Engineering Failure Analysis 70 (2016) 290–304

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Engineering Failure Analysis

journal homepage: www.elsevier.com/locate/engfailanal

Studies on failure behaviour of wire rope used in underground

coal mines
R.P. Singh, Mousumi Mallick ⁎, &, M.K. Verma
Metallurgy Section, MHM, CSIR-Central Institute of Mining & Fuel Research, Brawa Road, Dhanbad-826015, India

a r t i c l e i n f o a b s t r a c t

Article history: Wire ropes operate at high stress levels and are almost invariably subject to fluctuating loads.
Received 7 June 2016 The continuous degradation of wire rope affected with operative services will ultimately lead
Received in revised form 25 August 2016 to failure. Study of the causes of failure of two wire ropes from two different Indian coal
Accepted 2 September 2016
mines have been carried out and discussed here. The investigating parameters comprises of
Available online 4 September 2016
physical examination, wear & corrosion, lubrication, macro & micro-examination and chemical
composition. The investigation revealed that the major cause of failure was due to excessive
Keywords: wear and corrosion resulted in high reduction in diameter ranging from 50%–90% and poor
Wire rope failure
lubrication condition of wire rope. Micro-examination also revealed intergranular corrosion
Types of failure in wire rope
with cracks and pittings, uniform corrosion with pitting along the grain. Further elongated
Wire rope
Corrosion on wire rope grain which was indicative of stress due to excessive corrosion with sudden impact resulted
in its failure.
© 2016 Elsevier Ltd. All rights reserved.

1. Introduction

Wire rope has its many application like aerial ropeways, offshore oil mining, suspension bridge, and mine hoisting. It plays an
important role in operating open cast and underground coal mines. Mining operation is essential to produce coal, the primary
source of energy involving lots of man power. In view of safety of mine and miners, the performance evaluation of mine
appliances on regular basis is utmost important.
Wire ropes are complex assembly of steel wires Fig. 1 [1]. The steel used has very high strength. This high strength is achieved because
of high carbon content in plain carbon steel and a very fine grain structure. Metallurgical analysis such as micro-examination, tensile
strength, hardness, compressive strength, and chemical analysis is therefore important for its quality testing and safe use. The wire
rope has essential combination of high axial strength and stiffness with flexibility in bending which allows the use of brittle steel at a
very high stresses [2]. This helps in ensuring a wire rope toughness which prevents local damage of wires.
Every wire rope has a definite life. The continual processes of degradation in operational service, will ultimately lead to failure
of the wire rope. The service degradation processes are complex and different for different application. The great majority of safety
critical rope applications involve fatigue coupled with other degradation mechanism such as wear or corrosion, which together
determine a finite service life. Wire ropes operate at high stress levels and are subject to fluctuating loads. In running ropes
the important source of stress fluctuation is the repeated bending and straightening as ropes run over sheaves, and on and off
drums [2].

⁎ Corresponding author.
E-mail addresses: rpsingh_cmri@yahoo.co.in (R.P. Singh), mousumi.mallick_cimfr@yahoo.com, mousumi_nitdgp@yahoo.co.in (M. Mallick),
vmanoranjan51@yahoo.com (M.K. Verma).

http://dx.doi.org/10.1016/j.engfailanal.2016.09.002
1350-6307/© 2016 Elsevier Ltd. All rights reserved.
 R.P. Singh et al. / Engineering Failure Analysis 70 (2016) 290–304 291

Fig. 1. Wire rope structure.

The paper deals with brief review on failure behaviour of wire ropes, probable reason for failure and two case studies of failed
wire ropes used in two different underground coal mines of BCCL, India. The metallurgical parameters like physical examination,
wear and corrosion, retention of lubricant, chemical composition, macro and micro-examination have been considered for
descriptive failure analysis.

