Lab Iron for AFA Modules

The auditor will review the failed iron samples that the RTC/MPC will use for lab sessions. For
each AFA module listed below, circle which lab iron samples are available.

Due to difficulty in obtaining failed iron samples, the RTC/ MPC may use the same sample for
multiple uses, i.e.: a brittle fracture sample of a component may also be used as a brittle fracture
sample for fractures lab. Most of the 1st priority iron should be available before certification,
but no longer than a year after certification. 2nd priority iron should be gathered within three
years, and 3rd priority iron should be gathered as available over continuing years. It is intended
that collection of failed iron samples shall be an ongoing process for certified failure analysis
programs.

1. Principles of Fractures
Sample 1st Priority 2nd Priority 3rd Priority
Brittle fracture(s) X
Ductile fractures (s) X
Fatigue fracture (s) X
Bending X
Rotating bending X
Examples of stress raisers
Inclusions X
Pipe defect X
Shrinkage in casting X
Gas bubble in casting X
Identification marks X
In service damage X
Precracks X
Grinding X
Forging X
Rolling X
Straightening X
Heat treat quench crack X
2. Principles of Fractures (Review and Update)
Sample 1st Priority 2nd Priority 3rd Priority
Brittle fracture(s) X
Cleavage type fracture X
Intragranular type fracture X
Ductile fractures (s) X
Overload X
Fibrous tearing X
Radial tearing X
Impact shear X
Torsional shear X
Woody ductile X
Fatigue fracture (s) X
Axial or bending X
Reverse bending X
Rotating bending X
Torsional tensile 45 X
High cycle X
Low cycle X
Examples of stress raisers
Inclusions X
Pipe defect X
Shrinkage in casting X
Gas bubble in casting X
Identification marks X
In service damage X
Precracks
Grinding X
Forging X
Rolling X
Straightening X
Heat treat quench crack X

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3. Principles of Wear
Sample 1st Priority 2nd Priority 3rd Priority
Adhesive Wear X
Abrasive wear X
Cavitation X
Contact stress fatigue X
Sliding X
Rolling X
Corrosion X
Erosion X
Fretting / Fretting corrosion X
Stress Corrosion Cracking X

4. Engine Bearings
Sample 1st Priority 2nd Priority 3rd Priority
Contact stress fatigue X
Cavitation erosion X
Misalignment X
Bond separation X
Adhesive wear; all stages X
Glycol; coolant contamination X
Fuel dilution X
Abrasive wear X
Electrical discharge; arcing X
Fretting corrosion; hot spots X
Overlay sheeting X
Impact damage; "chomped" X

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5. Crankshafts
Sample 1st Priority 2nd Priority 3rd Priority
Bending fatigue X
Reverse bending fatigue X
Torsional fatigue X
Abrasive wear X
Adhesive wear X
Electric discharge pitting X
Crankshaft manufacturing problems
Welding X
Grinding crack X
Straightening crack X
Fillet profile X
Material flaw X

6. Engine valves
Sample 1st Priority 2nd Priority 3rd Priority
Head thermal fatigue cracking X
Head dishing / tuliping X
Head oxidation / scaling X
head/stem ductile fracture X
Stem transverse fatigue at keeper X
Head chordal fatigue - misalignment X*
Head chordal fatigue - overheating X*
Head/stem brittle stem fracture X
Head/stem brittle chordal fracture X
Head channeling/guttering X
Corrosion X
Head with foreign material damage X
Inertia weld fracture/separation X
* Lab iron pieces should include a chordal fracture due to misalignment or overheating to start
with. The missing type should be included as soon as possible.

