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TRANSPORTATION COMPONENT FAILURES

Aircraft-Aerospace
Aircraft Accident Caused by Explosive Sabotage
Cracking in an Aircraft Main Landing Gear Sliding Strut
Cracking in an Aircraft Nose Landing Gear Strut
Failed Mixer Pivot Support of an Army Helicopter
Failure Analysis of a Space Shuttle Solid Rocket Booster Auxiliary Power Unit
(APU) Fuel Isolation Valve
Failure of Aircraft Target Towing Cables
Failure of a Transport Aircraft Relay Valve Guide
Fatigue Fracture of a Helicopter Tail Rotor Blade Due to Field-Induced Corrosion
Processing-Induced Fatigue Fracture of a Helicopter Tail Rotor Blade
Fatigue Fracture of a Transport Aircraft Crankshaft During Flight

Ground Transportation Components
Contact Fatigue Failure of a Bull Gear
Failure of Four Cast Steel Gear Segments
Failure of Trailer Kingpins Caused by Overheating During Forging
Failure of a Sprocket Drive Wheel in a Tracked All-Terrain Vehicle
Failure Analysis of an Exhaust Diffuser Assembly
Fatigue Failure of Steering Arms Due to Forging Defects
Fracture of a Train Wheel Due to Thermally Induced Fatigue and Residual Stress
In-Service Failure of SAE Grade 8.1 Wheel Studs
Mechanical Failure of a Repair Welded Ferritic Malleable Cast Iron Spring Hanger
Quench Cracking in a Turntable Rail
Three-Wheel Motorcycle Frame Failures and Redesign

PROCESS EQUIPMENT FAILURES

Heat Exchangers
Failure of Admiralty Brass Condenser Tubes
Failure of Nickel-Base Superalloy Heat-Exchanger Tubes in a Black Liquor Heater
Failure of a Copper Condenser Dashpot
Stress-Corrosion Cracking of a Brass Tube in a Generator Air Cooler Unit
Thermal Fatigue Failure in a Vaporizer

Pressure Vessels
Failure of AM350 Stainless Steel Bellows
Failure of Three Cyclone Separators
Intergranular Stress-Corrosion Cracking Failure in AISI Type 316 Stainless Steel
Dished Ends Near Weld Joints
Liquid Metal Embrittlement of Bronze Rupture Discs
Transgranular Stress-Corrosion Cracking Failures in AISI 304L Stainless Steel
Dished Ends During Storage

Pipes and Pipelines
Acidic Pitting in Waterwall Tubing
Alkaline Type Boiler Tube Failures Induced by Phosphate Water Treatment
An Unusual Case of Hydrogen-Induced Failure in a Refinery Boiler Tube
Caustic Gouging and Caustic-Induced Stress-Corrosion Cracking of Superheater Tube
U-Bends
Caustic-Induced Stress-Corrosion Cracking of a Flue Gas Expansion Joint
Corrosion Failure of a Chemical Piping Cross-Tee Assembly
Corrosion Failure of Stainless Steel Thermowells
Cracking in a Reducing Pipe From a Pressurized Water Reactor
Cracking of Inconel 800H in a Steam Methane Reformer Furnace
Dealloying in Aluminum Bronze Components
Failure of Carbon Steel Superheater Tubes
Failure of a High-Pressure Steam Pipe
Failure of a Pipe Slip-on Flange
Failure of a Reactor Tube
Failure of an Aluminum Brass Condenser Tube
Failure of an Embrittled Tube
Galvanic Corrosion Failure of Austenitic Stainless Steel Pipe Flange Assemblies
Graphitization Related Failure of a Low-Alloy Steel Superheater Tube
Leaks in Copper Tubing From Cooling Coils of a Large Air-Conditioning Unit
Mercury Liquid Embrittlement Failure of 5083-O Aluminum Alloy Piping
Short-Term Failure of Carbon Steel Boiler Tubes
Steam Superheat 800H Tube Failure
Stress-Corrosion Cracking in a Downcomer Expansion Joint
Stress-Corrosion Cracking in a Stainless Steel Emergency Injection Pipe in a
Nuclear Reactor
Stress-Corrosion Cracking of Stainless Steel Superheater Tubing
Stress-Corrosion Cracking of a Swaged Stainless Steel Reheater Pendent Tube
Thermal Fatigue Failure of Alloy UNS NO8800 Steam Superheating Tubes 235-239

Tanks
Brittle Fracture Explosive Failure of a Pressurized Railroad Tank Car
Failure of Welded Helium Tanks
Failure of a Stainless Steel Tank Used for Storage of Heavy Water/Helium
Fatigue Failure at Fillet-Welded Nozzle Joints in a Type 316L Stainless Steel Tank

Auxilliary Components
Failure of AISI Type 347 Stainless Steel Bellows
Failure of a Martensitic Stainless Steel Ball Valve
Failure of a Reversible Flap Valve in a Thermal Power Station
Hydrogen Damage in a Waterwall Boiler Tube Section