2. Literature review

Steel wire ropes are critical load-bearing components used in cranes, lifts, mine haulage, etc. generally fails because of wear
and corrosion, tension, bending, fatigue. Wear and corrosion are the two main reason of failure, as the protective layer will be
exposed to corrosion by wear increasing its rate and thereafter affects the internal composition of the material and its mechanical
properties and ability to resist wear. [3].
Wire ropes used in different mining and non-mining operation requires lubrication to reduce the friction between individual
wires, between strands, between rope coils, and between other surfaces and rope, such as sheaves and drums. The wires and
strands must slide with each other for stress distribution and equalization.
Chemical analysis is an important parameter for determination of metal properties. The percentage of elements present in the
materials used in mine appliances play an important role in enhancing the safety in mines. Chemical analysis does however
ensure quality, productivity, safety, consistency, control and many other factors.
In a case study on failure analysis of hoisting steel wire rope, a steel rope in a hoist system of a drilling rig was damaged. The
wires of the upper strands were broken. The investigation reveals different rope grades on the upper strand which was damaged.
This combination of low and high strength wires in the upper layer of the rope causes differences in loading while in service. The
wires having lower strength thus free from the strands and deform leading to the fracture development at weak part [4].
In another case study of the failure of a multistrand wire rope used in drilling rig hook, the wire rope failed during the raising
of the rig which has been used for a few times only for up-down of the rig and its structure got damage. The failure analysis was
done by metallurgical examinations and computational analyses utilizing the finite element method. The wire rope was of AISI
1095 steel and extra extra improved plow steel (EEIPS) grade. The morphologies of fractured surfaces show tensile overloading
of wires. Finite element analysis confirms the overload in core and strands, and contact stresses between wires and sheave
surface. The failure was due to small ratio of sheave-to-rope diameter and high tensile stresses due to the overload [5].
In the case study of failure analysis of crane wire rope, the main reason for the failure of wire rope was cyclic torsional stress
which originates from the outer strand wires because of running over sharp-angle of small sheaves diameter resulted in fatigue.
The stress gradually transferred to the core wire and finally failure occurs which is of ductile in nature [6].
In investigation of failure of crane rope from DSV DSND PELICAN by I M L Ridge, J E Bradon and C R Chaplin [7], it was found
that the primary cause of rope failure was corrosion which reduces the strength of the rope as the protective galvanizing layer
and lubricant had been lost making it susceptible to corrosion induced wear type failures of tensile nature.
Microstructure of both new and used rope plays a very important role for determination of the mechanical properties of the
rope. Any inborn manufacturing defects (micro pipe, inclusions, improper microstructure etc.) work together along with service
conditions and affect the continuous process of degradation which ultimately lead to failure. The process of service degradation
(abrasive/plastic wear, stress corrosion, pitting corrosion, martensitic transformation etc.) is reflected in appearance and in
characteristics of the rope [8].
In an investigation of failure analysis of a wire rope, a wire rope in auto tensioning system suffered premature failure. The
cause was fatigue cracks initiating at nonmetallic inclusions near the surface of individual wire strands in the rope. The inclusions
were identified as Al\\Ca\\Ti silicates in a large number of stringers, and some oxide and nitride inclusions were also found. The
wire used in the rope did not conform to the composition specified for AISI 316 grade steel, nor did it satisfy the minimum tensile
strength requirements. The ultimate fracture of the rope was the result of overload that occurred after fatigue failure had reduced
the number of wire strands supporting the load [9].
In another Failure Analysis - Industrial Case Studies it has been observed in a paper of failure of a wire rope on a crane by
Dr. David J Grieve [10], the strength of the rope was reduced due to fatigue cracks as its tensile strength was reduced significantly
as compared with the manufacturer's statement. The rope failed due to an overload and the presence of fatigue cracks along with
blocking of rope between sheave and groove.
292 R.P. Singh et al. / Engineering Failure Analysis 70 (2016) 290–304

Fig. 2. Mechanical wear.

In an investigation of wire rope failure in marine tragedy by The Test House (TTH), during drilling a life boat was being
recovered and hoisted when the forward fall wire parted, causing the life boat to swivel on the aft hook. It has been found in
the investigation that the strength of the rope was below the standard certified value. The rope condition was poor revealing
from open lay, internal rusting and wire break [11].

