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Fracture
Analysis Job Aid
Fracture Analysis
Procedure
Identify Fractures
Brittle Fractures
Ductile Fractures
Fatigue Fractures
Initiation Sites
Stress Raisers
Load Types
Fracture Analysis
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Fracture Analysis
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Identify Fractures
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Fracture Analysis
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Brittle Fractures
Fracture Analysis
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Ductile Fractures
Fracture Analysis
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Fatigue Fractures
root cause of failure making them the most interesting and useful
fracture.
Fracture Analysis
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Initiation Sites
The initiation site is one of the most important sites on any fracture
as it is the location where cracks first started.
The initiation site of a brittle fracture can be just about anywhere on
the surface.
The initiation site of a ductile fracture usually occurs at the part's
smallest cross section and is of little importance.
Initiation sites of fatigue fractures are stress raisers and are very
important to helping identify why the fatigue crack started.
Once a stress raiser has been identified, the next step is to
determine whether it is a normal stress raiser or abnormal stress
raiser.
Fracture Analysis
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Stress Raisers
Stress raisers are physical changes in a part that results in an increase of
internal stress in the part at the location of the physical change. This
change can be a simple dimensional change such as a reduction in
diameter of a rod, it can be a design feature such as a keyway or it can be
something more subtle such as residual tensile stress due to heat
treatment.
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Stress raisers that are part of the design and manufacturing of the
component are considered normal stress raisers while stress raisers due to
wear, corrosion, excessive residual stress, dents, cracks or material
problems are abnormal stress raisers.
When analyzing fatigue fractures, once the initiation site is located, the
stress raiser starting the fatigue should be identified and investigated to
see if it is normal or abnormal.
Abnormal Stress Raisers
Normal Stress Raisers
Fracture Analysis
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Load Types
Fracture Analysis
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Knowledge Checks
Analyzing Fractures
Fracture Analysis
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Glossary of Terms
A
B
Brittle fractures are fractures that occur very rapidly with the entire part,
component or structure breaking in two in a fraction of a second to a few
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L
Load
M
N
O
P
Plastic deformation occurs when parts are loaded beyond their normal
strength and are forced to bend, twist, distort or stretch changing the shape
of the part noticeably and permanently.
Q
R
S
Shear lips are jagged rough edges extending part or all of the way around
the circumference of ductile fractures. The shear lip is formed when the last
material to fracture finally tears apart on about a 45 degree angle.
Sparkles means a fracture surface glitters when it is moved in the light. It
appears to have tiny diamonds embedded in the surface. It is typical of
fractures of steel and cast aluminum and indicates a brittle fracture
occurred. Sparkles are caused by crystals of the metal fracturing along flat
crystalline surfaces. It is also referred to as crystalline fracture.
Stress is the internal force that exists on each small cross sectional area of
material in a part and is caused by the external applied load.
Stress raisers are physical changes in a part that results in an increase of
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internal stress in a part at the location of the physical change. This change
can be a simple dimensional change such as a reduction in diameter of a
rod, it can be a design feature such as a keyway or it can be something
more subtle such as residual tensile stress due to heat treatment. Wear,
corrosion or other surface damage can also be stress raisers.
T
U
V
W
X
Y
Z
Fracture Analysis
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In this module we will learn the basics of identifying the three different
types of fractures that occur in metals. Then will will learn how to use these
fractures to locate the starting point of the crack. Once we have this
information we can usually find the reason why cracking started.
Most product failures are a result of improper operation, application or
maintenance and the fractures can identify this. Less frequently, product
problems can cause fractures and we can discover this also by knowing
how to analyze the fracture surfaces. The final purpose is to help arrive at
the events that can be used to build a time line to arrive at the root cause
of failure.
Eight Steps of Applied Failure Analysis
In This Presentation
Basic Terminology
Different Rates of Loading
Fracture Analysis
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Brittle Fractures
Chevrons
Chevrons are ridges on brittle fractures that usually get closer together as
they approach the initiation site of a brittle fracture.
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Brittle Fractures
Sparkles
sparklesmeans means a fracture surface glitters when it is moved in the
light. It appears to have tiny diamonds embedded in the surface. It is
typical of fractures of steel and cast aluminum and indicates a brittle
fracture occurred. Sparkles are caused by crystals of the metal fracturing
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Fracture Analysis
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Ductile Fractures
Shear Lips
Shear lips are jagged rough edges extending part or all of the way around
the circumference of ductile fractures. The shear lip is formed when the last
material to fracture finally tears apart on about a 45 degree angle.
A shear lip on this connecting rod bolt can be seen sticking out at the lower
edge of the bolt.
