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Questions and Answers
Which factor contributes to failure in metals as weld lines or knit lines in moulded plastics?
What is a common trouble-prone area for metals according to the text?
Which failure mode is characterized by static load and results in brittle fracture?
What type of fracture is associated with low stress, long-term exposure, and high temperature?
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Which factor is a manifestation of failure involving rupture, fracture, and change of metals?
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What is a failure analysis?
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Which of the following is NOT a factor contributing to material failure?
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How can a component be said to have failed?
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What can lead to material failure?
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Why is it important to understand failures in product design?
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What does failure in a component imply?
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Study Notes
Failure Definition and Analysis
- Failure is the inability of a component to function properly, not necessarily implying fracture.
- A part or system is said to have failed when it no longer complies with its design intent.
- Failure analysis is the examination of a failed component and the failure situation to determine the causes of the failure.
- The purpose of a failure analysis is to define the mechanism and causes of the failure and recommend a solution.
Factors Contributing to Failure
- Original Design:
- Modification of material to the extent it no longer serves its original purpose.
- Material subjected to high stresses or stress concentrations due to design alterations.
- Material Properties:
- Adverse thermo-mechanical history.
- Poor microstructure.
- Material defects and contamination from foreign particles.
- Manufacturing and Processing:
- Porosities and voids in metal castings and plastic molded parts.
- Weldments are a trouble-prone area for metals.
- Weld lines or knit lines in molded plastics.
- High residual stresses from metal forming, heat treatment, welding, and machining.
- Service Factors:
- Loading.
- Environment.
- Repair procedures.
Failure Manifestation
- Failure can manifest through:
- Elastic deformation.
- Plastic deformation.
- Rupture or fracture.
- Change of metals.
- Failure-inducing agents:
- Force.
- Time.
- Temperature.
- Reactive environment.
- Failure locations:
- Body type.
- Surface type.
- Failure modes:
- Ductile.
- Brittle.
- Fatigue.
- Creep.
- Wear.
- Weld.
Examples of Failure Modes
- Excessive elastic deformation.
- Plastic deformation:
- High stress/short term.
- Low stress/long term/high temperature.
- Brittle fracture:
- Static load.
- Fatigue.
- Wear.
- Corrosion/degradation.
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Description
Learn about the concept of failure in engineering, common types of failures, and the importance of failure analysis in improving design and preventing future failures.