3. Probable reason of failures

The main reasons for wire rope failure are [12]:

• Mechanical wear
• Bending fatigue
• Corrosion
• Tensile overload
• Shear
• Martensite formation
• Heating
• Rotation

3.1. Mechanical wear

The removal of material due to mechanical abrasion is known as mechanical wear (Fig. 2). The mechanical wear can be
reduced by following ways:

• Lubricating the rope;

• Choosing a suitable rope design for example mechanical wear is less where the outer strand is compact.

3.2. Bending fatigue

Wire ropes operations are subject to fluctuating loads due to stress caused by repeated bending and straightening of running
over the sheaves and the drums. Fatigue occurs when the individual wires lose their ability to bend, and often it is caused by
some constraint that prevents the rope wires from moving freely and smoothly, and working with each other wires. These con-
straints may be from undersized sheaves, improper sheave maintenance, groove type and lack of lubrication. Rope constructions
also plays a significant role for example, a lang lay rope provides more resistance to abrasion and bending fatigue than a regular
lay rope and would, therefore, be found more often in harsh environments where the rope bends frequently over small radii [13].
Fig. 3 below shows broken wire due to bending fatigue.

3.3. Corrosion

Corrosion is the electrochemical reaction between a material, and its environment which deteriorates the material and its
properties. Steel wire rope loses its strength and flexibility when corroded which resulted in development of fatigue cracks.
The amount of corrosion can be reduced by galvanizing the rope wires or by plastic coating. Internal and external lubrication
also prevents corrosion. Static ropes are more susceptible to corrosion that running rope (Fig. 4).

Fig. 3. Bending fatigue.

 R.P. Singh et al. / Engineering Failure Analysis 70 (2016) 290–304 293

Fig. 4. Corrosion of wire rope.

3.4. Tensile overload

Wire rope is subjected to load at operation when this load exceeded its breaking strength, two phenomena occurs viz. the
strands bear against one another causing individual wires to experience shear but when sheared wire no longer support the
load it then passes to the remaining wires and the destruction speeds up. When the strength of the remaining wires cannot
bear the load then the rope fails and the wires breaks with excessive tensile loading. Wires fails from tensile loading will form
cup and cone type of morphology (Fig. 5) [14].

3.5. Shear

High axial load combined with compression of the wire causes shear break. Their break surface is inclined about 45° to the
wire axis. The fracture surface is more or less smooth in appearance (Fig. 6) [14].

3.6. Martensite formation

Sometimes the temperature of the rope increases may be due to operating condition or due to friction between wires and
thereby sudden cooling leads to martensite formation on the surface. This formation makes the rope brittle in nature (Fig. 7).

Fig. 5. Formation of cup & cone in tensile overlooked.

Fig. 6. Failure due to shear.

294 R.P. Singh et al. / Engineering Failure Analysis 70 (2016) 290–304

Fig. 7. Martensite formation on the surface.

3.7. Heating

Wire ropes are good conductor of heat as it is made up of steel. In certain cases like lightning or arcing if strikes the
temperature will raise resulted in recrystallization of the microstructure. This will reduce the tensile strength of the rope. Further
lubrication of the rope will melt if the temperature goes beyond 100 °C. Fig. 8 below shows damage of wire rope due to heat [12].

3.8. Rotation

Steel wires are twisted to form the rope. If the rope is twisted in opening sense there is a possibility of inlaying (Fig. 9). This
can travel a distance and accumulated at a single point which will create problem for proper functioning of the rope.

4. Failure analysis of wire rope (case study)

The descriptive metallurgical parameters for failure analysis have been considered are:

1. Macro-examination
2. Wear & corrosion
3. Lubrication
4. Micro-examination
5. Chemical composition

Fig. 8. Damage of wire rope due to heat.

Fig. 9. Damage of wire rope due to rotation.

 R.P. Singh et al. / Engineering Failure Analysis 70 (2016) 290–304 295

Used fresh piece

Fibre core

Broken end

Fig. 10. As received samples.

