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    11 - Leo Vega Bolt Failure Analysis

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    symkimon
    The document outlines the process and techniques used in metallurgical failure analysis. It discusses typical elements of an analysis such as visual examination, fractography, and metallography. Specific techniques are described like scanning electron microscopy, energy dispersive x-ray spectroscopy, and hardness testing. Different damage mechanisms like fatigue, corrosion, and manufacturing defects are also covered. Finally, three case studies are presented analyzing failures from fatigue, hydrogen embrittlement, and fatigue, respectively, to demonstrate applying the techniques.

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    11 - Leo Vega Bolt Failure Analysis

    Uploaded by

    symkimon
    243 views35 pages
    The document outlines the process and techniques used in metallurgical failure analysis. It discusses typical elements of an analysis such as visual examination, fractography, and metallography. Specific techniques are described like scanning electron microscopy, energy dispersive x-ray spectroscopy, and hardness testing. Different damage mechanisms like fatigue, corrosion, and manufacturing defects are also covered. Finally, three case studies are presented analyzing failures from fatigue, hydrogen embrittlement, and fatigue, respectively, to demonstrate applying the techniques.

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    bolt failure

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    The document outlines the process and techniques used in metallurgical failure analysis. It discusses typical elements of an analysis such as visual examination, fractography, and metallography. Specific techniques are described like scanning electron microscopy, energy dispersive x-ray spectroscopy, and hardness testing. Different damage mechanisms like fatigue, corrosion, and manufacturing defects are also covered. Finally, three case studies are presented analyzing failures from fatigue, hydrogen embrittlement, and fatigue, respectively, to demonstrate applying the techniques.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    243 views35 pages

    11 - Leo Vega Bolt Failure Analysis

    Uploaded by

    symkimon
    The document outlines the process and techniques used in metallurgical failure analysis. It discusses typical elements of an analysis such as visual examination, fractography, and metallography. Specific techniques are described like scanning electron microscopy, energy dispersive x-ray spectroscopy, and hardness testing. Different damage mechanisms like fatigue, corrosion, and manufacturing defects are also covered. Finally, three case studies are presented analyzing failures from fatigue, hydrogen embrittlement, and fatigue, respectively, to demonstrate applying the techniques.

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    of 35

    Leo Vega

    SEMINAR ON LEAK
    REDUCTION
    Bolt Failure Analysis
    Topics of Discussion
    Elements of a Failure Analysis
    Metallurgical Characterization Techniques
    Types of Damage Mechanisms
    Case Studies
    Summary
    Typical Elements of a Failure
    Analysis
    History of Component
    Visual Examination
    Photographic
    Documentation
    Sample Selection
    Collect Deposits
    Sectioning
    Fractography
    Metallography
    SEM/EDS/XRD
    Chemical Analysis
    Mechanical Testing
    NDE
    Metallurgical Characterization
    Techniques
    Visual Examination
    Metallography
    Fractography
    Scanning Electron Microscopy (SEM) and
    Energy Dispersive X-ray Spectroscopy (EDS)
    Hardness Testing
    Non-destructive Evaluation (NDE)
    Visual Examination
    Fractography
    Flat
    fracture
    Shear lip
    Microstructural Evaluation
    Metallography
    To assess material
    condition and features
    SEM/EDS and XRD Analysis
    Deposit Analysis
    1000
    100 m
    keV
    10 9 8 7 6 5 4 3 2 1 0
    C
    o
    u
    n
    t
    s
    3,500
    3,000
    2,500
    2,000
    1,500
    1,000
    500
    C
    O
    Si Cl Ca Mn
    Fe
    Fe
    Fe
    Ni
    Ni
    Ni
    Cu Cu
    Cu
    Hardness Testing
    Rockwell tests on a failed shank
    1 10
    Hardness on Failed Shaft
    No. Hardness, HRC
    1 35
    2 36
    3 30
    4 31
    5 31
    6 29
    7 31
    8 27
    9 26
    10 19
    Micro Hardness
    Testing
    Microhardness Values of Sample in Longitudinal Orientation
    0
    100
    200
    300
    400
    500
    600
    700
    0
    .
    0
    0
    3
    0
    .
    0
    5
    0
    .
    0
    0
    8
    0
    .
    0
    1
    0
    .
    0
    1
    3
    0
    .
    0
    1
    5
    0
    .
    0
    1
    8
    0
    .
    0
    2
    0
    .
    0
    2
    3
    0
    .
    0
    2
    5
    0
    .
    0
    2
    8
    0
    .
    0
    3
    Distance from Edge of Hole, inches
    K
    n
    o
    o
    p

