Forensic Engineering / Metallurgical Failure Analysis

Forensic Engineering / Metallurgical Failure Analysis

Forensic Engineering is the application of the art

and science of engineering towards failure
analysis and accident investigations. Forensic
engineering provides solutions to the cause of the
failure and/or accident and makes
recommendations based on standards and sound
engineering practice in an attempt to prevent
future failures from occurring.

Testlabs International Ltd. engineers routinely

perform forensic engineering in the fields of:
•Metallurgical Failure Analysis (failure of metallic
components) Forensic engineering of a
ruptured pressurized rail tank car
•Polymeric Failure Analysis (failure of plastic
components)
•Protective Coating Failures
•Corrosion Engineering
 Forensic Engineering / Metallurgical Failure Analysis

Representative failures that we have analyzed include those

occurring due to:
•fatigue
•stress overload
•creep and stress rupture
•corrosion related failure (see corrosion engineering)
•wear failures
fretting
spalling
galling
cavitation
rolling contact fatigue
•brittle fracture
•poor design
•poor heat treatment "Fishmouth" Rupture of a
•poor mechanical properties Boiler Feed Water Tube
•Poor material selection
Combination of mismatched dissimilar materials
 Forensic Engineering / Metallurgical Failure Analysis
Case Histories

Fatigue Failure
Specimen: 1.0-in. diameter x 2.75-
in. square head steel pins from
agricultural equipment.

Material: Specified as AISI/SAE

4140 low allow carbon steel.

Background: The pins were

specified to be carbonitrided to
create a 0.003-in. case hardened
layer for increased wear resistance.
Fatigue fracture of an AISI/SAE 4140
The pins were fracturing at a point low alloy carbon steel pin
of impact loading approximately 1.5
- 2.0-in. from the head of the pin.
 Forensic Engineering / Metallurgical Failure Analysis

Findings: Examination of the pin fracture

surface (shown above) revealed the
presence of beach marks across
approximately 90% of the pin cross-
section. Beach marks are fracture surface
features indicating progressive crack
growth, or fatigue crack propagation. The
bolts were failing due to fatigue with the
cracks initiating at a point of impact
loading. Micro-hardness testing of the
case hardened layer revealed a case
hardness in the range of Rockwell C 40 -
50. Carbonitriding of the surface had Fatigue fracture of an AISI/SAE 4140
increased the wear resistance but at the low alloy carbon steel pin
cost of reducing impact strength. The
hardened case did not have sufficient
ductility to withstand the repeated
impact/bending loads imposed upon the
pins.
 Forensic Engineering / Metallurgical Failure Analysis
Case Histories
Spalling of Nitrided Surface Layer
Specimen:
Nitrided Landing Gear Component (Aerospace
Industry)

Material:
Age-Hardenable Nitriding Steel

Background:
The nitrided component was part of a landing gear
on an aircraft. Inspection of the component revealed
it had suffered surface damage (Figure A).
Service Life: The landing gear had been in service
for approximately 500 hours, with a total of 596
landings. Upon which time it had been removed from
the aircraft and subjected to several load tests,
estimated at approximately 1000 - 3000 landing load •Overall view of the localized damage observed
on the landing gear component (Magnification ˜
40X),
cycles. The landing gear assembly was then b) Scanning Electron Microscopy (SEM) image of
the surface spalling of the nitrided surface layer
disassembled, at which point it was noticed that one (Magnification ˜ 500X)

of the four nitrided components had been damaged.

 Forensic Engineering / Metallurgical Failure Analysis

Findings: The localized damage

observed on the surface of the
nitrided component was caused by
an excessively hard nitride surface
layer (1117 - 1148HK). The impact
loading the landing gear absorbed
as a result of the aircraft touching
down during landing, in conjunction
with the sliding motion between the
nitrided surface and landing gear
parts had resulted in the initiation of
subsurface cracking. The
subsurface cracking, propagated
parallel to the surface and led to the
spalling of the nitride layer on the
surface (Figure B).
•Overall view of the localized damage observed on the landing gear
component (Magnification ˜ 40X),
b) Scanning Electron Microscopy (SEM) image of the surface spalling of
the nitrided surface layer (Magnification ˜ 500X)
 Forensic Engineering / Metallurgical Failure Analysis
Case Histories
Cap Screw Failure – Hydrogen Embrittlement