ROTATING EQUIPMENT FAILURES

Blades, Disks, and Rotors
Cracking in a Steam Turbine Rotor Disk
Failure Analysis of a Cracked Low-Pressure Tube Blade
Failure of Non-Magnetic Retaining Ring in a High-Speed Generator Rotor
Failure Analysis of Turbine Blades
Fatigue Cracking of Gas Turbine Diaphragms
Fatigue Failure of Titanium Alloy Compressor Blades
Fatigue Fracture of a Fan Blade
Fatigue Fracture of a Precipitation-Hardened Stainless Steel Actuator Rod End
Metallurgical Analysis of Steam Turbine Rotor Disc
Thrust Bearing Failure Leading to the Destruction of a Propeller Rotor

Impellers
Aluminum/Refrigerant Reaction Resulting in the Failure of a Centrifugal

Compressor
Cracking of a Main Boiler Feed Pump Impeller
Fatigue Failure of an Aluminum Turbine Impeller
Metallurgical Failure Analysis of Cracks in a Compressor Turbine Impeller

Shafts
Failure Analysis of a Hydroturbine Shaft
Failure of a Crane Long-Travel Worm Drive Shaft
Failure of a Service Water Pump Shaft
Fatigue Failure of a Circulating Water Pump Shaft
Fracture of a Coupling in a Line-Shaft Vertical Turbine Pump

VALVE FAILURES
Dezincification of a Chrome-Plated Cylinder Gas Valve
Failure of Brass Hot Water Reheat Valves
Failure of Three Valve Body Castings
Fracture of a Spike Maul

FASTENER FAILURES
Anomalous Fractures of Diesel Engine Bearing Cap Bolts
Cracking at the Threads of Stud Bolts Used for Lifting Plastic Mold Dies
Failed Bolts From an Army Tank Recoil Mechanism
Failed Main Rotor Pitch Horn Bolt from an Army Helicopter
Failure Analysis of a Helicopter Main Rotor Bolt
Fracture of a Trunnion Bolt Used To Couple Railway Cars
Hydrogen-Assisted Stress Cracking of Carburized and Zinc Plated SAE Grade 8 Wheel
Studs
Hydrogen Embrittlement Delayed Failure of a 4340 Steel Draw-in Bolt

ELECTRICAL EQUIPMENT FAILURES
Arcing Fault Burndown in Low Voltage Residential Service Entrance with Aluminum
Conductors
Corrosion Fatigue Failure of Stainless Steel Load Cells in a Milk Storage Tank
Failure of Nickel Anodes in a Heavy Water Upgrading Plant
Fatigue Failures of Connecting Bolts in a Truck Crane
Formation of Refractory Films on Metal Contacts in an Electrical Switchgear
Stress-Corrosion Cracking in Stainless Steel Heater Sheathing
Termination Delamination of Surface-Mount Chip Resistors

MISCELLANEOUS FAILURES

Biomedical Components
Failure of a Stainless Steel Hip Fracture Fixation Device
Fatigue Fracture of Titanium Alloy Knee Prostheses
Fracture of a Cast Stainless Steel Femoral Prosthesis

Springs
Analysis of Music Wire Springs Used in a Printer Mechanism
Failed Missile Launcher Detent Spring

Tools
Brittle Failure of Titanium Nitride-Coated High Speed Steel Hob
Cracking on the Parting Line of Closed-Die Forgings
Spalling of a Ball-Peen Hammer

Industrial Structures
Brittle Fracture in a Large Grain Storage Bin
Chloride-Induced Stress-Corrosion Cracking of Coling Tower Hanger Rods

Nonmetallic Material
Failure of a Laminated-Paper Food Cooking Tray
Failure of a Squeeze-Clamped Polyethylene Natural Gas Pipeline
Feedwater Piping Erosion at a Waste-to-Energy Plant
Hydrogen Damage of Waterwall Tubes
Solvent-Induced Cracking Failure of Polycarbonate Ophthalmic Lenses

High-Temperature
Creep Failure of a Superheater Tube Promoted by Graphitization
Failure of a Reformer Tube Weld by Cracking
Hot Corrosion of Stage 1 Nozzles in an Industrial Gas Turbine

General
Corrosion Failure of Stainless Steel Components During Surface Pretreatment
Cracking During Forging of Extruded Aluminum Alloy Bar Stock Material
Failure of Compound Bow Handle Risers
Failure of a Steel Wire Rope From a Television Tower
Failure of a Transmission Brake Disc
Explosion of an Oxygen Line
Fatigue Failure of a Carbon Steel Piston Shaft on an Extrusion Press Billet-
Loading Tray
Fracture of the Bottom Platen of an 800 Ton Hydraulic Press
Hydrogen Embrittlement Cracking in a Batch of Steel Forgings
Index