Title Failure analysis : fundamentals and applications in mechanical components / Jose Luis Otegui

Published Cham : Springer, 2014

Table of Contents
1.	Introduction					1
1.1.	Historical Perspective					1
1.2.	Current Technology is Conditioned by our History					2
1.3.	The Danger of Myths and the Public					4
1.4.	Defects in Components, Ductile and Brittle Materials					6
1.5.	The Industrial Revolution and Failures in Pressure Components					7
1.6.	The Advent of Fracture Mechanics					9
1.7.	Scope of the Failure Analysis					10
1.7.1.	Example 1.A Expert Analysis After a Traffic Accident					13
1.8.	Concluding Remarks					15
	References					18
2.	Tools for Preliminary Analysis of a Mechanical Failure					19
2.1.	Methodologies for Field Investigation After a Failure					19
2.2.	Collecting Data and History					21
2.3.	Visual Inspection Techniques and Field Photography					21
2.4.	How to Detect the Site of Initiation of Mechanical Failure					25
2.4.1.	Fractographic					25
2.4.2.	Example 2.A Identification of Failure Origin					28
2.4.3.	Initiation Site of a Fracture					29
2.4.4.	Example 2.B Detection of Previous In-Service Damage					32
2.5.	Failure of Threaded and Rotating Elements					33
2.5.1.	Example 2.C Failure of a Bolted Structure					36
2.6.	Extraction and Storage of Samples					39
2.7.	Inspection by NDT Techniques					42
2.8.	Organization of Work Teams					48
	References					51
3.	Tools for the Microscopic Analysis of a Mechanical Failure					53
3.1.	Microstructural and Metallographic Characterizations of Metallic Parts					53
3.2.	Cutting and Preparation of Samples					54
3.3.	The Polycrystalline Nature of Metals					58
3.4.	Microscopic Examination of the Structure of Metals					60
3.4.1.	Example 3.A Metallographic Analysis of a Welded Pipe					65
3.5.	Microscopic Examination of Fracture Surfaces					66
3.5.1.	Example 3.B Fractographic Analysis of a Thick-Walled Tube					68
3.6.	Identification of Subcritical Growth Surfaces					71
3.6.1.	Example 3.C Failure of a Flexible Connection					73
3.7.	High Magnification Tools, Electron Microscopy					75
3.7.1.	Example 3.D SEM Analysis					76
3.8.	Extra-High Definition Fractographic Analyses, Nano Devices					80
	References					83
4.	Mechanisms of Damage and Failure					85
4.1.	Introduction					85
4.2.	Failure Mechanisms					87
4.3.	Mechanisms of In-service Damage					89
4.4.	Corrosion					90
4.4.1.	Example 4.A Corrosion in Exchanger Tubes					96
4.5.	Propagation of Cracks, Fatigue					100
4.5.1.	Example 4.B Fatigue Failure in a Pipeline					100
4.6.	Hydrogen Damage					104
4.7.	Damage by Prolonged Exposure to High Temperature					106
4.7.1.	Example 4.C Fire in a Hydrocarbon Furnace					107
4.8.	Environment Assisted Cracking					111
4.8.1.	Example 4.D Cracks in a Heat Exchanger Tube Plate					114
4.9.	Discontinuities or Defects Introduced During Manufacture					116
	References					120
5.	Damage Resistance Tests of Materials					121
5.1.	Tensile Testing					122
5.1.1.	Example 5.A A Stainless Steel Tube at High Temperature					125
5.2.	Ductile-Brittle Transition Temperature					126
5.3.	Experimental Determination of Fracture Toughness					129
5.4.	Spectrometry Analysis and Hardness Tests					132
5.5.	Experimental Measurement of Residual Stresses					135
5.6.	Experimental Determination of the Resistance to In-service Damage					137
5.7.	Testing of Fatigue Life					138
5.8.	Techniques for Corrosion Monitoring					140
5.9.	Estimation of SCC Propagation Rates and Threshold Stress					142
5.10.	Creep Resistance and Monitoring of In-service Damage					144
	References					148
6.	Modeling Tools Applied to the Analysis of Mechanical Failures					149
6.1.	Introduction					149
6.2.	Numerical Modeling Tools					152
6.2.1.	Example 6.A Modeling of Soil-Pipeline Interaction					155
6.3.	Criteria for Modeling Pressure Components					158
6.3.1.	Example 6.B Stress Analysis of Damper Vessel					161
6.4.	Stress Analysis of Cracked Components					162
6.5.	Calculation of the Load Required for Brittle Fracture					164
6.6.	Calculation of the Conditions for Ductile Fracture					168
6.6.1.	Example 6.C Calculation of Applied Stress at a Pre-existing Defect					170
6.7.	Mechanical Modeling of Longitudinal Cracks in Pipes					172
6.8.	Mechanical Modeling of Fatigue Crack Propagation					174
6.8.1.	Example 6.D Modeling of Fatigue Crack Growth in Compressor					177
6.9.	Determination of Fracture Toughness in Post-failure Samples					178
	References					180