4.1. Case study – I

The failed wire rope sample in two pieces (fracture end & used fresh end) of 25 mm diameter FMC wire ropes have been
received for investigation from Bastacolla Area, BCCL (Fig. 10). The wire rope construction was 6 × 10 F.S. (7/3) F.C. [14].
From the above figures it is clear that fibre core of the rope has come-out of the fracture end. The fracture end of the rope was
badly damaged. The causes of the failure can be detailed out from the following metallurgical examination.

4.1.1. Macro examination

4.1.1.1. Strand 1. On visual examination the nature of failure of 7 numbers of wires was revealed as fatigue failure of wire reduced
by abrasion and 3 numbers of wires as conical tensile failure shown in Fig. 11.

4.1.1.2. Strand 2. On visual examination of strand no. 2 of the fractured rope sample, it revealed the nature of failure of 8 numbers
of wires as fatigue failure on heavy reduction by abrasion & nicking and 2 numbers of wires as conical tensile failure shown in
Fig. 12.

Fig. 11. Nature of failure of strand 1.

Fig. 12. Nature of failure of strand 2.

296 R.P. Singh et al. / Engineering Failure Analysis 70 (2016) 290–304

Fig. 13. Nature of failure of strand 3.

4.1.1.3. Strand 3. In strand no. 3 of the fractured rope sample on visual examination, it revealed the nature of failure of 4 numbers
of wires as conical tensile fracture and 6 numbers of wires as fatigue failure on heavy reduction by abrasion and nicking shown in
Fig. 13.

4.1.1.4. Strand 4. In strand no. 4 of the fractured rope sample on visual examination, it revealed the nature of failure of 3 numbers
of wires as conical with tensile fracture, 3 numbers of wires as fatigue failure on wire reduced by abrasion and 4 numbers of wires
as fatigue failure on full section of wire shown in Fig. 14.

4.1.1.5. Strand 5. On visual examination in strand no. 5 of the fracture rope sample, it revealed the nature of failure of 5 numbers of
wires as conical tensile failure and 5 numbers of wires as fatigue failure on wire reduced by abrasion shown in Fig. 15.

4.1.1.6. Strand 6. On visual examination in strand no. 6 of the fracture rope sample, it revealed the nature of failure of 4 numbers of
wire as conical tensile failure and 6 numbers of wire as fatigue failure on heavy reduction by abrasion shown in Fig. 16.

Fig. 14. Nature of failure of strand 7.

Fig. 15. Nature of failure of stand 5.

 R.P. Singh et al. / Engineering Failure Analysis 70 (2016) 290–304 297

Fig. 16. Nature of failure of stand 6.

