METZ LAB An ISO 9001 : 2015 certified company Failure Analysis By - K.Sevugarajan Contact details Metz Lab Pvt.Ltd. First floor, Thangavel Nagar Walajabad Main Road, Mannivakkam-600048 Cell: +91-8190810222 Mail: sevuarajan@metzlab.org www.metzlab.orgOutline . Principles Types of failures Failure modes * How to conduct failure analysis Analyze data Failure mechanism . . . Prevention of Failures * Failures examples www. metzlab.org METZ LABIntroduction e The objective of this course is to provide a basic overview of failure analysis. It will include discussion of failure mechanisms, analytical techniques and case histories * To provide you with a clear understanding of terms used so that you can ask the right questions and interpret common observations with ease METZ LAB www. metzlab.org1. Principles Examinations ¢Detection and characterization of damage Materials ¢ldentification of damage mechanisms, allowing application of appropriate damage initiation/ propagation modelisation Engineering Analysis ¢ldentifications of damage development with respect to specific manufacturing process ¢Basis for determining safe operating periods and expected remaining life. METZ LAB www. metzlab.org1: Principles Qualities Desired in an Analyst : Ability to remain unbiased and reject conventional wisdom. Ability to facilitate a group of people (if using a team) towards a common objective. + Trained in logic tree approaches to failure analysis. Affinity for listening and questioning for understanding. + Patience and perseverance. METZ LAB www.metzlab.org fan 180 9001 : 2035;1: Principles Failure Analysis Tasks * Prioritize - Determine what is most important to work on. + Analyze - Analyze the failure event to determine root causes. + Recommend - Develop recommendations as solutions to the causes are discovered. METZ LAB www. metzlab.org1: Principles First Principle of Failure Analysis Do Not Touch!!!!!! Observe !! Remember the phrase “See but do not touch” Visual Examination is everything Macroscopic/Microscopic Gut feel is very important Understand the Operating conditions of the part rece ar METZ LAB www.metzlab.org fn 180 9001: 2015 cote compar2. Types of failures Ductile Brittle Fatigue High Temperature Static Delayed Stress Raisers www.metzlab.org 00: 2035 Excess deformation,elastic or plastic, tearing or shear failure Cleavage, sudden Cycling load, strain, thermal, corrosion, rolling contact, fretting Creep, oxidation, local melting, warping Embrittlement. - Hydrogen, caustic, liquid metal, temper, environmental Sharp fracture initiation points METZ LAB3. Failure modes Failures can be classed in three broad categories: failures caused by the deformation of parts, failures due to rupture and failures due to surface damage. PERMANENT DISTORTION : The part can no longer be used because it is deformed. FRACTURES : Various types of rupture may be distinguished, depending on the appearance of the fracture surface and the forces applied. Static sudden fracture under or static constant load, resulting from an impact or-from exceedence of the maximum allowable load. Ductile and brittle fracture Delayed breakage Fracture due to hydrogen embrittlement Stress corrosion fracture Fatigue fracture Creep fracture Stress corrosion fracture METZ LAB www. metzlab.org fa 150 9001 : 2025 contied company3. Failure modes SURFACE DAMAGE : This category covers many different types of damage affecting a wide variety of mechanisms. £ The. common characteristic of all these is that they cause deterioration of the surface of the metal, which eventually leads to the destruction of the part. Surface fatigue (or “contact fatigue”) Frosting or hairline cracks Uniform spalling Wear Abrasive wear Adhesive wear or scuffing Fretting-corrosion wear Cavitation-Erosion Thermal fatigue CORROSION : METZ LAB www.metzlab.org fn 150 9001 : 2025 certied compar3. Failure modes Causes of Failure * Misuse or Abuse « Assembly errors * Manufacturing defects + Improper maintenance * Fastener failure * Design errors * Improper materials + Improper heat treatments » Unforeseen operating conditions + Inadequate quality assurance * Inadequate environmental protection/control METZ LAB www.metzlab.org * Casting discontinuities ia 50 9003. Failure modes Frequency of Causes of Failure in Some Engineering Industry Investigations - Origin % * Improper material selection 38 + Fabrication defects : 15 + Faulty heat treatments 15 + Mechanical design fauit 1 + Unforeseen operating conditions 8 + Inadequate environmental control 6 + Improper or lack of inspection 5 and quality control 2 «. Material mix-up METZ LAB www. metzlab.org3. Failure modes Frequency of Causes of Failure in Some Engineering Industry Investigations - www. metzlab.org Cause | % * Corrosion 29 * Fatigue 25 « Brittle Fracture 16 « Overload 11 « High-temperature corrosion 7 + Stress Corrosion, Corrosion Fatigue, 6 Hydrogen Embrittlement 3 + Creep 3 * Wear, Abrasion and Erosion METZ LAB4. How to conduct failure analysis Practical Issues in Failure Analysis