7.	Root Cause Analyses					183
7.1.	Introduction					183
7.2.	The Explosion of the Challenger Space Shuttle					184
7.3.	Methodology for Root Cause Analysis					187
7.3.1.	Example 7.A Is a Blown Fuse a Failure?					189
7.4.	The Cause--Effect Tree					189
7.5.	Data Collection: Interviews and Statements					191
7.5.1.	Example 7.B Causal Tree in a "Hot Tap" Repair					193
7.6.	Data Collection: Documents and Records					198
7.7.	Rebuttal, Iteration, Coincidence, and Causality					199
7.7.1.	Example 7.C RCA of Failure in Directional River Crossing					202
7.8.	Levels in Failure Analyses					209
7.9.	Alternative Formats for a Failure Investigation					212
7.9.1.	Example 7.D RCA of Fire in a Heater at a Petrochemical Plant					214
	References					217
8.	Damage and Failure Mechanisms in Machinery					219
8.1.	Definition of Failure in Machinery					219
8.2.	Modes of Failure in Shafts					220
8.2.1.	Example 8.A Failure of Shaft in a Hydraulic Pump					220
8.3.	Failures of Bearings					221
8.3.1.	Example 8.B Failure of Bearing in A.C. Generator					225
8.4.	Failure in Sliding or Plain Bearings					227
8.4.1.	Example 8.C Failure of Sliding Bearing in a Large Gas Engine					228
8.5.	Failure of Transmission Elements: Gears and Couplings					230
8.5.1.	Gears					230
8.5.2.	Couplings					233
8.5.3.	Example 8.D Failure of a Flexible Coupling					234
8.6.	Failure of Fasteners, Bolts, and Other Threaded Elements					237
8.6.1.	Example 8.E Failure of an Allen Type Fastening Bolt in a Compressor Piston Head					241
8.7.	Characteristic Failures in Turbo Machines					244
8.7.1.	Steam Turbines					244
8.7.2.	Example 8.F Failure in the Rotor of a Steam Turbine					246
8.7.3.	Gas Turbines					247
	References					250
9.	Failure Mitigation and Extension of Service Life					251
9.1.	Introduction and Historical Perspective					251
9.2.	Failure Mode and Effect Assessment					253
9.3.	Procedures for Assessing Fitness for Service					255
9.4.	Evaluation of General and Local Loss of Thickness					257
9.5.	Evaluation of Geometrical Discontinuities and Cracks					259
9.6.	The Leak Before Break Criterion for Pressurized Components					264
9.7.	Monitoring Damage and Stresses During Service					264
9.8.	Strength Tests Using Instrumented Indentation					270
9.9.	Monitoring of Machines					271
9.9.1.	Vibration Analysis					273
9.9.2.	Lubricant Analyses					274
9.9.3.	Acoustic Emission Analysis					275
9.9.4.	Analysis by Infrared Thermography					276
9.10.	Estimation of Residual Life Against Damage Mechanisms					276
9.10.1.	Example 9.A Fatigue Life Prediction in a Pipeline					278
	References					281
10.	Consequences of a Failure Analysis					283
10.1.	Writing Reports After a Failure Analysis					283
10.2.	Failure Analysis in Potentially Litigious Cases					285
10.3.	Learning or not Learning from Accidents, Here the Question					288
10.4.	On Human Error					291
10.5.	Human Errors at Different Levels, the Chernobyl Case					293
10.5.1.	The Worst Nuclear Disaster					293
10.5.2.	Levels in the Chain of Human Errors					295
10.6.	Business Impositions and Political Decision-Making					297
10.6.1.	Example 10.A Incident on a Water Pumping Plant					298
10.7.	The Rules are Relaxed: The Case of the Macondo Oil Well					301
10.8.	Underestimating Consequences of Natural Events, the Fukushima Event					305
10.9.	Management of Old Plants and Equipment					307
10.10.	Causes and Consequences of the Most Famous Accident					310
	References					313

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Description 1 online resource (xix, 313 pages) : illustrations Contents Tools for Preliminary Analysis of a Mechanical Failure -- Tools for the Microscopic Analysis of a Mechanical Failure -- Damage and Failure Mechanisms -- Characterization and Testing of Materials -- Mechanical Modelling Tools applied to Failure Analysis -- Root Cause Analysis -- Damage and Failure Mechanisms in Machinery -- Mitigation and Life Prediction -- Consequences of a Failure Analysis Summary 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 Bibliography Includes bibliographical references Notes English Online resource; title from PDF title page (SpringerLink, viewed January 6, 2014) Subject Failure analysis (Engineering) Equipment Failure Analysis TECHNOLOGY & ENGINEERING -- Civil -- General. Ingénierie. Failure analysis (Engineering) Form Electronic book ISBN 9783319039107 3319039105 3319039091 9783319039091

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