Failure Evaluation of the Broken Pump Shaft

Submitted to

Enfourtech Corporation Limited

By

Failure Analysis and Corrosion Technology (FACT) Research Team

National Metal and Materials Technology Center (MTEC)
National Science and Technology Development Agency (NSTDA)
FA-report of broken pump shaft__________________________________________________Page 2 of 9

1. Background Information

Enfourtech Co., Ltd. discovered a failure of the drive shaft of pump as shown in
Fig. 1. It was made of steel Grade DIN 1.7225. In service, the shaft was exposed to
ambient condition of oil. The drive shaft had broken during operation after being in service
for only 1 year. Furthermore, it is reported that there was fire at the time of failure.

In order to find out the root cause of failure of shaft, the company requested Failure
Analysis and Corrosion Technology (FACT) Research Team, National Metal and
Materials Technology Center (MTEC) to perform metallurgical failure analysis of the
shaft. The results obtained from the failure investigation will be used for prevention of the
catastrophic damage of the components in the future.

Fig. 1: The failed shaft after burning for determination of failure root cause.

2. Analytical Procedures
2.1 Visual Examination and Fracture Surface Examination
Physical appearances of the fracture surface of the sample were investigated by
visual examination with the aids of an optical stereo microscope. Then the component was
photographed by a digital camera. In addition, high magnification observation was
performed to examine the fracture mode by using a scanning electron microscope (SEM).

2.2 Cross Section and Microstructure Analysis

The sample was cross-sectioned through the locations where the crack were
originated. Afterwards, it was cold-mounted, polished and etched with 2% natal solution,
respectively. The microstructure analysis was performed under an optical reflected light
microscope. The main objective of the microstructure analysis is to determine the
microstructure appearance and any evidences associated with failure.

2.3 Chemical Analysis

An optical emission spectrometer was used to determine the bulk chemical
composition of the failed shaft to compare with that of the specification of DIN 1.7225
steel.

2.4 Hardness Testing

A hardness survey was made across the longitudinal section of the sample using
HV-scale hardness tester according to ASTM E92. A number of readings at various
locations across the cross section of the bolts were conducted in order to determine the
variation of hardness.
FA-report of broken pump shaft__________________________________________________Page 3 of 9

3. Results
3.1 Visual Examination and Fracture Surface Examination
The failed shaft for failure analysis is shown in Fig. 2. The as-fractured shaft was
thoroughly visually examined and with the aid of an optical stereo microscope. Visual
examination reveals that cracks are occurred in several areas of the threads (Fig. 3).

Fig. 2: The failed shaft for failure analysis.

Fig. 3: The cracks are originated in several areas of the thread roots.

The physical appearances with ductility and bent are also observed (Fig. 4a). The
fracture surface of the shaft was covered with a heavy dark-brown and blackish scale
which was occurred from burning (Fig. 4b). It exhibited fracture propagation direction by
radial marks. The lines of those radial marks present on the fracture surface indicate the
propagation direction of cracking outward from the origin. Figure 5 shows the closed view
of the fracture origin area, densely deposits were also observed.

a) Side view b) Fracture surface

Fig. 4: The side view and fracture surface of the shaft.
FA-report of broken pump shaft__________________________________________________Page 4 of 9

Fig. 5: Enlarge image at the fracture origin showing a scale buildup on the fracture surface.

High magnification observation of the broken shaft with SEM are shown in Fig. 6.
SEM image at area 1 in Fig. 5 show that cracking pattern of the scale buildup during
burning (Fig. 6a). Formation of adhered scale on fracture appearance, and then it cannot
determine the fracture mechanism. SEM image at area 2 in Fig. 5 exhibited shear dimple
rupture and cracking of material (Fig. 6b).

a) Area#1 in Fig. 5 b) Area#2 in Fig. 5

Fig. 6: SEM image showing the surface morphology at a fracture origin site.

3.2 Cross Section and Microstructure Analysis

The sample was longitudinally sectioned through the fracture origin as in Fig. 7.
Microstructures of the failed shaft are shown in Figs. 8-10. The material structure of the
used pump shaft shows a combination of ferrite and pearlite (Fig. 8) typical for a
normalized (annealed) material. Close observation at the fracture origin and at the center of
at the fracture surface area revealed the decarburization of pearlite (Figs. 9-10). This
phenomenon might occur from the exposure to heat after the cracking of the shaft.
FA-report of broken pump shaft__________________________________________________Page 5 of 9

Fig. 7: The longitudinally sectioned through the fracture origin sample for microstructure
analysis.