A closer look at the bolt shows a shear lip extends all the way around the
bolt.
The shear lip is largest at the bottom and also at the more difficult to see
top area of the bolt where it is still down in the bolt hole.
Fracture Analysis
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Ductile Fractures
Plastic Deformation
Plastic deformation occurs when parts are loaded beyond their normal
strength and are forced to bend, twist, distort or stretch changing the shape
of the part noticeably and permanently.
Fracture Analysis
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Fatigue Fractures
Beach Marks
Beach marks are similar to growth rings in a tree and usually expand out
and away from the initiation site. They focus on the starting point of the
fracture. The beach marks on this fracture point to the lower edge as the
initiation site.
Fracture Analysis
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Fatigue Fractures
Ratchet Marks
The two bright radial features on this fracture at the initiation site are
ratchet marks. Ratchet marks form when two fatigue fractures are growing
at the same time at approximately the same location with one being just a
little above or below the other. At some point in time the material
separating the two fractures breaks vertically between them producing a
vertical wall or ratchet mark.
Fracture Analysis
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Fatigue Fractures
Final Fracture
The large area on this fracture above the beach marks is the final fracture.
This portion of the fracture occurred in just a fraction of a second when the
part could no longer carry the repeated cyclic loading. Final fracture size
can tell a lot about the applied load. A large final fracture indicates a very
high applied load.
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Stress Raisers
Abnormal Stress Raisers
Abnormal stress raisers generally are of five kinds
Material problems
Pre-cracks in parts
Surface damage such as corrosive pitting, unusual wear,
dents, nicks, or scratches
Improper manufacturing processes
The first two will produce fatigue cracks starting subsurface.
The others will start fatigue cracks on the surface.
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This large crankshaft has fractured at a main journal fillet. A closeup of the
initiation site located by the arrow is to the right.
A typical material problem produced the abnormal stress raiser that started
a subsurface fatigue crack in the crankshaft. This type of fatigue fracture is
sometimes called a bull's eye since it produces a target like appearance
with the impurity at the center.
This piston pin contains a material impurity which started a fatigue fracture
which eventually produced a major engine failure. The picture to the right is
a closeup view of the material problem.
The straight line running from left to right near the center of the picture is
the material impurity. Beach marks can be seen growing upward and
downward fromt this area.
This steel casting shows another material problem that sometimes occurs
in castings. The closeup at the right is of the problem area.
The closeup shows a cavity or large hole in the casting caused by improper
pouring practices. It is called a shrinkage cavity. This hole was so large
that it failed abruptly very early in its life.
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This picture has the various areas mentioned in the previous picture
identified to help locate the pre-crack and the other features of the fracture.
This marked up image shows the location of the pre-crack and the ratchet
marks and beach marks starting inside the part at the bottom edge of the
pre-crack.
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This closer view shows the abnormal stress raiser and the initiation site of
the fatigue crack.
This bolt has not fractured yet but has a high risk of a fatigue crack starting
at the reddish stained area of fretting corrosion. This type of surface
damage produces surface pitting which can be a severe stress raiser
resulting in fatigue fracture. The source of the vibration that caused the
fretting should be identified and corrected
Fracture Analysis
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This ground engaging tool had a fatigue fracture start from a dent. In this
case the dent was intentional. It is the letter "T" in the word CAT. The
trademark location had to be moved as it created an abnormal stress raiser
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The fillet radius on this cylinder rod was machined much too small creating
a very abnormal stress raiser
Fracture Analysis
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Stress Raisers
Normal Stress Raisers
Radii such as at the root of gear teeth are normal stress raisers
Fracture Analysis
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Tests
Analyzing Fractures
For each question below, click on the circle next to the correct answer.
When you are finished with the test, push the 'Score my test' button at the
bottom of the page. Good luck!
Question #1
Which of the following answers best describes the various types of
fracture?
A. Brittle and ductile
B. Fatigue and brittle
C. Fatigue and ductile
D. Brittle, ductile and fatigue
E. All of the above
Question #2
Which type of fracture is usually a result and not the root cause of a
failure?
A. Brittle
B. Ductile
C. Both brittle and ductile
D. Fatigue
E. All of the above
Question #3
Which of the following are characteristics of brittle fracture?
