Objective 8: Failure Analysis Procedures

1. Secure the area (similar to a police investigation)

2. Collect background information and documentation
➢ Service History
3. Nondestructive testing
➢ Visual inspection is sometimes all you need!
4. Mechanical testing
➢ Is the material in-spec? (compare results to specifications)
➢ Confirm that the working stress is below the UTS (for overloading) and the
endurance limit (for fatigue)
➢ Take stress concentration into account!
5. Chemical analysis
➢ Is the material in-spec? (compare results to specifications)
 Objective 8: Failure Analysis Procedures
6. Metallographic testing
➢ Sectioning and metallographic preparation (polishing and etching)
➢ Characterize the microstructure around the crack location
7. Fractographic analysis
➢ Examine the fracture surface to determine the fracture type and origin
8. Simulated service testing
➢ Very expensive! (ex: full-scale pipe burst test to replicate failure)
9. Write the report
➢ Analyze the evidence, make conclusions and recommendations
Collecting Background Information
• The crane had been in service for about five years on several building
sites and it had passed inspection 4 months before the incident. It
was on this new site for the past 3 months.
• The crane collapsed because of the fracture of 23 out of the 24 bolts
that connect the tower to the crane base.
• These bolts were made from high-strength steel and each bolt had a
diameter of 0.87 inches.
• There was evidence that some or all of the bolts may have been
slightly loose in service.
Nondestructive Testing
• A visual inspection was
thoroughly performed.

• It was found that the bolts

were fractured close to the
end of the threaded part.
Mechanical Testing and Stress Analysis
• Bolt material that was away from the fracture surface was tested in
tension, hardness, fatigue strength and fracture toughness.
➢ Test results complied with the material specification as required in
the design process.

• Stress analysis calculations confirmed that the design was sound and
that the proper bolt size and material were selected.
➢ The working stress was below the design stress in fatigue loading.
These should not have failed due to fatigue under normal conditions.
Chemical Analysis
• Material chemistry is consistent and complies with the material
specification.
Metallographic Analysis
• Longitudinal and transverse samples from the bolt at fracture were
sectioned, mounted and metallographically prepared.

• Optical microscopy showed an elongated microstructure in the

longitudinal direction of the bolts close to the crane head

➢Deformation implies severe work hardening effects

 Fractography
• The fracture surfaces of the bolts were investigated using a low
magnification optical microscope and a high magnification scanning
electron microscope.

• Beach marks were evident on all of the bolts

• Scanning electron micrographs showed striations
(microscopic lines similar to beach marks)

➢ Failure caused by fatigue (cyclic loading)

Judging the Cause of Failure
• The failure likely occurred mainly because the bolts were slack, not
properly tightened at the start of this new job 3 months ago.
• Due to the normal operation of the crane, the bolts close to the head
were deformed and therefore severely cold worked.
• The work-hardened material exhibited less fracture toughness
properties due to the increased strength and decreased ductility.
• Due to the cyclic nature of loading, fatigue developed and propagated
in the work hardened material. This led to fatigue fracture of the
bolts.
Recommendation
• The initial tightening of bolts should be checked and inspected on a
regular basis

• Scheduled non-destructive testing could be beneficial in detecting

fatigue cracks before they propagate beyond a critical length that can
lead to instantaneous failure