Failure Analysis

This book addresses the failures of structural elements, i.e. those components whose primary mission is to withstand mechanical loads. The book is intended as a self-contained source for those with different technical grades, engineers and scientists but also technicians in the field can benefit from its reading.

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Engine failures result from a complex set of conditions, effects, and situations. To understand why engines fail and remedy those failures, one must understand how engine components are designed and manufactured, how they function, and how they interact with other engine components. To this end, this book examines how engine components are designed and how they function, along with their physical and technical properties. Translated from a popular German reference work, this English edition sheds light on determining engine failure and remedies. The authors present a selection of engine failures, investigate and evaluate why they failed, and provide guidance on how to prevent such failures. A large range of possible engine failures is presented in a comprehensive, readily understandable manner, free of manufacturer bias. The scope of engines covered includes general-purpose engines found in heavy commercial vehicles, railway locomotives and vehicles, electrical generators, prime movers, and marine engines. Such engines are technical precursors to automotive engines. This book is for all who deal with engine failures: those who work in repair shops, shipyards, engineering consultancies, insurance companies and technical oversight organizations, as well as R&D departments at engine and component manufacturers. Researchers, academics, and students will learn how even the theoretically impossible can-and will-happen.

Component failures result from a combination of factors involving materials science, mechanics, thermodynamics, corrosion, and tribology. With the right guidance, you don’t have to be an authority in all of these areas to become skilled at diagnosing and preventing failures. Based on the author’s more than thirty years of experience, Practical Plant Failure Analysis: A Guide to Understanding Machinery Deterioration and Improving Equipment Reliability is a down-to-earth guide to improving machinery maintenance and reliability. Illustrated with hundreds of diagrams and photographs, this book examines... · When and how to conduct a physical failure analysis · Basic material properties including heat treating mechanisms, work hardening, and the effects of temperature changes on material properties · The differences in appearance between ductile overload, brittle overload, and fatigue failures · High cycle fatigue and how to differentiate between high stress concentrations and high operating stresses · Low cycle fatigue and unusual fatigue situations · Lubrication and its influence on the three basic bearing designs · Ball and roller bearings, gears, fasteners, V-belts, and synchronous belts Taking a detailed and systematic approach, Practical Plant Failure Analysis thoroughly explains the four major failure mechanisms—wear, corrosion, overload, and fatigue—as well as how to identify them. The author clearly identifies how these mechanisms appear in various components and supplies convenient charts that demonstrate how to identify the specific causes of failure.

Metallurgical Failure Analysis: Techniques and Case Studies explores how components fail and what measures should be taken to avoid future failures. The book introduces the subject of failure analysis; covers the fundamentals and methodology of failure analysis, including fracture and fractography of metals and alloys and the tools and techniques used in a failure investigation; examines 37 case studies on high performance engineering components; features experimental results comprised of visual-, fractographic-, or metallographic- examination, hardness measurements and chemical analysis; includes illustrations and evidence obtained through test results to enhance understanding; and suggests suitable remedial measures when possible. The various case studies are classified according to the major causes of failures. The case studies pertain to: Improper Material Selection, Manufacturing Defects, Casting Defects, Overload, Fatigue, Corrosion Induced Failures, Hydrogen Embrittlement and Stress Corrosion Cracking, Wear and Elevated Temperature Failures. The book contains information gathered over three decades of the author’s experience handling a variety of failure cases and will go a long way toward inspiring practicing failure analysts. The book is designed for scientists, metallurgists, engineers, quality control inspectors, professors and students alike. Explores the fundamentals and methodology of failure analysis Examines the major causes of component failures Teaches a systematic approach to investigation to determine the cause of a failure Features 37 case studies on high performance engineering components

The growing use of polymer composites is leading to increasing demand for fractographic expertise. Fractography is the study of fracture surface morphologies and it gives an insight into damage and failure mechanisms, underpinning the development of physically-based failure criteria. In composites research it provides a crucial link between predictive models and experimental observations. Finally, it is vital for post-mortem analysis of failed or crashed polymer composite components, the findings of which can be used to optimise future designs.Failure analysis and fractography of polymer composites covers the following topics: methodology and tools for failure analysis; fibre-dominated failures; delamination-dominated failures; fatigue failures; the influence of fibre architecture on failure; types of defect and damage; case studies of failures due to overload and design deficiencies; case studies of failures due to material and manufacturing defects; and case studies of failures due to in-service factors.With its distinguished author, Failure analysis and fractography of polymer composites is a standard reference text for researchers working on damage and failure mechanisms in composites, engineers characterising manufacturing and in-service defects in composite structures, and investigators undertaking post-mortem failure analysis of components. The book is aimed at both academic and industrial users, specifically final year and postgraduate engineering and materials students researching composites and industry designers and engineers in aerospace, civil, marine, power and transport applications. Examines the study of fracture surface morphologies in uderstanding composite structural behaviour Discusses composites research and post-modern analysis of failed or crashed polymer composite components Provides an overview of damage mechanisms, types of defect and failure criteria

Failure Analysis in Engineering Applications deals with equipment and machine design together with examples of failures and countermeasures to avoid such failures. This book analyzes failures in facilities or structures and the ways to prevent them from happening in the future. The author describes conventional terms associated with failure or states of failure including the strength of materials, as well as the procedure in failure analysis (materials used, design stress, service conditions, simulation, examination of results). The author also describes the mechanism of fatigue failure and prediction methods to estimate the remaining life of affected structures. The author cites some precautions to be followed in actual failure analysis such as detailed observation on the fracture site, removal of surface deposits (for example, rusts) without altering the fracture size or shape, The book gives examples of analysis of failure involving a crane head sheave hanger, wire rope, transmission shaft, environmental failure of fastening screws, and failures in rail joints. This book is intended for civil and industrial engineers, for technical designers or engineers involved in the maintenance of equipment, machineries, and structures.