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Library of Failures
A library of classical material failure examples. Use the filter options to
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Materials

Aluminium Bronze Cast Iron Copper

Polymer Stainless Steel Steel

Failure Investigation
 Corrosion/Environment Cracking
Surface contamination Hot Cracking
Corrosion Fatigue Quench Cracking
microbially induced corrosion Stress Corrosion Cracking

Erosion/Wear Fatigue
Fretting Rolling contact fatigue
False brinelling Low cycle
Smearing Thermal fatigue

Material Defects Overload

Forging Defects Brittle
Welding Defect Ductile
Casting Defect

+ +
Torsional Overload of
Lifting Chain
Fractured chain used in
service to lift a skip used
inside a grit-blasting
chamber. The chain
consisted of 10mm links
with a C-hoo...
Stress Corrosion
Cracking of a Copper
Alloy Component
A copper alloy component
had cracked in service and
the cracks exhibited a
degree of ‘yawning’
(opening) indicative of the
pre...
+
Casting Defect in
Copper Alloy
Tapping Tee joints used in
water pipe applications
had been found to leak
from a pin hole defect
after installation in service.
Th...
 + +
Casting Defect in
Cast Steel flange
The crack propagation was
consistent with the
opening (and joining up)
of pre-existing
interdendritic shrinkage
cracks. A shrinkag...
+ +
Torsional Overload of
Threaded Shaft
A threaded shaft had
fractured at an end face of
a nut. The shaft had failed
by torsional overload and
evidence of twisting of th...
Degradation of
Kolsterising Coating
and associated
damage
One end of a control arm
used in a high
temperature environment
had seized in service. The
control arm exhibited an
eyelet, into w...
Torsional Overload of
Crankshaft Spline
The fracture surface was
relatively flat and displayed
radial arced markings on
the majority of the fracture
surface, and a coarse...
+
Fracture of
Aluminium
Component Due to a
Casting Defect
Examination of the
fracture at low
magnification revealed a
change in fracture surface
colour and form for
approximately two third...
+
Staged Overload of
Threaded
Component
Visual examination of the
fracture revealed the
initiation portion to be at
nominally 45°, which is
typical of shear. The
fractur...
 + + +
Reverse Engineering Quench Cracking of Overload Cracking of
of 1960s Locomotive Forging Gear
Component
A forging was found to be The gear flanks exhibited
A bell housing used on a cracked at inspection by large amounts of
1960’s locomotive required using magnetic particle deformation and wear
remanufacturing and the inspection. Metallurgical consistent with high loads
original component, that examination revealed that during service. Cross-
was beyond economical th... sectional examina...
repai...

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