4.1.2. Examination of wear & corrosion

4.1.2.1. Fracture rope (broken rope)

4.1.2.1.1. Strand 1. 4.1.2.1.1.1. Outer wires. The galvanized round steel rope wire sample on physical examination revealed abra-
sive & plastic wear, helical indentation marks, nicks and corrosion pitting on the surface of the wire.
Maximum percentage reduction in outer wire diameter: 14.17%.
4.1.2.1.1.2. Inner wires. The galvanized inner core wires sample on physical examination revealed abrasive & plastic wear, helical
indentation marks, nicks and corrosion pitting on the surface of the wire.
Maximum percentage reduction in core wire diameter: 12.30%.
4.1.2.1.2. Strand 2. 4.1.2.1.2.1. Outer wires. The galvanized round steel rope wire sample on physical examination revealed abra-
sive & plastic wear, helical indentation marks, nicks and corrosion pitting on the surface of the wire.
Maximum percentage reduction in outer wire diameter: 58.17%.
4.1.2.1.2.2. Inner wires. The galvanized inner core wires sample on physical examination revealed abrasive & plastic wear, helical
indentation marks, nicks and corrosion pitting on the surface of the wire.
Maximum percentage reduction in core wire diameter: 41.53%.
4.1.2.1.3. Strand 3. 4.1.2.1.3.1. Outer wires. The galvanized round steel rope wire sample on physical examination revealed abra-
sive & plastic wear, helical indentation marks, nicks and corrosion pitting on the surface of the wire.
Maximum percentage reduction in outer wire diameter: 23.77%.
4.1.2.1.3.2. Inner wires. The galvanized inner core wires sample on physical examination revealed abrasive & plastic wear, helical
indentation marks, nicks and corrosion pitting on the surface of the wire.
Maximum percentage reduction in core wire diameter: 12.95%.
4.1.2.1.4. Strand 4. 4.1.2.1.4.1. Outer wires. The galvanized round steel rope wire sample on physical examination revealed
abrasive & plastic wear, helical indentation marks, nicks and corrosion pitting on the surface of the wire.
Maximum percentage reduction in outer wire diameter: 29.27%.
4.1.2.1.4.2. Inner wires. The galvanized inner core wires sample on physical examination revealed abrasive & plastic wear, helical
indentation marks, nicks and corrosion pitting on the surface of the wire.
Maximum percentage reduction in core wire diameter: 8.29%.
4.1.2.1.5. Strand 5. 4.1.2.1.5.1. Outer wires. The galvanized round steel rope wire sample on physical examination revealed
abrasive & plastic wear, helical indentation marks, nicks and corrosion pitting on the surface of the wire.
Maximum percentage reduction in outer wire diameter: 25.85%.
4.1.2.1.5.2. Inner wires. The galvanized inner core wires sample on physical examination revealed abrasive & plastic wear, helical
indentation marks, nicks and corrosion pitting on the surface of the wire.
Maximum percentage reduction in core wire diameter: 34.71%.
4.1.2.1.6. Strand 6. 4.1.2.1.6.1. Outer wires. The galvanized round steel rope wire sample on physical examination revealed
abrasive & plastic wear, helical indentation marks, nicks and corrosion pitting on the surface of the wire.
Maximum percentage reduction in outer wire diameter: 22.05%.
4.1.2.1.6.2. Inner wires. The galvanized inner core wires sample on physical examination revealed abrasive & plastic wear, helical
indentation marks, nicks and corrosion pitting on the surface of the wire.
Maximum percentage reduction in core wire diameter: 19.17%.

4.1.2.2. Used fresh rope. The galvanized round steel rope wire sample on physical examination revealed light helical indentation
marks and no any type of wear & tear on the surface of the wire. The Maximum percentage reduction in wire diameter was
satisfactory and as per standards and DGMS guidelines.
298 R.P. Singh et al. / Engineering Failure Analysis 70 (2016) 290–304

4.1.3. Lubrication content in FMC wire rope

Broken end
Retention of lubricant in fibre main core.
Percentage retention of lubricant in FMC = 6.43%.
The lubrication condition of the wire rope has been examined as per IS: 6594-1977. The lubrication condition was found
dry.
Used fresh rope
Retention of lubricant in fibre main core.
Percentage retention of lubricant in FMC = 9.17%.
The lubrication condition of the wire rope has been examined as per IS: 6594-1977. The lubrication condition does not
confirm to IS: 6594-1977.

4.1.4. Micro-examination

4.1.4.1. Broken end. The broken sample after cutting, grinding and polishing was examined under the microscope in an un-etched
condition. The sample revealed no harmful inclusion as per IS: 4163-1982 except corrosion pitting & abrasive wear shown in
Fig. 8 on the surface of the wire.

Depth of wear

Corrosion pittings

Stress corrosion

Fig. 17. Micro-examination of the broken rope in un-etched condition.

 R.P. Singh et al. / Engineering Failure Analysis 70 (2016) 290–304 299

After etching in 1% nital solution the transverse section revealed uniform distribution of sorbitic pearlitic structure with forma-
tion of martensitic structure in outer side and the longitudinal section revealed good cold drawn structure of high carbon steel
with peripheral damage of zinc coating, stress corrosion pittings and martensite formation in the fracture end as shown in
Fig. 17 and Fig. 18.

4.1.4.2. Micro-examination of used fresh rope. The New rope (fresh piece) sample after cutting, grinding and polishing was examined
under the microscope in an un-etched condition. The sample revealed no harmful inclusion as per IS: 4163-1982.

