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Brittle Fracture of a Clapper Weldment for a Disk Valve Due to Improper Filler Metal 由于填充金属不当导致阀瓣瓣焊件脆性断裂
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0048767
The clapper in a 250 mm diam disk valve (made from ASTM A36 steel, stress relieved and cadmium plated) fractured at the welded joint between the clapper and a 20 mm diam support rod (also made of same material). The valve contained a stream of gas consisting of 55% H2S, 39% CO2, 5% H2, and 1% hydrocarbons at 40 deg C and 55 kPa during operation. Voids on the fracture surface and evidence of incomplete weld penetration were revealed by examination. Brittle fracture was indicated by the overall appearance through some fatigue beach marks were observed. Very narrow bands of high hardness were revealed at the edges of the weld metal. It was revealed by chemical analysis of this band that a stainless steel filler metal had been used which produced mixed composition at the weld boundaries. The plating material was revealed to be nickel by chemical analysis. It was concluded that clapper failed by fatigue and brittle fracture because it was welded with an incorrect filler metal. A clapper assembly was welded with a low-carbon steel filler metal, then cadmium plated.
直径为250毫米的阀瓣阀瓣(由ASTM A36钢制成,消除应力并镀镉)在阀瓣和直径为20毫米的支撑杆(也由相同材料制成)之间的焊接接头处断裂。阀门在运行过程中,在40℃、55 kPa的条件下,含有55% H2S、39% CO2、5% H2和1%碳氢化合物的气体流。通过检查,发现了断口上的空洞和焊缝未焊透的痕迹。通过观察到一些疲劳滩痕,整体外观显示脆性断裂。焊缝金属的边缘出现了非常窄的高硬度带。对该带的化学分析表明,在焊缝边界处使用了不锈钢填充金属,产生了混合成分。经化学分析,镀层材料为镍。结果表明,阀瓣的疲劳脆性断裂是由于焊料不正确导致的。一个阀组件是用低碳钢填充金属焊接的,然后镀镉。
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引用次数: 0
Failure of Non-Magnetic Rotor Banding Wire From Stress-Corrosion 非磁性转子带线应力腐蚀失效研究
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001397
Banding wires of the rotor of an 1800 hp motor were renewed following replacement of the banding rings. After about six months of service, a breakdown occurred due to bursting of the banding wires in several places. The 0.064 in. diam wire was nonmagnetic and of the 18/8 Cr-Ni type of austenitic stainless steel. The fractures were short and partially crystalline, with no evidence of slowly developing cracks of the fatigue type. Microscopical examination of sections taken through the fractures showed the cracking to be of the multiple branching type. Because the material was in the heavily cold-worked condition, it was not possible to determine with certainty if the cracks were of the inter- or trans-granular type. It was concluded that failure was due to stress-corrosion cracking in a chloride environment. Failure of the wires was likely due to the use of a chloride-containing flux during the soldering operation.
1800马力电机转子的捆扎线在更换捆扎环后进行了更新。在使用了大约六个月后,由于几个地方的绑带线破裂而发生故障。0.064英寸。直径钢丝无磁性,为18/8 Cr-Ni型奥氏体不锈钢。断口较短,部分呈晶状,未发现缓慢发展的疲劳型裂纹。通过断口切片进行的显微检查显示,裂纹为多分支型。由于材料处于严重的冷加工状态,因此不可能确定裂纹是跨晶型还是跨晶型。结果表明,失效是由于在氯化物环境中应力腐蚀开裂所致。电线的故障很可能是由于在焊接过程中使用了含氯化物的助焊剂。
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引用次数: 0
Primary Grain Boundary Cracks in Cast Ingots and Flaky Crankshafts 铸锭和片状曲轴的初生晶界裂纹
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001253
F. Naumann, F. Spies
Octagonal cast ingots weighing 6.5 tons and made of unalloyed heat treated steel CK 45 according to DIN 17200, and crankshafts forged from these ingots showed internal separations during ultrasonic testing. To determine the cause of defect, an ingot slice and a crank arm were examined metallographically. Investigation showed this was a case where flaky forgings were made from cast ingots with primary grain boundary cracks. This parallelity supports the often expressed opinion that both occurrences have the same origin, i.e. that hydrogen precipitation was the driving force in the formation of primary grain boundary cracks in cast ingots.