Fig. 8: The microstructure of shaft shows a combination of ferrite and pearlite.

FA-report of broken pump shaft__________________________________________________Page 6 of 9

Fig. 9: The microstructure at the fracture origin of shaft shows a sign of decarburization of
pearlitic structure.

Fig. 10: The microstructure at the center of fracture surface of shaft shows a sign of
decarburization of pearlitic structure under the scale buildup layer.
 FA-report of broken pump shaft__________________________________________________Page 7 of 9

3.3 Chemical Analysis

The optical emission spectrometer was used to determine the chemical composition
of the bulk of the failed shaft in comparison to that of the DIN 1.7225 specification. The
results of analysis are shown in Table 1. The results reveal that the shaft has chemical
compositions in accordance to the specification of DIN 1.7225.

Table 1: Chemical compositions of the pump shaft specimen

Element C Mn P S Si Cr Mo
Pump shaft 0.44 0.79 0.006 0.007 0.22 1.04 0.19
DIN 1.7225 0.38- 0.6-0.9 0.025 0.035 0.40 0.90- 0.15-
0.45 Max. Max. Max. 1.20 0.30
Remarks: 1. Reported values are average values of 3 measurements
2. Precision is up to the second decimal

3.4 Hardness Testing

A hardness survey was made across the longitudinal section of the shaft using
hardness tester (100-g. load) in the HV scale according to ASTM E92. The indentation site
for hardness measurement are showed in Fig. 11. The hardness values are given in Fig. 12.
The lower hardness at the outer surface is consistent with the presence of the carburized
structure of pearlite.

Fig. 11: The longitudinal section of the shaft showing the indentation positions.

Fig. 12: Hardness values of the longitudinal section shaft.

FA-report of broken pump shaft__________________________________________________Page 8 of 9

4. Discussion
Numerous machine components, including the rotor shaft of a centrifugal pump,
are loadbearing structures. Since the shaft experiences fluctuating load, fatigue is a
common source of the failure. Evidence of fatigue failure is often traceable to the visible
beach lines on the fractured surface.
It is worth noting that the fracture plane is oriented almost perpendicular to the
longitudinal plane of the pump shaft, as shown in Fig. 4. Such orientation of the fatigue
fracture plane is indicative of the Mode-I (opening) crack propagation under the cyclic
loading. However, it cannot be identify the mode of fracture due to loss of fractographic
features during post fracture firing. In the as-received condition, the fracture surfaces of
shaft was covered with scale deposits.
Radial marks could be distinguished on the surface exposed. In macroscopic scale,
the crack origins were located at the thread portion of the shaft (Fig. 4b). Radial marks
appeared to point toward a region at the thread root where the crack was likely initiated.
Figures 9-10 show the microstructure of burnt material in the region near its
surface. As can be clearly seen the decarburization of pearlite can also be observed. In the
context of the present failure, it is probable that such microstructure can be considered as a
surface phenomenon of the fired shaft. The lower hardness at the decarburization area,
even more, confirmed the burning condition.
The composition of the shaft material was found conforming to the specification.

5. Conclusion
According to the above analysis, the failure was occurred at the thread portion of
the shaft. From fracture surface analysis, it cannot determine the fracture mechanism due
to the formation of adhered scale on fracture appearance. From microstructure analysis, the
decarburization of pearlite were found close to the crack initiation. It indicates that it might
generate from the exposure to heat during burning after the cracking of the shaft.
FA-report of broken pump shaft__________________________________________________Page 9 of 9

Tested and Analyzed by:

(Mr.Warapong Tongkratok) (Mr.Kosit Wongpinkaew)

Assistant Engineer Senior Engineer

Approved by:
(Mr.Siam Kaewkumsai)
Project Manager

Remarks
1. MTEC does not allow any alteration or modification of this report, or any part of this report,
without prior formal written permission from MTEC.
2. MTEC will not accept liability for any damage whatsoever, resulting directly or indirectly,
from using data, results, conclusions or recommendations in this report for the purpose of
designing, manufacturing or for other purposes.
3. Testing results are only valid for the specimens tested.
4. This report is not a certificate of product quality