Practical Engineering Failure Analysis

by Tawancy; Hani M.

• ISBN13: 9780824757427
• ISBN10: 0824757424
• Edition: 1st
• Format: Hardcover
• Copyright: 2004-08-30
• Publisher: CRC Press

Summary

Filling a gap in the literature, Practical Engineering Failure Analysis vividly demonstrates the correct methodology to conduct successful failure analyses, as well as offering the background necessary for these investigations. This authoritative reference covers procedures to reduce the occurrence of component failures due to errors in material selection, design, and manufacturing, as well as fatigue, stress, cracking, creep, and operating conditions. A single-source tool to help professionals avoid costly system failures, improve plant operation and system reliability, and prevent accidents related to component malfunction

Author Biography

Nureddin M. Abbas is Associate Professor, Department of Chemical Engineering, and Manager of the Materials Section, Center for Engineering Research, Research Institute, King Fahd University of Petroleum and Minerals, Dhahran, Saudi Arabia.

Table of Contents

Preface	iii
Introduction	1	(17)
Engineering Products and Their Performance	1	(3)
Engineering Properties of Materials	4	(5)
Classes of the Engineering Alloys	9	(1)
Structure of Engineering Alloys	10	(1)
Failure of Engineering Products	11	(1)
Imperfect vs. Defective Products	12	(2)
Definition and Objective of Failure Analysis Investigations	14	(1)
Approach to Failure Analysis Investigations	14	(2)
Background Requirements of the Failure Analyst: Scope of the Book	16	(2)
Engineering Design--Fabrication--Performance	18	(26)
Introduction	18	(2)
Stages of Engineering Design	20	(1)
Material Selection	21	(1)
Fabrication of Engineering Alloys	22	(1)
Solidification of Ingots	23	(2)
Cold Working	25	(1)
Recrystallization	26	(1)
Thermomechanical Processing	27	(1)
Primary Fabrication Techniques	28	(6)
Secondary Fabrication Techniques	34	(3)
Joining Techniques	37	(4)
Service Performance	41	(1)
Common Causes of Failure	42	(2)
Principles of Mechanics	44	(17)
Introduction	44	(1)
Concepts of Mechanics	45	(1)
Concept of Mechanical Force	46	(2)
Concepts of Work and Energy	48	(1)
Force and Motion	49	(2)
Conservation of Energy	51	(1)
Concept of Machines	51	(1)
State of Mechanical Equilibrium	52	(1)
Concept of Strain	53	(2)
Concept of Stress	55	(4)
Hook's Law	59	(2)
Property Evaluation	61	(36)
Introduction	61	(1)
Nondestructive Tests	61	(9)
Destructive Tests: Measurement of Mechanical Properties	70	(27)
Stress Analysis	97	(58)
Introduction	97	(1)
Uniaxial State of Stress	98	(2)
Generalized State of Stress	100	(13)
Multiaxial Stress-Strain Relationship	113	(3)
Loading Conditions and Stress	116	(4)
Thermal Stress	120	(1)
Type of Stress Required to Produce Plastic Deformation	121	(1)
Maximum Stresses	122	(1)
Design Stresses	123	(1)
Criterion for the Onset of Plastic Deformation (Yielding)	124	(1)
Stress Concentration	125	(3)
Criteria for Mechanical Failure	128	(1)
Applications: Analysis of Stresses in Specific Components	128	(13)
Solved Problems	141	(14)
Macroscopic Aspects of Fracture and Fracture Mechanics	155	(54)
Definition of Fracture	155	(1)
Objective of Fracture Mechanics	156	(1)
Use of the Terms Brittle and Ductile in Fracture	157	(2)
Crack Loading Modes and Macroscopic Morphology of Fracture Surfaces	159	(2)
Crack Propagation Under a Plane Strain Condition	161	(2)
Crack Propagation Under a Plane Stress Condition	163	(1)
Crack Propagation Under a Mixed State of Plane Strain and Stress	164	(1)
Sequence of Events Leading to Fracture	164	(4)
Classification of Crack Propagation Modes According to Loading Conditions	168	(4)
Variables Affecting Fracture Behavior	172	(7)
Basic Principles of Fracture Mechanics	179	(1)
Linear Elastic Fracture Mechanics (LEFM)	180	(7)
Use of Fracture Mechanics in Design	187	(2)
Concept of Allowable Crack Size	189	(5)
Use of Fracture Mechanics in Failure Analysis	194	(10)
Selection of Materials Resistant to Fracture	204	(5)
Structure of Engineering Alloys	209	(82)
Introduction	209	(1)
Principles of Thermodynamics	209	(5)
Elements of Internal Structure	214	(1)
Structure of the Atom	215	(4)
Significance of the Electronic Structure of Atom	219	(1)
Electronic Structure and Chemical Properties: Classes of Elements	219	(3)
Origin of Interatomic Binding Forces	222	(1)
Types of Interatomic Binding Forces	223	(5)
Bond Strength and Properties of Materials	228	(3)
Arrangement of Atoms in Perfect Crystals	231	(6)
Understanding the Microscopic Plasticity of Perfect Crystals	237	(3)
Crystal Imperfections	240	(16)
Understanding the Microscopic Plasticity of Real Crystals	256	(9)
Alloy Phases and Phase Change	265	(11)
Equilibrium Phase Diagrams	276	(9)
Methods of Strengthening Engineering Alloys	285	(6)
Materials Characterization	291	(53)
Introduction	291	(1)
Techniques for Microstructural Characterization	291	(20)
Techniques for Chemical Analysis	311	(23)
Microstructure of Engineering Alloys	334	(10)
Corrosion	344	(53)
Introduction	344	(1)
Low-Temperature Aqueous Corrosion	345	(32)
High-Temperature Corrosion	377	(20)
Metallurgical Aspects of Fracture and Fractography	397	(16)
Introduction	397	(1)
Microscopic Aspects of Crack Nucleation	398	(2)
Microscopic Mechanisms of Crack Propagation	400	(9)
Fracture Modes and Fractography	409	(4)
Failure Analysis Procedure	413	(9)
Introduction	413	(1)
Definition of the Problem	414	(1)
Technical Background	415	(1)
Experimental Program and Analysis	415	(3)
Mode of Failure vs. Cause of Failure	418	(1)
Data Interpretation and Terminology	419	(1)
Recommendations	419	(1)
Failure Analysis Reports	420	(2)
Case Studies	422	(159)
Introduction	422	(1)
Failure of Engineering Alloys Due to Improper Processing Practice	423	(27)
Failure of Engineering Products During Manufacturing	450	(7)
Effect of Variations in Design on Service Performance	457	(9)
Failure of Engineering Products During Service Because of Unanticipated Service Conditions	466	(30)
Failure of Engineering Products During Service Because of Improper Material Selection	496	(48)
Failure of Engineering Products During Service Because of Improper Service Conditions	544	(37)
Appendix A Chemical Composition and Classification of Selected Steels	581	(6)
Appendix B Units of Measurements in Mechanics	587	(3)
Appendix C Moment of Inertia of Selected Cross Sections	590	(1)
Index	591