Visual Inspection - surface cleanliness Electrical tests for continuity. ‘ * “Drop and suck’test - solvent placed in local area, sucked and analyzed for contaminants. * Cross sectioning to see thickness variations during processing Scanning/Auger Spectroscopy or Rutherford Back Scattering Delamination METZ LAB www. metzlab.org4. Steps in Failure Analysis + Description of Failure Situation + Visual Examination + Design/Stress Analysis + Chemical Analysis + Fractography + Metallographic Examination » Properties- hardness or other mechanical properties « Failure Simulation METZ LAB www.metzlab.org fn 150 9001 : 2025 certied comparwww. metzlab.org 4. Stages In a Failure Analysis * Collect data * Visually examine failure * Non Destructive Testing * Select samples * Examine and analyze * Determine failure mechanism * Write report METZ LAB4. Sample Preparation * Fracture surface is dirty and contaminated - Rinse in alcohol or acetone using ultrasonic cleaner - Dry - Replicate using cellulose acetate tape - Gold or carbon coat (200°A) the surface - Examine in microscope METZ LAB www. metzlab.org4. Collection of Data * Collect information * Review sequence of events leading to failure * Get drawings.and records, repair history * Photograph the failure in several angles before destruction for examination * Get information on good samples for comparison METZ LAB www. metzlab.org4. Visual Examination * Examine before cleaning + DO NOT TRY TO FIT THE BROKEN PIECES BACK TOGETHER! YOU MAY DESTROY THE REAL EVIDENCE- AVOID THE TEMPTATION METZ LAB www. metzlab.orga. Typical Non destructive te ing total ery UEC UM Len (rl i eRe Deluca Coe eee Eee en a urd Lee Clemo OU ei ad eR) Peer eee CU EMU ae aioe Eure steel hel) Dra Ui Ue Cae in ferromagnetic materials by flux leakage Cat Pete COE ete lc Bie} the surface in many materials via liquid retention Peete) ule ch) TC Tr) Identification of material flaws and features Pu ie ROUGE a acted st Pr eure eee reflection of ultrasonic pulses4.Materials analysis Chemical analysis: Chemical analysis is an integral part of an investigation, because it indicates whether a component is made of the specified material Metallography : Examination of cross sections of materials involved in a failure can provide important insights into the probable cause of the incident. Metallography can reveal such as : * macrostructure, + depth of surface hardening * microstructure, such as grain size and the phases present * non-metallic inclusions * porosities... METZ LAB www.metzlab.org fa 150 9001 : 2025 contied company4.Materials analysis Fractography and SEM examination : Fractography generally involves a scanning electron microscope SEM observations can reveal such as : * fine microstructure, such as phases and precipitations * cracks initiation and fatigue striations * fracture modes (dimples, cleavage, intergranular fracture) Microanalysis : Corrosion products, inclusions, metallurgical phases can be also chemically. identified via electron microscopy and energy dispersive spectrometry. Mechanical testing :\n addition to the examination methods, hardness measurements can be realized. METZ LAB www.metzlab.org fa 150 9001 : 2025 contied company4.Materials analysis Surface aspect evaluation : Surface roughness can also be evaluated. Special testing This group of tests includes all those that do not easily fit into the previous categories. The following are a few of the more important techniques. * Finite element analysis: Finite element analysis, or FEA, is an advanced modeling technique that can help to predict the magnitude of stresses on individual components within complex assemblies. ¢ Simulation: In some instances, sophisticated test apparatus can be developed for approximating the service conditions involved in a materials failure. METZ LAB www.metzlab.org fa 150 9001 : 2025 contied company5. Analyze data The assembled results from the different analysis and tests must be considered collectively, because the final hypothesis needs to be in substantial agreement with all physical evidence and test results. METZ LAB www.metzlab.org fn 150 9001 : 2025 certied comparDetermine failure mechanism Apart or assembly is considered failed if one of the following conditions occur: * It becomes completely inoperable ‘It's operable butno longer functions satisfactorily + It'sdeterioratedto the point it is unsafe or unreliable. METZ LAB www. metzlab.orgFailure Mechanisms There are four different types of bre eakage : ductile fractures, intergranular brittle fractures or cleavage fractures, and semi-brittle zig-zag fractures Brittle fracture Brittle fracture cracks cracks grains. Fracture surface iceted texture of different orientation of cleavage planes in grains. B. Intergranular fracture: Fracture crack propagation is along grain boundaries (grain boundaries are weakened “or embrittled by impurities segregation etc.) Intergranular >) ia Transgranular cm www. metzlab.org ‘ho 150 9001: 2015 certiied compa AB!Failure Mechanisms i f Ductile f Ductile