Specimen:
¾-inch Cap Screw from Automobile Suspension
System
Background:
A metallurgical failure analysis was conducted for
a number of suspension cap screws. The cap
screws had been zinc plated (galvanized), and
had originated from an off-shore manufacturer.
Service Life:
Mileage at the time of failure ranged from 30,000
to 50,000 miles.
Findings:
The forensic engineering failure analysis of the
cap screw found that the re-occurring under-head
catastrophic failures were caused by hydrogen
embrittlement originating most likely from a poor
cleaning and galvanizing procedure during the
manufacture of the cap screws.
 Forensic Engineering / Metallurgical Failure Analysis
Case Histories
Graphitic Corrosion
Specimen:
8.25-in. ID cast iron water pipe

Material:
Ferritic-pearlitic Gray Cast Iron

Environment:
Buried in soil

Background:
The 8.25-in. ID water pipe was part
of a riser serving a sprinkler system.
The pipe, which was buried
Longitudinal cross-section through the wall of a
underground, had fractured into two cast iron pipe, exhibiting severe graphitic corrosion,
sections. i.e. dissolution of the iron from the cast iron pipe
leaving behind layers of intact graphite.
Service Life: The cast iron piping
had been in service for
approximately 30 years.
 Forensic Engineering / Metallurgical Failure Analysis

Findings:
Examination of a
longitudinal cross-section
cut through the pipe wall
(shown above) revealed
several regions of severe
localized corrosion in
which the iron constituent
of the cast iron had Longitudinal cross-section through the wall of
dissolved away leaving
a cast iron pipe, exhibiting severe graphitic
only a layer of brittle and
weak graphite. This type of
corrosion, i.e. dissolution of the iron from the
cast iron deterioration is cast iron pipe leaving behind layers of intact
known as graphitic graphite.
corrosion.
A metallographic examination of a cross-section transverse to the fracture surface
revealed the presence of a wall thickness composed entirely of graphite. The
remaining graphite is extremely brittle and weak. Thus, slight loading imposed
upon the pipe could result in the fracture of the pipe.
 Forensic Engineering / Metallurgical Failure Analysis
Case Histories

Cavitation Damage
Specimen:
Cast iron injection housing

Material:
ASTM A 536 Grade 65-45-12 ductile
iron
Background:
The cast iron injection piston housing
had been subject to approximately 1
million cycles in a plastic injection
moulding system. Seven identical a) Region of cavitation damage on a
cast iron injection housing,
failures of localized damage to the ring
seal on identical cast iron injection
piston housings had occurred.
Service Life:
Approximately 1.5 years, or 1 million
cycles
 Forensic Engineering / Metallurgical Failure Analysis

Findings:
Visual examination of the region of
localized damage revealed areas of
large "craters" surrounded by
smaller craters or micro-pits. Such
damage is typical of cavitation
damage. Cavitation damage is
defined as the wearing away of
metal through the formation and
collapse of cavities in a liquid,
subject to rapid and intense
pressure changes. In this situation,
the liquid was the oil used to
lubricate the piston and housing.
The very rapid movement of the
piston through the housing caused
the rapid and intense pressure
changes in the oil, thus causing
a) Region of cavitation damage on a cast iron injection housing,
cavitation damage. b) Scanning electron microscopy image of a typical "cavity"
caused by cavitation damage
 Forensic Engineering / Metallurgical Failure Analysis
Case Histories
Chemical Degradation of High-Density Polyethylene

Specimen:
High-density Polyethylene Sulfuric
Acid Storage Tank (mining industry)
Material:
High-density Polyethylene
Background:
The plastic sulfuric acid storage tank a) Interior surface of the HDPE
had been in service for sulfuric acid tank which had
approximately 15 years. An clearly suffered chemical attack
during the 15 years of service
inspection of the tank was performed
to determine if it was still suitable for
further service.
Service Life:
Approximately 15 years.
 Forensic Engineering / Metallurgical Failure Analysis