根据DIN 17200标准,由非合金热处理钢ck45制成的重6.5吨的八角形铸锭和由这些铸锭锻造的曲轴在超声波测试中显示出内部分离。为了确定缺陷的原因,对铸锭片和曲柄臂进行了金相检查。调查表明,这是一种由带有初生晶界裂纹的铸锭制成的片状锻件。这种相似性支持了人们经常表达的观点,即两种现象具有相同的起源,即氢的析出是铸锭初次晶界裂纹形成的驱动力。
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引用次数: 0
Use of Electron Fractography to Diagnose Cracking in a 7075-T6 Aluminum Forging 利用电子断口学诊断7075-T6铝合金锻件裂纹
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001541
J. A. Scott
A forging of 7075-T6 aluminum alloy, which formed a support for the cylinder of a cargo door, cracked at an attachment hole. Fluorescent penetrant inspection showed the crack ran above and below the hole out onto the machined flat surface of the flange. A 6500x electron fractograph proved the crack to be a forging defect called a cold shut. Because defects of this type are usually detected when the raw forging is inspected, this occurrence was considered to be an isolated instance.
7075-T6铝合金锻件,用于支撑货舱门筒体,在连接孔处开裂。荧光渗透检查显示,裂纹在孔的上方和下方延伸到法兰的加工平面上。6500倍的电子断口分析证实该裂纹是一种被称为冷闭的锻造缺陷。由于这种类型的缺陷通常是在检验原锻件时发现的,因此这次发生被认为是一个孤立的实例。
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引用次数: 0
Brittle Zinc Layer on a Hot-Galvanised Hook 热镀锌钩上的脆锌层
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001215
Egon Kauczor
The surface of a hook did not possess the smooth and shiny zinc bloom surface normally observed on hot galvanized steel parts but was matte and rough. Large cracks were observed in the zinc layer. The hook was made of silicon-killed alloy steel 41Cr4. A silicon content of 0.27% was established analytically. Silicon accelerates the reaction between iron and zinc, which should have been taken into account in the present case by reducing the dip time or a small addition of aluminum (0.1 to 0.2%) to the galvanizing bath to retard the extremely rapid growth of the zinc layer and the strong alloy formation. Even in the case of steel parts with lower silicon contents the reaction between iron and zinc can continue until the pure zinc layer has been consumed entirely if the work piece is not cooled sufficiently after withdrawal.
钩子的表面不具有通常在热镀锌钢件上观察到的光滑和有光泽的锌花表面,而是哑光和粗糙。锌层出现了较大的裂纹。该吊钩由硅杀合金钢41Cr4制成。经分析确定硅含量为0.27%。硅加速了铁和锌之间的反应,在本案例中应该考虑到这一点,通过减少浸镀时间或在镀锌液中添加少量铝(0.1至0.2%)来延缓锌层的极快生长和强合金的形成。即使在硅含量较低的钢件中,如果工件在取出后没有充分冷却,铁和锌之间的反应也可以继续进行,直到纯锌层完全消耗。
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引用次数: 0
Brittle Fracture of a Clamp-Strap Assembly 夹带组件的脆性断裂
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0045988
During installation, a clamp-strap assembly, specified to be type 410 stainless steel-austenitized at 955 to 1010 deg C (1750 to 1850 deg F), oil quenched, and tempered at 565 deg C (1050 deg F) for 2 h to achieve a hardness of 30 to 35 HRC, and used for securing the caging mechanism on a star-tracking telescope, fractured transversely across two rivet holes closest to one edge of the pin retainer in a completely brittle manner. Comparison with a non-failed strap using microscopic examination, spectrographic analysis, and slow-bend tests showed that both fit the 410 stainless steel specs, but hardness and grain size were different. Reheat treatment of full-width specimens showed that coarse grain size (ASTM 2 to 3) was responsible for the brittle fracture, and excessively high temperature during austenitizing caused the large grain size in the failed strap. The fact that the hardness of the strap that failed was lower than the specified hardness of 30 to 35 HRC had no effect on the failure because that of the non-failed strap was even lower. Recommendation was that the strap should be heat treated as specified to maintain the required ductility and grain size.
在安装过程中,夹带组件,指定为410型不锈钢-奥氏体化,在955至1010摄氏度(1750至1850华氏度),油淬火,并在565摄氏度(1050华氏度)下回火2小时,以达到30至35 HRC的硬度,用于固定星跟踪望远镜上的保持机构,在最接近销钉固定器的一个边缘的两个铆钉孔横向断裂,完全脆性。通过显微检查、光谱分析和慢弯测试与未失效的表带进行比较,结果表明两者都符合410不锈钢规格,但硬度和晶粒尺寸不同。全宽试样的再热处理表明,粗晶粒尺寸(ASTM 2 ~ 3)是脆性断裂的原因,而奥氏体化过程中过高的温度导致失效带的晶粒尺寸过大。失效带的硬度低于规定的硬度30 ~ 35 HRC对失效没有影响,因为未失效带的硬度更低。建议应按照规定对表带进行热处理,以保持所需的延展性和晶粒尺寸。
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引用次数: 0
True Brinelling of Ball-Bearing Raceways During Ultrasonic Cleaning 超声清洗过程中滚珠轴承滚道的真正布林化
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0047956
Randomly selected dictating-machine drive mechanisms, which contained small ball bearings, were found to exhibit unacceptable fluctuations in drive output during the early stages of production. It was indicated that the bearing raceways were being true brinelled before or during installation of the bearings. The preinstallation practices and the procedures for installing the bearings were carefully studied. It was revealed that during one preinstallation step, the lubricant applied by the bearing manufacturer was removed and the bearing was relubricated with another type of lubricant prior to which the bearings were ultrasonically cleaned in trichloroethylene to ensure extreme cleanness. Equally spaced indentations resembling true brinelling were revealed by careful examination of the bearing raceways. It was concluded that the ultrasonic energy transmitted to the balls brinelled the raceways enough to cause fluctuations in machine output. Solvent-vapor cleaning was employed as a corrective technique for removing bearing lubricant.
