Practical 3

Individual Materials Expertise

Overview of practical

You will find several failed metal components from your nearest environment and examine
them metallographically and in any other ways that seem appropriate. You will attempt to
determine the material used, and any likely processing routes and forming and joining
methods used to make the component. You will try to deduce service conditions (loading,
environment, etc.) from information available on the fracture surface or available by
microstructural examination. These all data help you in assigning cause (or causes) for
failure. You will then consider why that component was failed. In other words imagine that
you are a materials expert, and you will conduct the typical failure analysis. This practical has
three parts (2 h. per each). In the part I we will perform macroscopic examinations and select
the samples for microstructural evaluation. In the next parts we will examine the material of
component, its chemical composition, microstructure, hardness, etc. and we will identify the
likely reasons of failure.

Objectives

On completion of this practical, you will be able to:

 List the principal steps to follow in performing a failure analysis on any type of metal
part.
 Understand the role of visual examination in failure analysis.
 Comprehend the complexities of failure analysis and why great care must be taken
not to alter the physical appearance of critical areas of the failed part.
 Identify the various types and characteristics of failure mechanisms.

Choice of a component

One of the objects of the exercise is to look at a wide variety of components and materials.
Choose a component with this in mind. Try to find ferrous and non-ferrous materials,
components of both complex and simple shapes, subject to high stresses and low stresses,
high temperatures, corrosive environments, etc. You might, for example, look at:

Failed engine parts:

 The piston / connecting rod / crankshaft system - including the bearings.

 The cylinder / piston system - including the piston rings.
 The gearbox assembly.
 The engine housings.
 The various types of bearings.
 The cylinder head, camshaft, valve and guide assembly.
Failed tools and metal parts from:
 garden equipment
 home workshop
 garage

This list is not meant to be exclusive.

Method of the examination

Don't rush into cutting up the component. First of all look at it as a whole; does the surface
appear to have been machined, cast or what? General colour and appearance? Is it magnetic?
How dense is it?
Now think before you reach for the hacksaw. Is the surface likely to be treated ? Is it likely
to vary in any other way from place to place or with direction of section ? Choose the
cutting direction to examine this.
Now cut and, if necessary, mount the section in a cold mounting compound or Bakelite.
Grind and polish. Try some etchants. The ones that don't work might help with identification,
as well as any etchant that does reveal the microstructure. Examine first at low magnifications,
e.g. by eye or hand-lens, to see what large scale variations in microstructure there might be.
Draw what you see (not what you expect to see!) or take a digital image. Choose the
magnification(s) used to best show what is going on.
Would a hardness test help ? You might use the materials handbooks, to see what hardness
values various alloys have. These are often also useful in that they give information about the
usual applications of real alloys.

Safety note: Make sure you wear a laboratory coat, suitable gloves and eye-protection
when etching your samples.

Questions you should try to answer

1) What does the component do?

2) What are the principal "loads" on it (stresses, chemicals, temperature, wear, etc.)?
3) What other design constraints are there (shape, possible forming / joining methods, cost...)?
4) What type of material would you expect?
5) What did your examination of the component tell you about:
 What material was used?
 What heat treatment it was subject to?
 How was the surface treated?
 How was the component made?
6) What alternatives might have been used? Why weren't they?
7) How did the component fail?
8) How could it be improved?

Structure of the report

Your report should include the following items:

 Preliminary evaluation of the failed part – visual inspection (sketch with description of
fracture surface)
  Determination of failure mode
 Chemical analysis of the component material and any coatings and/or corrosion
products
 Selection of samples for microscopic examination
 Microstructural evaluation
 Formation of root-cause conclusions
 Recommendations for product modification (if any)

The report should also include necessary sketches or images of the components and
microstructures, at the most appropriate scale

Useful reference texts

"How Things Work" or similar.

ASM Materials Information, ASM Handbooks on-line, vol. 11, 2010.