Findings:
Examination of the interior of
the tank revealed the interior
surface was riddled with
surface cracking - caused by
chemical attack of the sulfuric
acid on the HDPE. A cross-
section through the tank wall
revealed the presence of
micro-cracking. Based upon
the condition of the tank, it
was deemed unfit for further
service and it was
recommended that the tanks a) Interior surface of the HDPE sulfuric acid tank
be replaced immediately. which had clearly suffered chemical attack during
the 15 years of service, b) A cross-section through
the tank wall revealed the presence of micro-
cracks.
 Forensic Engineering / Metallurgical Failure Analysis

Corrosion Compromising Integrity of Structural Steel Floor

Location:
Crawlspace beneath a grocery store

Material:
Wide Flange Steel Beams, Steel Decking,
Concrete Floor

Background:
A corrosion investigation was performed in a
100,000 ft2 store crawlspace which was built over
what was once a low lying marsh and landfill site.
The wide flange steel beams had severely
corroded reducing their life assessment to only
an additional 2 to 5 years. Additionally, severe
deterioration to the underside of the floor was
detected, requiring immediate repair.

Service Life:
The grocery store was built 15 years prior to the
corrosion inspection.
 Forensic Engineering / Metallurgical Failure Analysis

Corrosion Compromising Integrity of

Structural Steel Floor

Findings:
The corrosion inspection concluded that
there was virtually no air movement in
the crawlspace area. The lack of air
movement combined with the extremely
wet environment of the crawlspace had
resulted in this severe condition.
Recommendations were provided for the
repair of the concrete and to increase
airflow and reduce moisture in the
crawlspace to mitigate the corrosion
problem and increase the life expectancy
of the floor structure.
 Forensic Engineering / Metallurgical Failure Analysis

Severe Graphitic Corrosion in Cast Iron Drain Lines in a Health Care Facility
Environment:
Vertical and horizontal waste water drain line located in a health
care facility. Pipes were located in both finished walls, and in the
crawl space.

Material:
Cast iron drain lines are to conform to ASTM A888, the analyzed
pipe did not conform to these specifications.

Manufacturer:
Titan

Installation Date:
approx. 1983

Service Life:
approx. 23 years

Mode of Failure:
Severe graphitic corrosion, and cracking due to the use of a cast
iron material which did not meet specifications for this use.
 Forensic Engineering / Metallurgical Failure Analysis

Severe Graphitic Corrosion in

Cast Iron Drain Lines in a Health
Care Facility

Findings:
The drain line system contained
multiple longitudinal and
transverse cracks in the cast iron
piping. In addition, sever graphitic
corrosion had reduced the wall
thickness of piping in some
locations to 1/16-inch or less,
creating holes and leak sites, in
some locations, appearing as
‘carbunkle’ leak sites.
Corrosion and Cracking of a Titan 3 1/8 inch Drain Line
Elbow. This elbow was likely in a horizontal position as
this portion of the pipe wall had thinned to 1/16 inch
or less
 Forensic Engineering / Metallurgical Failure Analysis

Chloride Stress Corrosion Cracking

Specimen:
1.25-in. OD tubing

Material:
Type 316L stainless steel, bright solution
annealed.

Environment:
The tubes were from a liquor heat exchanger
in a pulp and paper mill.

Background: The tubes were from an upper

liquor heat exchanger that operated at 200 psi
and approximately 375°F (190°C) with steam
on the outside and liquor on the inside of the
tubes. Periodically, the tubing in the heat
exchanger was acid cleaned by recirculating
inhibited acid - usually hydrochloric acid (HCl).

Service Life:
Approximately 3 months
 Forensic Engineering / Metallurgical Failure Analysis

Chloride Stress Corrosion Cracking

a) 1.25-in. OD Type 316 stainless

steel tubing,
b) View of the cracking on the outer
surface of the tubing - there was
approximately 10 - 12 cracks per
linear inch,
c) Metallographic cross-section
through the tubing wall revealed the
presence of fine, branched stress
corrosion cracks
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Forensic Engineering / Metallurgical Failure Analysis
Forensic Engineering / Metallurgical Failure Analysis
Forensic Engineering / Metallurgical Failure Analysis
Forensic Engineering / Metallurgical Failure Analysis
Forensic Engineering / Metallurgical Failure Analysis
Forensic Engineering / Metallurgical Failure Analysis
Forensic Engineering / Metallurgical Failure Analysis
Forensic Engineering / Metallurgical Failure Analysis
Forensic Engineering / Metallurgical Failure Analysis
Forensic Engineering / Metallurgical Failure Analysis