Martensitic structure Martensitic Structure

Corrosion Pittings Damage of Zinc coating
& Corrosion Pitting

Martensitic Structure Martensitic Structure

Tempered martensite

Corrosion pittings

Cold Drawn Structure

Sorbitic - pearlitic
structure
Martensitic Structure Martensitic Structure

Martensite formation on fracture end

Fig. 18. Micro-examination of the broken rope in etched condition.

300 R.P. Singh et al. / Engineering Failure Analysis 70 (2016) 290–304

Sorbitic - pearlitic structure in transverse section Good cold drawn structure in the longitudinal section

Fig. 19. Micro-examination of the used fresh rope in etched condition.

After etching in 1% nital solution the transverse section revealed uniform distribution of sorbitic pearlitic structure and the
longitudinal section revealed good cold drawn structure of high carbon steel shown in Fig. 19.

4.1.5. Chemical analysis (in percentage)

Fracture rope

Element % of element

Carbon 0.776
Manganese 0.89
Silicon 0.224
Sulphur 0.020
Phosphorus 0.032
Nickel 0.015
Copper 0.040
Chromium 0.030

Used fresh rope

Element % of element

Carbon 0.776
Manganese 0.89
Silicon 0.224
Sulphur 0.020
Phosphorus 0.032
Nickel 0.015
Copper 0.040
Chromium 0.030

The chemical composition are accordance with the IS standards.

4.2. Case study – II

Two samples of failed guide rope of 32 mm diameter (6 pit east side & 6 pit west side) of 32 mm diameter from a colliery
have been received for investigating the causes of its failure from Katras Area, BCCL [15]. The construction of guide rope sample
was six over one (6/1).

4.2.1. Macro examination

The visual examination of the received samples showed that the guide rope was physically in poor condition with fracture
of wire rod, wear, corrosion & pittings on the surface of the rope. After cleaning, the guide rope was found to be in very poor
condition due to heavy corrosion and pitting as shown in Fig. 20A, B & C.
 R.P. Singh et al. / Engineering Failure Analysis 70 (2016) 290–304 301

Failure broken end

Failure broken end

A) Failure guide rope of 6pit mine B) Heavy corrosion pittings

Failure broken end

C) Heavy corrosion pittings

Fig. 20. A: Failure guide rope of 6 pit mine B: Heavy corrosion pittings C: Heavy corrosion pittings.

4.2.1.1. Broken end of 6 pit west side. The fractured guide rope sample on visual examination revealed that one wire has been broken
from below one feet of fracture end portion of the rope. The nature of failure seems to be tensile in nature shown in Figs. 21, 22
and 23.

4.2.1.2. Broken end of 6 pit east side. The fractured guide rope sample on visual examination revealed that the nature of failure of the
wires Fig. 24 was tensile and fatigue.

Fig. 21. Failure broken end of 6 pit west side.

Fig. 22. After cleaning the broken rope wire.

302 R.P. Singh et al. / Engineering Failure Analysis 70 (2016) 290–304

Pittings

Crack & pittings

Fig. 23. Crack & corrosion pittings on the west side guide rope wire.

4.2.2. Examination of wear & corrosion

4.2.2.1. 6 pit west side

4.2.2.1.1. Outer wire. The un-galvanized guide rope wire sample on physical examination revealed heavy abrasive and plastic
wear, helical indentation marks and severe corrosion pittings & crack on the surface of the wire.
Max. Percentage reduction in diameter: 94.97%
4.2.2.1.2. Core. The un-galvanized guide rope wire sample on physical examination revealed abrasive wear, helical indentation
marks and deep corrosion pittings on the surface of the wire.
Max. Percentage reduction in diameter: 32.53%

4.2.2.2. 6 pit east side

4.2.2.2.1. Outer wire. The un-galvanized guide rope wire sample on physical examination revealed heavy abrasive and plastic
wear, helical indentation marks and deep corrosion pittings on the surface of the wire.
Max. Percentage reduction in diameter: 59.90%
4.2.2.2.2. Core. The un-galvanized guide rope wire sample on physical examination revealed abrasive wear, helical indentation
marks and corrosion pittings on the surface of the wire.
Max. Percentage reduction in diameter: 10.67%

4.2.3. Lubrication content in guide rope

The lubrication condition of the given guide rope sample has been examined and calculated on the basis of mass factor as per
IS: 6594-2001 & IS: 3623-1978. The lubrication condition was found insufficient i.e. K = 0.449796 kg/100 m-mm2. The mass of
the rope as per IS 3623:1978 was also found to be below the prescribed value of 512 kg/100 m.
Further, the rope was opened for the visual examination of the lubrication condition. The lubrication condition was found
insufficient.

