Lion DVD

AFA

CHAPTER: Principles of Fractures

Principles of
Fractures
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Lion DVD

AFA

CHAPTER: Principles of Fractures

In this presentation

Metal strength
Loads on parts
Stress raisers
Brittle fracture characteristics
Ductile fracture characteristics
Fatigue fracture characteristics

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Lion DVD

AFA

CHAPTER: Principles of Fractures

Metal strength
Weakest link

Overloaded
Abnormal stress raiser
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Lion DVD

AFA

CHAPTER: Principles of Fractures

Metal strength & temperature

Steel

Strength
Aluminum
Temperature

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Lion DVD

AFA

CHAPTER: Principles of Fractures

Metal strength & temperature

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Lion DVD

AFA

CHAPTER: Principles of Fractures

Approximate Temper color vs. Temperature

Pale Yellow
Straw Yellow
Yellow/Brown
Red
Violet
Dark Blue
Light Blue
Blue/Gray
Gray

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175C / 350 F
205C / 400 F
232C / 450 F
260C / 500 F
288C / 550 F
315C / 600 F
343C / 650 F
371C / 700 F
400C / 750 F

Lion DVD

CHAPTER: Principles of Fractures

AFA

Load vs. Component life

Cyclic
Load

Endurance Limit
Safety Factor
Design Load
Cycles to Failure

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Lion DVD

AFA

CHAPTER: Principles of Fractures

Basic terminology

Stress raiser physical change in a part

Initiation site starting point of fracture
Final fracture last area to crack
Fast growing cracks
Brittle and ductile
Slow growing cracks
Bending fatigue
Rotating bending fatigue

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Lion DVD

AFA

CHAPTER: Principles of Fractures

Stress raisers

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AFA

CHAPTER: Principles of Fractures

Stress raisers

Physical irregularities that concentrate existing stress

~1.5

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~3.0

~3.0 8.0

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AFA

CHAPTER: Principles of Fractures

Stress Raiser Examples

Part Geometry

Diameter change
Holes
Keyways
Material Impurities
Inclusions
Laminations
Voids
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Process problems
Forging laps
Grinder burns
Quench cracks
Mishandling
Scratches
Rust
Dents
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Load

AFA

CHAPTER: Principles of Fractures

Stress Raiser Fracture

Impact

No

Brittle
Fast/Rough/Result

Single
overload

No

Cyclic
Load

Yes

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Ductile
Fast/Rough/Result

Fatigue
Slow/Smooth
Associated with
the root cause
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AFA

CHAPTER: Principles of Fractures

Different Rates of Loading Components

Impact

Applied
Load

Overload

Cyclic
Time
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AFA

CHAPTER: Principles of Fractures

Factors Affecting Fracture

Brittle Fracture
Ductile Fracture
High hardness
Low hardness
Low temperature
High temperature
Sharp stress raiser
No stress raiser
Fast load rate
Slower load rate

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AFA

CHAPTER: Principles of Fractures

Fracture Examination
Fracture Cleaning
Nonabrasive/Corrosive cleaning
Air or blow dry
Fracture Analysis
Use good lighting
Rotate the part in light
Use magnification
Preservation
Coat part with rust inhibitor
Package to prevent shipping contact
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AFA

CHAPTER: Principles of Fractures

Brittle Fracture Characteristic

Fast
Crystaline
No Plastic Deformation
Wrought Metals
Many Chevrons
Bright
Cast Metal
Few Chevrons
Dull
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CHAPTER: Principles of Fractures

Brittle Crack Growth

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AFA

CHAPTER: Principles of Fractures

Brittle Fracture

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AFA

CHAPTER: Principles of Fractures

Brittle Fracture

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AFA

CHAPTER: Principles of Fractures

Brittle Fracture

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AFA

CHAPTER: Principles of Fractures

Brittle Fracture

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AFA

CHAPTER: Principles of Fractures

Brittle Fracture

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AFA

CHAPTER: Principles of Fractures

Brittle Fracture

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CHAPTER: Principles of Fractures

Ductile Fracture Characteristics

Fast
Large Shear Lips
Dark
Rough & Woody
Plastic Deformation

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AFA

CHAPTER: Principles of Fractures

Ductile Crack Growth

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AFA

CHAPTER: Principles of Fractures

Ductile Crack Growth

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CHAPTER: Principles of Fractures

Shear Lip Formation

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CHAPTER: Principles of Fractures

Ductile Fracture

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AFA

CHAPTER: Principles of Fractures

Ductile Fracture

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AFA

CHAPTER: Principles of Fractures

Ductile Fracture

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AFA

CHAPTER: Principles of Fractures

Fatigue Fracture Characteristics

Light Color
Slow
Flat and Smooth
Beach Marks
Ratchet Marks

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AFA

CHAPTER: Principles of Fractures

Fatigue Crack Growth

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AFA

CHAPTER: Principles of Fractures

Fatigue Fracture

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AFA

CHAPTER: Principles of Fractures

Fatigue Fracture

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CHAPTER: Principles of Fractures

Fatigue Fracture

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CHAPTER: Principles of Fractures

Fatigue Fracture

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CHAPTER: Principles of Fractures

Fatigue Fracture

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AFA

CHAPTER: Principles of Fractures

Rotating Bending Fatigue Fracture

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AFA

CHAPTER: Principles of Fractures

Rotating Bending Fatigue Fracture

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AFA

CHAPTER: Principles of Fractures

Rotating Bending Fatigue Fracture

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AFA

CHAPTER: Principles of Fractures

Rotating Bending Fatigue Fracture

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AFA

CHAPTER: Principles of Fractures

Remember
Brittle and ductile fractures are usually results
Fatigue fractures are usually connected to the root
cause
Examine fatigue initiation sites for abnormal
stress raisers
If cracking starts internally, indicates a material
or fabrication problem (bulls eye or pre-crack)
If cracking starts at the surface look for
presence of abnormal stress raisers
If stress raiser is normal, investigate for cyclic
overloading

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