Understanding why structural materials fail and the methods for analyzing and predicting the structural integrity of a material during service are extremely important in industry, both at the initial design stage as well as in-service and end-of-life analysis of components. This is a critical process in determining the physical root causes of problems. The process is complex, draws upon many different technical disciplines, and uses a variety of observation, inspection, and laboratory techniques. One of the key factors in properly performing a failure analysis is keeping an open mind while examining and analyzing the evidence to foster a clear, unbiased perspective of the failure. Collaboration with experts in other disciplines is required in certain circumstances to integrate the analysis of the evidence with a quantitative understanding of the stressors and background information on the design, manufacture, and service history of the failed product or system. Just as failure analysis is a proven discipline for identifying the physical roots of failures, root-cause analysis(RCA) techniques are effective in exploring some of the other contributors to failures, such as the human and latent root causes. Properly performed, failure analysis and RCA are critical steps in the overall problem-solving process and are key ingredients for correcting and preventing failures, achieving higher levels of quality and reliability, and ultimately enhancing customer satisfaction.
This book briefly introduces the concepts of failure analysis, root-cause analysis, and the role of failure analysis as a general engineering tool for enhancing product quality and failure prevention. The discipline of failure analysis has evolved and matured, as it has been employed and formalized as a means for failure prevention. Consistent with the recent trend toward increased accountability and responsibility, its purpose has been extended to include determining which party may be liable for losses, be they loss of production, property damage, injury, or fatality. The discipline has also been used effectively as a teaching tool for new or less experienced engineers. Clearly, through the analysis of failures and the implementation of preventive measures, significant improvements have been realized in the quality of products and systems. This requires not only an understanding of the role of failure analysis, but also an appreciation of quality assurance and user expectations. Achieving the levels of quality that meet and exceed customer expectations is paramount to customer satisfaction in a customer-focused management system. Since a customer's perspective of quality is strongly tied to the function and service life of a product or system, it follows that failure to provide adequate measures of function and service life presents problems. One proven technique to improving quality is problem solving. Problems can range broadly, from maintenance training issues, to marginal equipment reliability, to business systems conflicts, to policy inconsistencies, to poor working conditions on the shop floor. When a problem occurs, the responsible organization will analyse the problem to determine the cause and solve it. However, due to various business or cultural pressures, some organizations fall into the following pitfalls when problems arise. In an enlightened organizational culture, products or systems require a systematic approach to problem solving, based on analysis, to achieve the levels of quality and customer satisfaction defined by the new management systems. The cultural aspect is critical, as those who have identified problems must be encouraged to come forward. Furthermore, resources and commitment are required to formulate the solutions and implement necessary changes.
This book Covers the basic principles of failure of metallic and non-metallic materials in mechanical design applications. Updated to include new developments on fracture mechanics, including both linear elastic and elastic-plastic mechanics.
Editor

Preface vii

1.Introduction 1

Fundamentals of Fracture·Analysis· Metallurgical Failure Analysis· The Role of Failure Prevention Analysis in Mechanical Design· Modes of Mechanical Failure· Component Failure

2. Strength and Deformation of Engineering Metals 23

Properties · Mechanical Properties of Metals · Strength of Materials

3. State of Stress 48

Relationships between Stress and Strain· Testing· Stress Strain Curve· Combined Stress Theories of Failure and Their Use in Design· Stress Concentration· Causes· Fillet · Creep, Stress Rupture, and Fatigue· Ultimate Tensile Strength

4. Concepts of Cumulative Damage, Life Prediction, and Fracture Control 120

Cumulative Damage · Life Prediction and Fracture Control ·Continuum Mechanics· Linear Elastic Fracture Mechanics·Elastic T Stress· Fracture Toughness

5. Use of Statistics in Fatigue Analysis 153

Fatigue Life · Infamous Fatigue Failures · Fatigue Testing Procedures and Statistical Interpretations of Data

6. Fretting, Fretting Fatigue, and Fretting Wear 172

Steel · Frettin Wear · Shock and Impact · Buckling and Instability· Columns· Instability

7. Wear, Corrosion, and Other Important Failure Modes 197

Surface Treatments· Tribometre· St Venants Theory· Theory·Saint-Venant's Theorem· Low Cycle Fatigue Prediction

8. Creep Stress Rupture and Fatigue 240

Stress Rupture Properties· Precision Velocity Measurements ·Composite Material · Examples· Constituents· Woodworking Applications· Size Effect · Z-Factor· Stress· Stresson a Plane · Cyclic Stress

9. Types of Corrosion 294

Leaching of Zinc· Sensitization Effect· Intergranular Fracture·Abrasive Wear

Bibliography 309

Index 311

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