1st Edition

Practical Engineering Failure Analysis

    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

    INTRODUCTION
    Engineering Products and Their Performance
    Engineering Properties of Materials
    Classes of Engineering Alloys
    Structure of Engineering Alloys
    Failure of Engineering Products
    Imperfect vs. Defective Products
    Definition and Objective of Failure Analysis Investigations
    Approach to Failure Analysis Investigations
    Background Requirements of the Failure Analyst: Scope of the Book
    ENGINEERING DESIGN-FABRICATION-PERFORMANCE
    Introduction
    Stages of Engineering Design
    Material Selection
    Fabrication of Engineering Alloys
    Solidification of Ingots
    Cold Working
    Recrystallization
    Thermomechanical Processing
    Primary Fabrication Techniques
    Secondary Fabrication Techniques
    Joining Techniques
    Service Performance
    Common Causes of Failure
    PRINCIPLES OF MECHANICS
    Introduction
    Concepts of Mechanics
    Concepts of Mechanical Force
    Concepts of Work and Energy
    Force and Motion
    Conservation of Energy
    Concept of Machines
    State of Mechanical Equilibrium
    Concept of Strain
    Concept of Stress
    Hook's Law
    PROPERTY EVALUATION
    Introduction
    Nondestructive Tests
    Destructive Tests: Measurement of Mechanical Properties
    STRESS ANALYSIS
    Introduction
    Uniaxial State of Stress
    Generalized State of Stress
    Multiaxial Stress-Strain Relationship
    Loading Conditions and Stress
    Thermal Stress
    Type of Stress Required to Produce Plastic Deformation
    Maximum Stresses
    Design Stresses
    Criterion for the Onset of Plastic Deformation (Yielding)
    Stress Concentration
    Criteria for Mechanical Failure
    Applications: Analysis of Stresses in Specific Components
    Solved Problems
    MACROSCOPIC ASPECTS OF FRACTURE AND FRACTURE MECHANICS
    Definition of Fracture
    Objective of Fracture Mechanics
    Use of the Terms Brittle and Ductile in Fracture
    Crack Loading Modes and Macroscopic Morphology of Fracture Surfaces
    Crack Propagation Under a Plane Strain Condition
    Crack Propagation Under a Plane Stress Condition
    Crack Propagation Under a Mixed State of Plane Strain and Stress
    Sequence of Events Leading to Fracture
    Classification of Crack Propagation Modes According to Loading Conditions
    Variables Affecting Fracture Behavior
    Basic Principles of Fracture Mechanics
    Linear Elastic Fracture Mechanics (LEFM)
    Use of Fracture Mechanics in Design
    Concept of Allowable Crack Size
    Use of Fracture Mechanics in Failure Analysis
    Selection of Materials Resistant to Fracture
    STRUCTURE OF ENGINEERING ALLOYS
    Introduction
    Principles of Thermodynamics
    Elements of Internal Structure
    Structure of the Atom
    Significance of the Electronic Structure of Atom
    Electronic Structure and Chemical Properties: Classes of Elements
    Origin of Interatomic Binding Forces
    Types of Interatomic Binding Forces
    Bond Strength and Properties of Materials
    Arrangement of Atoms in Perfect Crystals
    Understanding the Microscopic Plasticity of Perfect Crystals
    Crystal Imperfections
    Understanding the Microscopic Plasticity of Real Crystals
    Alloy Phases and Phase Change
    Equilibrium Phase Diagrams
    Methods of Strengthening Engineering Alloys
    MATERIALS CHARACTERIZATION
    Introduction
    Techniques for Microstructural Characterization
    Techniques for Chemical Analysis
    Microstructural Engineering Alloys
    CORROSION
    Introduction
    Low-Temperature Aqueous Corrosion
    High-Temperature Corrosion
    METALLURGICAL ASPECTS OF FRACTURE AND FRACTOGRAPHY
    Introduction
    Microscopic Aspects of Crack Nucleation
    Microscopic Mechanisms of Crack Propagation
    Fracture Modes and Fractography
    FAILURE ANALYSIS PROCEDURE
    Introduction
    Definition of the Problem
    Technical Background
    Experimental Program and Analysis
    Mode of Failure vs. Cause of Failure
    Data Interpretation and Terminology
    Recommendations
    Failure Analysis Reports
    CASE STUDIES
    Introduction
    Failure of Engineering Alloys Due to Improper Processing Practice
    Failure of Engineering Products During Manufacturing
    Effect of Variations in Design on Service Performance
    Failure of Engineering Products During Service Because of Unanticipated Service Conditions
    Failure of Engineering Products During Service Because of Improper Material Selection
    Failure of Engineering Products During Service Because of Improper Service Conditions
    APPENDIX A: CHEMICAL COMPOSITION AND CLASSIFICATION OF SELECTED STEELS
    APPENDIX B: UNITS OF MEASUREMENTS IN MECHANICS
    APPENDIX C: MOMENT OF INERTIA OF SELECTED CROSS SECTIONS
    INDEX

    Biography

    Hani M. Tawancy, Anwar Ul-Hamid, Nureddin M. Abbas