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Fractrography by Wulpi
Fractrography by Wulpi
The word fractography origin from the Latin word fractus, meaning
fracture, and graphy derives from the Greek term grapho, meaning
descriptive treatment.
“The science of studying the fracture surface is termed as
fractography”.
Thus, depending on the level of examination, one can have
macrofractography and microfractography.
1) Macroscopic examination
Macroscopic examination is carried out with unaided eye or a simple
handheld magnifier, or a stereomicroscope with low magnification (up
to 50X).
In the stereo microscope, reasonably large specimens can be handled,
and the microscope can easily be adopted for examination of
components in the field or accident site.
The features revealed during macroscopic examination are:
i. Type of fracture
ii. Origin of fracture
iii. Presence of secondary cracks
iv. Presence of external debris or corrosion products
v. Discoloration
vi. Presence of wear marks in the vicinity of fracture
vii. Plastic deformation preceding fracture
viii. Dimensional changes in the component
ix. Evidence of any overheating
x. Post-fracture damage such as rub marks
Example:
Fig. 15 View of another region of the surface of the impact fracture shown in
Fig. 14, showing facets that resulted from a combination of intergranular
rupture and transcrystalline cleavage. Note the array of small river patterns
at the bottom edge of the large facet at center. See also Fig. 16. SEM, 655×
Fig. 16 View of a third region of the surface of the impact fracture shown in
Fig. 14 and 15. Note the almost perfect grain-boundary surfaces and the
sharp edges and points at which the separated-grain facets meet. The
secondary cracks are equally clean separations. SEM, 670×
Example-8:
Fracture of SiC initiated at corrosion pits. The boron- and carbon-doped SiC
was injection molded and pressure less sintered. The sample was then
coated with 2 mg/cm2 (0.07 oz/ft2) Na2SO4 and exposed for 48 hat 1000
°C (1830 °F) in 0.1% SO2/O2 gas. Corrosion products were removed with a
solution of 10% HF inwater and the sample was broken in four-point
bending at a strain rate of 0.5 mm/min (0.02 in./min).
Fig. 1278: Fracture surface shows radial crack lines emanating from the
origin, which was a corrosion pit (top).
SEM (30° tilt), 115×.
Fig. 1279: Close-up of pit-ceramic interface reveals preferential grain-
boundary attack in advance of the pit.
SEM (30° tilt), 4300×
(J.L. Smialek and N.S. Jacobson, NASA Lewis Research Center)
Example-9
Metallography of Fracture Specimen:
The metallurgical microscope is yet another instrument very useful to
the failure analyst.
After collecting all the information through fractography of the failed
component, a section of the component can be cut transverse to the
fracture surface.
This section is then polished and examined in the metallurgical
microscope, both before and after etching. Inclusions present in the
material are observed on the as-polished surface.
The inclusion rating can be determined by standard quantitative
microscopy techniques.
By differences in color, reflectivity, and refractive index, they can also
be identified with some prior experience.
The polished specimen is then etched with suitable etchants to reveal
the microstructure of the material.
Abnormalities in the microstructure that may have been responsible for
the failure can be identified at this stage.
The path of a crack, whether it is intergranular or transgranular, and
branched or not branched, will be clear in the microstructure.
Cracks due to stress corrosion, hydrogen embrittlement, and liquid
metal embrittlement are generally intergranular with some exceptional
situations.
Fatigue cracks are transgranular. If a stress-corrosion crack
propagates by fatigue, the transition from intergranular to transgranular
mode can be seen in the microstructure.
Stress-corrosion cracks in certain stainless steels are transgranular
with extensive branching.
Plastic deformation of the component prior to fracture can be
recognized in the microstructure by the elongated grains.
Abnormal grain growth, segregation of brittle or weak phases at the
grain boundaries, and recrystallization are some of the other features
that can be identified by metallography.
Figure shows the intergranular and transgranular modes of crack
propagation, revealed by metallography.