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M. Sujata
Failure Analysis & Accident Investigation Group
Materials Science Division
Introduction
Classification of fracture
Fracture features
Macroscopic
Microscopic
Identification of fracture modes
Applications
Examples from failure analysis
Conclusions
Mode of fracture
Fatigue
Stress corrosion cracking
Hydrogen embrittlement etc
Reason for crack initiation
Stress concentration
Material defects
Corrosion etc
Non-fluctuating stresses
Fluctuating stresses
Mechanical
Chemical Thermal
Non-fluctuating stresses
Mechanical or overload: tension, compression,
bending, torsion, shear
Chemical: stress corrosion, hydrogen embrittlement,
liquid metal embrittlement, exfoliation
Thermal: creep
Fluctuating stresses
Mechanical or overload: fatigue (HCF, LCF), fretting,
fretting-fatigue, wear
Chemical: corrosion fatigue..
Thermal: fatigue
Mechanical
Ductile, brittle, fatigue
Environmental
Corrosion, corrosion-erosion
Mechanical-environmental
Stress corrosion cracking, hydrogen embrittlement,
corrosion fatigue
Ductile fracture
Ductile fracture involves gross plastic deformation
and less catastrophic
Substantial energy is absorbed by microvoid
coalescence (high energy fracture mode)
Brittle fracture
Brittle fracture does not involve gross plastic
deformation and catastrophic
Low energy is absorbed during fracture (low energy
fracture mode)
Dimple rupture
Tension
Torsion
Fractography
ASM Handbook
5 m
Chevron marks
Fatigue
Stress corrosion cracking (SCC)
Hydrogen embrittlement (HE)
Static overload
failure
Progressive crack
propagation
(Crack arrest marks/beach
marks) can be fatigue or
SCC or HE
Crack origin
12.4 mm
LE
18.9 mm
Overload Fatigue
Differential exposure to
environment
30 m 300 m
RBF
Intergranular
(SCC, HE)
Crack initiation
Fatigue striations
Failure Mechanisms & Fractography
Conditions for SCC and HE cracking
SCC HE
A susceptible alloy A susceptible alloy
Aggressive environment H2 in the material
Applied or residual stress Applied or residual stress
Residual Applied
Welding Quenching
Shearing, Punching, Thermal Cycling
Cutting Thermal Expansion
Bending, Crimping, Vibration
Riveting Rotation
Machining Bolting
(Lathe-Mill-Drill) Pressure
Heat Treating Dead Load
EDM, Laser/Wire Cutting
Grinding
Residual Applied
Melting (generally causes
blistering) Welding Quenching
Shearing, Punching, Thermal Cycling
Environment (H2O during Cutting Thermal Expansion
welding) Bending, Crimping, Vibration
Riveting Rotation
Surface treatment Machining Bolting
(Lathe-Mill-Drill) Pressure
Surface cleaning Heat Treating Dead Load
Plating EDM, Laser/Wire Cutting
Grinding
SCC
HE
100m
HE