fracture has dimpled, cup and cone fracture appearance. The dimples car become elongated by a lateral shearing force, or ifthe crack is in the opening (tearing) mode. ture The size and shape of the dimples dependsFailure Mechanisms = - Esai : tosses = isin I “METZ LAB © kn 180 9001 2035 certied compen www. metzlab.orgFailure Mechanisms Brittle fracture displays either eee (transgranular) or intergranular fracture. This depends upon whether "4 oe grain boundaries are stronger or weaker than the grains.Prevention of Failures + Many failures can be avoided by: + Correct design * Selection of appropriate materials * Correct processing * Consideration of service environment + Required: system engineering approach www. metzlab.org METZ LABPrevention of Failures: Design * Design for maximum stress * Include safety margin * Avoid and do not create stress raisers * Do not break fiber reinforcements NaRLMeEISE a METZ LABPrevention of Failures: Materials + Temperature range of operation + Do not cross polymorphic transformations + Understand fatigue conditions + Stress-rupture lifetime * Quenched and tempered materials loose strength at higher temperature + Age-hardened materials lose strength at high temperature METZ LAB www.metzlab.org fn 150 9001 : 2025 certied comparPrevention of Failures: Processing + Cast to required grain size + Casting may create gas porosity and segregation + Cold working and forging create cracks, flaws, inclusions + Welding creates gas porosity, cracks, recrystallization affecting strength + Heat treatment may create surface cracks upon quenching, decarburize surface layers, create agglomerations at grain boundaries METZ LAB www.metzlab.org fn 150 9001 : 2025 certied comparPrevention of Failures: Service Thermal and chemical environment must be understood Avoid overload Use tools for applications it was designed for Control wear Check parts by non-destructive testing methods Have rigorous maintenance program and quality control Avoid bogus parts METZ LAB www. metzlab.orgFailure Analysis Report * Description of the failed component * Service condition at the time of failure * Prior service history * Manufacturing and processing history of component * Mechanical and metallurgical study of failure * Metallurgical evaluation of quality * Event Summary of failure causing mechanism * Recommendations for prevention of similar failures METZ LAB www. metzlab.orgExamples Torsion Failures a tem 4 UH-1N Turbine: helical Shaft Failure F-18 Engine Shaft Torsional Buckling METZ LAB www.metzlab.org an 190 9001Gross Plastic Deformation UH-1N Engine Shaft/Bearing www.metzlab.orgDuctile & Brittle Failure in Tension METZ LAB www.metzlab.org fun 80 90012085Brittle Failures from Rotor Systems METZ LAB www.metzlab.org fn 80 90011Rivermarks & Chevrons Arrows shows origin of failure www. metzlab.org' Bending Deformation & Failure 4 In-flight failure Ree nb Ge) METZ LABMETZLABHeat Check Lines METZ www.metzlab.org ‘te 180 9001: 2015 certitied compa_ Feature of Stress Corrosion Cracking - Crack Branching eee METZ LABMicrostructure of Weld Zone METZ www.metzlab.org fn 150 9001 : 2025 certied comparCracks due to Thermal Stresses in the Weld Zone Ree nb Ge) METZ LABFailure in Super heater Outlet Header METZ www.metzlab.org fn 150 9001 : 2025 certied comparChevron Notches in Fasteners eee METZ LABBolt Failure Due to Ductile Overload aan Ra a | METZ LABDuctile and Brittle Fracture + Ductile fracture - Fracture accompanied by plastic deformation and, therefore, by energy absorption - cup and cone z + Brittle Fracture - No Energy absorption Left Bolt Re 57 Brittle Right Bolt Re 15 Ductile Pee METZ LAB www. metziab.org: ‘hn 1509 9001 + 20Failure of Bolts Bending fatigue of the bolt www. metzlab.orgFailure of Gears www. metzlab.orgDistortion failures occur when a structure or component is deformed. It fails because it can no longer support the load it was intended to carry. www. metzlab.org Distortion Failures METZ LAB fn 180 9001: 2015 cote comparWear Failures Wear - undesired removal of material from rubbing surfaces. + Abrasive + Adhesive’ : METZ LAB www. metzlab.org ‘ho 150 9001: 2015 certiied compaSpring Failure Spring failure by combination of bending, torsion and fatigue. aan Ra a | METZ LABCracking in Cup Stress corrosion cracking of deep-drawn brass cup rece ar METZ LAB www.metzlab.org fn 180 9001: 2015 cote comparCracking in Tube Stress corrosion cracking of brass tube Pee METZ LAB www. metziab.org: Aa 150 9001 | 2015 cortitied comparyHorse Bit Failure Fracture in horse bit rece ar METZ LAB www. metzlab.org sn 1508001: 201 cried someStirrup Failure Horse racing stirrup failure METZ LAB www. metzlab.orgBicycle Hub Failure Bicycle hub failure in rear wheel METZ LAB www. metzlab.orgBicycle Pedal Crank Failure www. metzlab.org Fatigue crack in a crank METZ LABHigh tensile steel bolt fatigue failure METZ LABRoad Vehicle Stub Axle Failure Bending fatigue of a steel stub axle www.metzlab.org cerita compan METZ LABCombustion chamber Engine Failure METZ LABMETZ LAB