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7. Pistons, Rings & Liners
Sample 1st Priority 2nd Priority 3rd Priority
Crown overheating - fuel X
Crown overheating - no oil/coolant X
Crown erosive wear - timing X
Crown erosive wear - impact damage X
Four corner skirt seizure X
Cold start skirt scuffing X
Ring flaking / fracture X
Skirt abrasive wear - particles in oil X
Rings/skirt abrasive wear - dirt in intake X
Cylinder liner corrosive wear X
Cylinder liner flange cracking X
Cylinder liner cavitration erosion X
Cylinder liner scaling - bad coolant X
Aluminum piston - brittle fracture X
Aluminum piston - fatigue fracture X
Ring band and insert - broken or loose X

8. Connecting Rods
Sample 1st Priority 2nd Priority 3rd Priority
Midshank fatigue fracture X
Midshank ductile fracture X
Imapact shear fracture X
Rod eye fracture X
Hydraulic lock - bent/failed rod X
Nut backed off - polished parting faces X
Con rod from bearing failure w/oil X
Con rod from bearing failure w/o oil X
Rod eye bushing failure X
One side loose - cap hinging example X
Rebuild error - one example X
Material problems
Forging lap X
Quench crack X

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9. Gears
Sample 1st Priority 2nd Priority 3rd Priority
Abrasive wear X
Adhesive wear X
Corrosive wear X
Misalignment X
Plastic yielding; rippling; ledging X
Contanct stress fatigue X
Case crushing X
Fatigue fracture X
Overload (fast) fracture
Ductile X
Brittle X
"Clamshell" impact chipping X
Brinelling / denting X
Normal wear X
Material / processing problems
Inclusions X
Machining X
Forging X
Heat treatment
Tip flaking X
Quench crack X

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10. Anti-friction Bearings
Sample 1st Priority 2nd Priority 3rd Priority
Abrasive wear X
Adhesive wear X
Corrosion X
Fretting/creep X
Contact stress fatigue X
Plastic yielding X
Electrical pitting / fluting X
Bearing damage due to
Handling X
Installation X
Removal X
Roller or race brittle fracture X
Roller or race fatigue fracture X
Loose tapered roller bearing X
Tight tapered roller bearing X
Out of round bearing X
Bearing / shaft misalignment X
Hot / dry look failure X
Hot / wet look failure X
Brinelling damage X
Foreign material damage/bruising X
Material / processing problems
Inclusion X
Heat treatment/soft X
Grinding X
Unfailed teaching samples
Ball bearing, variety X
Cylindrical roller bearing, variety X
Tapered roller bearing, variety X
Needle bearing, an example X
Spherical roller bearing, an example X

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11. Threaded Fasteners
Sample 1st Priority 2nd Priority 3rd Priority
Bending fatigue X
Reverse bending fatigue X
Ductile fracture due to overload X
Impact shear fracture X
Torsional shear fracture X
Stress corrosion cracking failure X
Nut backing off - bolt and nut X
Ductile fracture - over torqued X
Fretting / fretting corrosion X
Manufacturing flaws
Quench crack X
Seam / head burst X
Other forming defects X

12. Hydraulic Pumps & Motors1

Sample 1st Priority 2nd Priority 3rd Priority
Abrasive wear - 2 pump types X
Cavitation / Aaeration damage X
Adhesive wear damage X
Overheated fluid damage X
Overpressure damage X
Factory/rebuild assembly problem X
Dry start X
Brittle fractured pump parts X
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Include examples from gear, vane and piston pumps and motors wherever possible.

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13. Welds
Sample 1st Priority 2nd Priority 3rd Priority
Caterpillar Weld Defect Samples X
Examples of weld defects X
Examples of weld failures X

14. Shafts
Sample 1st Priority 2nd Priority 3rd Priority
Abrasive wear X
Adhesive wear X
Fretting / fretting corrosion X
Contact stress fatigue X
Brittle fracture
Transverse fracture X
Torsional fracture, 45 degree X
Ductile fracture X
Transverse torsionsal shear X
Fatigue fractures
Tensile load/transverse X
Longitudinal torsional shear X
Bending, transverse X
Reverse bending, transverse X
Rotating bending, transverse X
Torsional, 45 degree X
Reverse torsional, 45 two ways
"Monkey face" - holes X
"Starry" fracture - splines X
Material processing problems
Material inclusions X
Forging laps, hot spots X
Machining undercuts, grooves X
Heat treat internal rupture, q.crack X
Disassembly/assembly damage X

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15. Case Studies
Sample 1st Priority 2nd Priority 3rd Priority
Two AFA 1 Case Studies* X
Two AFA 2 Case Studies* X
Two AFA 3 Case Studies* X
* At least one good case study is required for each AFA course to be certified.

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