随机选择的口述机驱动机构,包含小滚珠轴承,发现在生产的早期阶段,驱动器输出出现不可接受的波动。结果表明,在轴承安装前或安装过程中,轴承滚道是真实的。仔细研究了预安装实践和安装轴承的程序。据透露,在一个预安装步骤中,轴承制造商使用的润滑剂被移除,轴承用另一种类型的润滑剂进行润滑,在此之前,轴承用三氯乙烯超声波清洗,以确保极度清洁。通过仔细检查轴承滚道,发现了类似于真正的布棱纹的等间距压痕。得出的结论是,传递到球的超声波能量使滚道产生足够的摩擦,从而引起机器输出的波动。采用溶剂-蒸汽清洗技术对轴承润滑油进行清洗。
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引用次数: 0
Assessing the Durability of Aluminum Castings 铝铸件耐久性评估
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001640
D. Aliya
A new supplier for aluminum die castings was being evaluated, and the castings failed to meet the durability test requirements. Specifically, the fatigue life of the castings was low. Initial inspection of the fatigue fracture surfaces revealed large-scale porosity visible to the naked eye. New castings with reduced porosity also failed the durability tests. The fatigue fracture surfaces of additional casting fragments were very rough and contained multiple ratchet marks along the inner fillet. These observations indicated the fatigue process was heavily influenced by the presence of surface imperfections. Improving the surface finish or choosing a stronger alloy, were more likely to improve part durability than reducing the porosity.
正在评估一个新的铝压铸件供应商,铸件没有达到耐久性测试要求。具体而言,铸件的疲劳寿命较低。对疲劳断口表面的初步检查发现肉眼可见大规模孔隙。降低孔隙率的新铸件也未能通过耐久性测试。附加铸件的疲劳断口表面非常粗糙,沿内圆角有多个棘轮痕迹。这些观察结果表明,疲劳过程受到表面缺陷的严重影响。改善表面光洁度或选择更强的合金,比减少孔隙率更有可能提高零件的耐久性。
{"title":"Assessing the Durability of Aluminum Castings","authors":"D. Aliya","doi":"10.31399/asm.fach.process.c9001640","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c9001640","url":null,"abstract":"\u0000 A new supplier for aluminum die castings was being evaluated, and the castings failed to meet the durability test requirements. Specifically, the fatigue life of the castings was low. Initial inspection of the fatigue fracture surfaces revealed large-scale porosity visible to the naked eye. New castings with reduced porosity also failed the durability tests. The fatigue fracture surfaces of additional casting fragments were very rough and contained multiple ratchet marks along the inner fillet. These observations indicated the fatigue process was heavily influenced by the presence of surface imperfections. Improving the surface finish or choosing a stronger alloy, were more likely to improve part durability than reducing the porosity.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"52 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"126582926","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Brittle Fracture of a Clamp Because of Burning During Forging 锻造过程中因燃烧造成的夹钳脆性断裂
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c0047176
A ring clamp (8740 (AMS 6322), steel forged and cadmium plated) used for attaching ducts to an aircraft engine became loose after three hours of service. When the clamp was removed from the engine, the hinge tabs on one clamp half were found to be broken. Analysis (visual inspection and microscopic and metallographic examination) supported the conclusion that both hinge tabs on the clamp half fractured in a brittle manner as the result of gross overheating, or burning, during forging. The mechanical properties of the metal, especially toughness and ductility, were greatly reduced by burning. Evidence that burning was confined to the hinge end of the clamp indicated that the metal was overheated before or during the upset forging operation. Recommendations included notifying the supplier of the burned condition on the end of the clamp. The clamps should be macroetched before cadmium plating to detect overheating. The clamps in stock should be inspected to ensure that the metal had not been weakened by overheating during the upset forging operation.