4.2.4. Micro-examination

4.2.4.1. Failure broken end. The broken sample after cutting, grinding and polishing was examined under the microscope in an un-
etched condition. The sample revealed no harmful inclusion as per IS: 4163–1982.
After etching in 1% nital solution the transverse section and longitudinal section revealed Normalized structure with uniform
distribution of fine pearlitic in ferrite matrices of low carbon steel. The different types of crack and corrosion pittings revealed are
as follows (Fig. 25A–F):
i) Intergranular corrosion cracks with corrosion pittings,
ii) Intergranular corrosion pitting,
iii) Uniform corrosion with corrosion pitting along the grain and
iv) Distorted grain on tensile fracture end.

Fig. 24. Failure broken end of 6 pit east side.

 R.P. Singh et al. / Engineering Failure Analysis 70 (2016) 290–304 303

A) Intergranular Corrosion crack 5x B) Intergranular corrosion pitting 10x

D) Intergranular Corrosion crack with corrosion

C) Distorted grain on Tensile fracture end 10x
pittings 5x

E) Normalized structure with corrosion pitting along the F) Normalized structure with corrosion pitting along
grain 20x the grain 20x

Fig. 25. Crack & corrosion pittings.

4.2.5. Chemical analysis (in percentage)

Broken end

Element % of element

Carbon 0.1600
Manganese 0.6200
Silicon 0.0710
Sulphur 0.0399
Phosphorus 0.0217
Chromium 0.0310
Nickel 0.0015
Copper 0.0058

According to IS 3623-1978 (reaffirmed 2012), the phosphorus and sulphur content of the steel shall not be more than 0.05%.
304 R.P. Singh et al. / Engineering Failure Analysis 70 (2016) 290–304

5. Conclusion

5.1. Case study – I

Physical examination of broken wire rope revealed that the condition of wire rope was very poor. Micro-examination of the
broken end shows the formation of martensite on the surface, stress corrosion pitting along with damage of zinc coating indica-
tive of deterioration of wire rope strength. Further the excessive reduction in wire diameter more than 58% and poor lubrication
may be responsible for its failure after sudden impact of load on it, which is further corroborated from the tensile and fatigue
nature of fracture end of the wires.

5.2. Case study - II

The micro-examination studies show intergranular corrosion cracks & pittings and uniform corrosion along the grain. The grain
has also been distorted revealing the exposure to tensile load. The high reduction in diameter (94.97%) leads to fracture and
thereby failure of tensile nature (indicative from the fracture end which is of cup and cone nature). Further the poor lubrication
of the guide rope may lead to intermittent friction of wires forming nicks, prone to corrosion of the wires. The chemical (sulphur
& phosphorous content) composition is found to be slightly above the standard requirement.

Funding

This work was sponsored by Bharat Coking Coal Limited, Dhanbad, India (CNP/3064/2011-12 & CNP/2859/2010-11).

Acknowledgements

The authors are grateful to Director, CSIR-CIMFR, Dhanbad, INDIA for his kind permission to publish the paper. The views
expressed in the paper are of the authors' and not of the organizations they serve.

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[13] K.K. Schrems, Wear-related fatigue in a wire rope failure, J. Test. Eval. 22 (5) (September 1994) 490–499.
[14] CIMFR Report “Study on failure of 25 mm diameter 6X8FS construction winding rope of Victory 2 pit (south side) Bastacolla Area, BCCL, Dhanbad, India.” March
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[15] CIMFR Report “Failure analysis of 32 mm dia guide rope of 6 pit mine of Katras Choittodih Colliery, Katras Area, BCCL” April 16.