    H
    a
    r
    d
    n
    e
    s
    s
    DrilledHole
    Laser Cut Hole
    NDE
    Wet
    magnetic
    particle
    Inspection
    of
    cracked bolt
    Types of Damage Mechanisms
    Fatigue Fractures
    Wear
    Welding Defects
    Corrosion
    Casting Flaws
    Liquid Metal
    Embrittlement
    Selective Dissolution
    Manufacturing/Metal
    Working Defects
    Quality Assurance/
    Quality Control (QA/QC)
    Fatigue Fractures
    Mechanical Failures
    Beach marks (macroscopic
    features)
    Fatigue Striations
    (microscopic features)
    Wear
    Gear reduction
    box

    Evidence of a
    surface
    treatment
    Absence of a
    surface
    treatment
    Corrosion
    Compressor Bi-metallic oil seal
    Pitting and subsequent cracking caused by water in
    zinc-type antiwear additives operating above 140
    deg F
    Liquid Metal Embrittlement
    SEM/EDS of Crack on
    Worn Shaft
    Pb
    Sn, Sb
    Ni alloy
    Selective Dissolution
    Dealuminification in
    NiAl Bronze selective
    attack of a phase
    Manufacturing/Metal Working
    Defects QA/QC Inspections
    Inspection at
    suppliers facility
    Incoming material
    inspection
    In-process
    inspection
    Finished material
    inspection
    Pipe Mill Defect -
    QA/QC
    Extrusion Laps
    Case Studies
    Case Study #1
    Failure of Compressor Cylinder Flange/Bolts (Fatigue)
    Case Study #2
    Failure of Riser Fasteners (Hydrogen
    Embrittlement/Intergranular Cracking)
    Case Study #3
    A fun one; Failed Spinal Screws (Fatigue)
    Case Study #1 - Compressor Station
    Hick-up PN 113175
    Case Study #1
    Fractured bolts and flange at
    compressor cylinder
    Case Study #1 The Line Up

    SEM Analysis
    Fatigue Striations
    Cut Threads
    Case Study #1
    276
    283 283
    Knoop micro hardness
    impressions at thread
    root.
    Cut threads are evident.
    Case Study #1 - Conclusions
    Fasteners failed by High Cycle Fatigue
    Material and strength levels were adequate
    Increase frequency of inspections
    Bolts with cut threads should be considered as
    replacements.
    Case Study #2
    Fasteners in bolted flange connection operating
    in a seawater environment
    Case Study #2 - Fractography
    Intergranular Fracture
    Case Study #2 - Metallography
    Intergranular cracking
    Case Study #2 Hardness Testing
    Micro hardness tests on
    banded structure
    Case Study #2
    Failure due to Hydrogen Embrittlement
    Intergranular fracture mode
    Improper heat treatment revealed by hardness
    variations in a banded structure, which may
    have contributed to the failure.
    Case Study #3
    Fractured Spinal Screw
    Stage I Crack Initiation
    Stage II Crack
    Propagation
    Stage III - Overload

    Stage I Stage II
    Stage III
    What to do (or not do)!
    SUMMARY
    A variety of characterization
    techniques are used in a
    metallurgical evaluation to
    characterize various damage
    mechanisms.
    Some projects require limited
    scope based on budget
    constraints.
    Some require multi-disciplined
    engineering support and extensive
    evaluations
    Each technique provides specific
    information that allows the
    investigator to assess the results
    and their contribution to the cause.
    Metallurgical Failure Analysis
    serves numerous clients in areas
    such as:
    Failure Analysis and Prevention
    Third party review, audits, and
    oversight of inspections
    On site metallurgical evaluations.
    Forensic Investigations
    Metallurgical Failure Analysis
    Leo Vega
    Contact Info:
    281-897-1045 direct
    832-868-7449 cell

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