用于将导管连接到飞机发动机的环形钳(8740 (AMS 6322),锻造钢和镀镉)在使用三个小时后变得松动。当夹钳从发动机上拆下时,发现夹钳一半上的铰链片已经坏了。分析(目视检查、显微和金相检查)支持这样的结论:由于锻造过程中严重过热或燃烧,夹钳上的两个铰链片都以脆性的方式断裂了一半。金属的机械性能,特别是韧性和延展性,由于燃烧而大大降低。有证据表明,燃烧仅限于夹具的铰链端,表明金属在镦锻操作之前或期间过热。建议包括通知供应商在夹具末端的烧伤情况。夹钳应在镀镉前进行宏观蚀刻,以检测过热。应检查库存的夹钳,以确保金属在镦锻过程中没有因过热而被削弱。
{"title":"Brittle Fracture of a Clamp Because of Burning During Forging","authors":"","doi":"10.31399/asm.fach.process.c0047176","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c0047176","url":null,"abstract":"\u0000 A ring clamp (8740 (AMS 6322), steel forged and cadmium plated) used for attaching ducts to an aircraft engine became loose after three hours of service. When the clamp was removed from the engine, the hinge tabs on one clamp half were found to be broken. Analysis (visual inspection and microscopic and metallographic examination) supported the conclusion that both hinge tabs on the clamp half fractured in a brittle manner as the result of gross overheating, or burning, during forging. The mechanical properties of the metal, especially toughness and ductility, were greatly reduced by burning. Evidence that burning was confined to the hinge end of the clamp indicated that the metal was overheated before or during the upset forging operation. Recommendations included notifying the supplier of the burned condition on the end of the clamp. The clamps should be macroetched before cadmium plating to detect overheating. The clamps in stock should be inspected to ensure that the metal had not been weakened by overheating during the upset forging operation.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"27 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128120598","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Printed Circuit Board Failures at Plated Through Holes 印刷电路板镀通孔故障
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.process.c9001493
An open electrical circuit was found between plated through-holes in a six-layer printed circuit board after thermal cycling. The copper plating was very thin in the failure area but did make an electrical contact during initial testing. During thermal cycling, differential z-expansion between the epoxy board and copper caused the thin plating to crack. During electrical testing of a four-layer circuit board, an open electrical circuit was found between the plated through-holes. Plating discontinuity was caused by poor drilling using a dull drill with improper speed (rpm) and/or feed rate as was observed by nonuniform plating and nodule formation in the plated layer. In a third example, an open electrical circuit was found in a six-layer board between two adjacent plated through-holes. A plating void was on one side of the conductor joining the two holes. Continuity was found when tested from one side of the board but lost when tested from the other. In a fourth case, an open circuit found between a plated through-hole and contact pad on a six-layer printed circuit board was caused by an etching defect.
热循环后,在六层印刷电路板的镀通孔之间发现了开路电路。铜镀层在失效区域非常薄,但在最初的测试中确实产生了电接触。在热循环过程中,环氧板和铜之间的z-膨胀差异导致薄镀层开裂。在对四层电路板进行电气测试时,发现在镀通孔之间有一个开路电路。镀层的不连续性是由于使用钝钻在不适当的转速和/或进给速率下钻孔不佳造成的,如镀层不均匀和镀层中形成结核。在第三个例子中,在两个相邻的镀通孔之间的六层板中发现了一个开路电路。导体的一侧有一个连接两个孔的电镀孔。从板的一侧测试时发现连续性,但从另一侧测试时失去连续性。在第四个案例中,在六层印刷电路板上的镀通孔和触点垫之间发现了开路,这是由蚀刻缺陷引起的。
{"title":"Printed Circuit Board Failures at Plated Through Holes","authors":"","doi":"10.31399/asm.fach.process.c9001493","DOIUrl":"https://doi.org/10.31399/asm.fach.process.c9001493","url":null,"abstract":"\u0000 An open electrical circuit was found between plated through-holes in a six-layer printed circuit board after thermal cycling. The copper plating was very thin in the failure area but did make an electrical contact during initial testing. During thermal cycling, differential z-expansion between the epoxy board and copper caused the thin plating to crack. During electrical testing of a four-layer circuit board, an open electrical circuit was found between the plated through-holes. Plating discontinuity was caused by poor drilling using a dull drill with improper speed (rpm) and/or feed rate as was observed by nonuniform plating and nodule formation in the plated layer. In a third example, an open electrical circuit was found in a six-layer board between two adjacent plated through-holes. A plating void was on one side of the conductor joining the two holes. Continuity was found when tested from one side of the board but lost when tested from the other. In a fourth case, an open circuit found between a plated through-hole and contact pad on a six-layer printed circuit board was caused by an etching defect.","PeriodicalId":294593,"journal":{"name":"ASM Failure Analysis Case Histories: Processing Errors and Defects","volume":"12 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128469954","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
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ASM Failure Analysis Case Histories: Processing Errors and Defects
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