axle bearings, before the usual catastrophic destruction of the evidence. Computed Tomography has been used to produce a map of the damage allowing targeted sectioning of subsurface cracking. Traditional metallographic techniques have revealed large white etched layers associated with the subsurface cracking, while observations with a scanning electron microscope have confirmed rolling contact fatigue crack propagation, possibly initiated from pre-existing electrical arcing damage of the raceways.

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Reduction in diversion due to coil break in CRNO grades of coils

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A new « Case study in Engineering Failure Analysis » published on ScienceDirect.com.

This paper reports investigations after diversion due to coil break in cold rolled non oriented (CRNO) grades of coils showed an increasing trend during Jan–May’12 at Silicon Steel Mill (SSM), Rourkela Steel Plant (RSP). Coil break increased from a level of less than 1% during to a level of 30% in May’12. Samples from hot rolled coils and finished coils were taken and detailed metallurgical investigation was carried out to ascertain the genesis of such defects. Further studies were carried out in the processing lines and material flow was tracked from steel making to final product. The probable reasons were identified and corrective measures were taken leading to reduction in diversion due to coil break less than 2%.

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Failure analysis of a vibration isolator used in launch vehicle applications

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A new paper published in « Case study in Engineering Failure Analysis »  on ScienceDirect.com.

Vibration isolators are used in launch vehicles to protect sensitive electronic equipments from the rigors of flight structural vibrations during the lift-off and ascent phase. Failure of one such vibration isolator made of AISI 304 is reported in the present study after ground level testing has been completed.  Finally, it was concluded that micro cracks formed during the deep drawing operation due to large strains at the fore end corner propagated during vibration testing resulting in the failure of the body of the vibration isolator.

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Fracture mechanisms of failed IN-738LC gas turbine blades

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An interesting  paper in « Case study in Engineering Failure Analysis » published on ScienceDirect.com. This paper outlines the problem of blades failure occurred because of excessive temperature exposure. Nickel based superalloys are widely used as gas turbine blade material. They suffer from microstructural instabilities and environmental damages. Creep properties of alloy was deteriorated by γ‘ particles dissolution.

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Brittle fracture of a grade E cast steel knuckle

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A new paper in « Case study in Engineering Failure Analysis » published on ScienceDirect.com. This paper investigated the brittle fracture mechanism of a grade E cast steel knuckle that is one of the key components of the coupler for railway wagon.

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A failure study of the railway rail serviced for heavy cargo trains

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rail fractureA paper published in« Case study in Engineering Failure Analysis ». In this case study, a failed railway rail which was used for heavy cargo trains was investigated in order to find out its root cause. The crack is supposed to be initiated from the weaker ferrite networks. Given all of that, the failed railway rail is considered to be caused by overload. It is of great importance to improve the welding technology, and control the load of train in order to prevent similar failure in future.

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Interfering part of a steam turbine journal bearing

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bearing part frettingJournal bearings as so sensitive parts of steam turbines are very susceptible to failure through different mechanisms of wear, fatigue and crush during service conditions. Failure occurring through these mechanisms lead to turbine completely shut down as a result of interfering in working conditions of bearing different parts. In this research, failed interfered part of a journal bearing related to a 320,000 kW steam turbine was examined.The studies were revealed that the bearing part loosing and inappropriate clearance can produce relative displacements under cyclic gradient loading. This condition was detrimental for the service life of turbine journal bearing via failure through fretting fatigue mechanism.

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