bar ne Dbig2' bp 1 Design datisonsiecr | Fi “ eee cose ees lca ana sea us SSenobe ee taki oe Sa ena rs Shane Seer Seat echsices ctha nome Se scesie eat Sire cittn utes issu este Sree canes eee came eee ee ee Seeeeee hao caer an ree stale tem Beta product form Type o [onzig Lage, Bursa Faken Seperation sparaton, Cavity shrinkage nelson ‘Gstngs; Foren, ae a mico shrinkage. Cary shrinkage, Seperation aus ‘Haleandahst- Bape crating, Lamination Flakes ‘Exinnons and drawn pets Bags cracking Seam, Steps Conta bust Pee 3- Manufacturing: Its defects introduced during the manufacturing process, Some examples of such manufacturing/installation anomalies are listed below Metal Removal Processes ‘Cracks due to rough machining Chatter or checking dus to spss and feeds “Miersteutural damage duet dll ol - Grinding burn - Electrical discharge machining recast layer cracking “Electrochemical machining intorgranular attack “Residual stress cracking due to overhes Metalworking Processes * Cracking, o necking due to forming/doep drawing “Laps due to thread rollingspinning fool marks and scratches from forming Residual stress cracking due to flow forming «Microstructural damage due to shearing, blanking, piercing Laps and cracks due to shot peening qi nshne zo sk oe11/01/1439 Heat Treatment Grain growth Tncomplste phase transformation Quench cracks alge he Decarburization : Inadequate precipitation Sonsitized microtracture Inbomogeneites im microstructure ps of properties die to overheating during pest plating bake Welding Track of fasoe rite cracking in heat affected none (HAZ) Sensitized HAZ ‘Residual stross cracking ‘Slag ielusions| ‘Cratering of fusion zone at endpoint Filler metal contour out of speciation Hor cracking Cracking at low exporure temperatures Hydrogen embrittlement due fo moisture contamination [iguid metal embritlement from plating contamination 4 Assembly defects: Including assembly at Factory/Installation at Site: Misalignment Missing/wrong parts Improper fit-up Inappropriate fastening system, improper torque Improper tools Inappropriate modification Inadequate surface preparation1101/1439 2-dellechion in arms . fobetione Ibu: add te tensik Ipaclsinsi Shuler & sis physical root Couses + 1 is design q anal as: REAL CASSES Example 1: Ice Cream Drink Mixer Blade Failures. Excessive assembly stresses ign Excess bl and inappropriate detail design caused the Recommendet von « Carrectite action » sh arebl Formny | Caase resthel stess , Checls Jv n of mixer plecle Comhaned p26) sembly st@ss and Materic. aia Alesis hee as wave stfess # wo Hess } Goold wor King a vibrchry less 2—————— 11/01/1439 Example 1: Ice Cream Drink Mixer Blade Failures. excessive assembly stresses and inappropriate detail design caused the failures. ‘The mixer blade is slightly deformed by the contact between tl ‘the bottom of the assembly and the bends at the bottom. ‘shoulders of the two mixer arms. A- The screw. that fastens the wavy washer and the mixer blade to the spindle in the centre of the assembly places an upward force on the bottoms of the arms. 2. This results in the observed inward deflection of the arms. 3- Bending force places the inside radii of the two shoulders in tension. 4- Rotational forces add to the tensile loads on the inside radii of the shoulders. ‘Analysis: aavinies revealed multiple fatigue crack origins on the inside radii of the bends at the bottom Shoulders . » Shaulders on the arms were cold bent, introducing tensile residual stresses othe inside radii of the shoulders and ereating a localized arcu of fatigue susceptibility due to the inherent notch sensitivity of cold-formed 300 series stainless steel. ap pu ew Usde7 ‘The physical Root Cause: eos L-Itis design deficiency of the mixer blade, which defined two bend areas that contained tensile residual stresses: Tensile assembly stresses: and a material cold working that added. to the normal operating rotational and vibratory stresses. Corrective-action: gesbieg Sdere pitde nomad wane! b> Ten 1- Recommendations included the addition of a stand-off washer between the wavy washer and the bottom shoulders of the blade, 2-Or modification of the shape of the wavy washer to prevent contact with the blade shoulders as assembled.ee 3 plades —» elie Example 2: High-performance air compressor Failure Deficiencies Due to Improper Service Conditions Due to inlet-flow blockage on a high-performance air compressor resultang An ‘excessive cyclic loads applied to the blades causing blade and drive shaft failures Maes alysis rovealed both the compressor rotor and the shaft sustained fatigue failures ai JayeiCe J j _hemat Fohigue FE , fiance Cate latent notin ne C hake daily Gly cectiow yze inlet “ Fe bipu crac K 4 _, unblane compressor rotor. Arrows indleate fractured portions of blades. Failed Robot it? 24 1.2111011439 physical —s Cadique Farlé r Ne. PX Thine >» fumon —> Matiaeé | 45 —> fadent = h ch Compressor blade fracture surface showing fatigue origins on low pressure (i.e., right) side of blade, as indicated by the arrows. Failed compressor rotor shaft. Fracture occurred at radius between large and small diameters. Arrows indicate some of