A. Rough
B. Little or no permanent change in shape
C. Chevrons
D. Crystalline fracture
E. All of the above
Question #4
Ductile fractures will usually have:
A. Beach marks
B. Ratchet marks
C. Chevrons
D. Little or no plastic deformation
E. Shear lips
Question #5
Beach marks show the:
A. Origin of a fatigue fracture
B. Location where the part finally failed
C. Location of least interest
D. Fracture was due to a sudden overload
E. None of the above
Question #6
Fatigue fracture origins can be of special interest because:
A. Fatigue starts at a stress raiser
B. They always indicate the root cause of failure
C. They indicate the part has been in service far too long
D. They indicate the part was used in an abusive manner
E. All of the above
Question #7
Once a stress raiser has been identified on a fatigue fracture, the next
thing to do is:
A. Examine all other failed parts
B. Determine if abuse caused the failure
C. Decide if wear played a role in failure
D. Determine if it is abnormal
E. Look for evidence of corrosion
Question #8
Fatigue starting inside the part at a well defined and localized area
indicates:
A. The part was used far too long
B. The part was subjected to a corrosive environment
C. The part may have been abused during service
D. The part is fine
E. None of the above
Question #9
Beach marks and ratchet marks that do not extend all the way to a part's
surface indicate:
A. The part was cracked before going into service
B. The part was not the cause of the problem
C. The part was subjected to a corrosive environment
D. The failure was related to excessive part wear
E. None of the above
Question #10
Fatigue that starts at a normal stress raiser indicates:
A. The application should be investigated
B. The part is the root cause
C. The part was used far too long
D. A material flaw caused the failure
E. The manufacturing process produced a cracked part
This test was made with free online software from Merex Corporation.
Analyzing Fractures
Fracture Analysis
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Analyzing Fractures
Eight Steps of Applied Failure Analysis
Fracture Analysis
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Analyzing Fractures
In This Presentation
Fracture Analysis
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Analyzing Fractures
Basic Terminology
There are three basic fracture types, brittle, ductile and fatigue.
Both brittle and ductile fractures occur rapidly, traveling thousands of
meters per second through metal in some instances. They produce rough
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fracture surfaces.
Fatigue usually occurs over a much longer period of time, maybe days,
weeks, months or years. It usually leaves a smooth fracture surface.
We might already guess that as we build time lines in Step 4, we would
expect fatigue fractures to be involved with events that occur early on the
time line and brittle and ductile fractures will be associated with events that
occur very close or at the end of the time line. For this reason we will say
that fatigue fractures are usually closely related to root causes, while
brittle and ductile fractures are usually related to results.
Initiation sites are the locations where fatigue cracking starts and this is
where we will find the stress raiser that started it.
Stress raisers are areas of physical differences contained by all parts that
cause the applied loads to be concentrated more heavily at certain
locations. We will give some examples later.
After a crack grows a certain distance through a part, the remaining cross
sectional area can no longer carry the loads and the remaining material
fractures. This area is called final fracture.
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Analyzing Fractures
Different Rates of Loading
Just a reminder that there are three basic loading rates which have an
effect in producing the three fracture types. Both impact and overloads are
single load applications. Cyclic loads are repeated. Remember to
distinguish between a single overload which usually causes ductile fracture
and cyclic overload which causes fatigue fracture
Fracture Analysis
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Analyzing Fractures
Brittle Fracture Characteristics
Now lets learn to identify brittle fractures. They have four characteristics.
They are rough.
They do not deform much at the edges during fracture, bend, twist,
shear called plastic deformation. This means you can put the two
halves of the fracture back together and the part looks very similar to
the way it looked before breaking.
Brittle fractures either sparkle like diamonds are embedded on the
fracture surface or ...
they have ridges forming chevrons or v-shaped structures on the
surface. Harder steels form sparkles while softer steels form chevrons.
This gives us a hint about the parts hardness. These characteristics
hold true for steel, aluminum and most other crystalline materials but
does not hold true for cast iron. Cast iron fracture is extremely difficult
to analyze, even by expert metallurgists.
The most important thing to remember about brittle fractures is they are
usually results.
Fracture Analysis
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Analyzing Fractures
Fractured Component
Fracture Analysis
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Analyzing Fractures
Track Tensioner Spring Fracture
Fracture Analysis
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Analyzing Fractures
Fractured Piston Skirt
Fracture Analysis
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Analyzing Fractures
Fractured Gear Tooth
Fracture Analysis
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Analyzing Fractures
Fractured Gear
Fracture Analysis
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Analyzing Fractures
Brittle cracks are most frequently caused by impact or shock loads. The
individual grains of steel making up the part have no time to deform and try
to carry this sudden extra load.
In most instances the grains fracture along the layers of unit cells. This is
known as cleavage.
If the metal is very hard and fractures almost entirely by cleavage, the
cleaved grains reflect light creating the sparkle on certain fractures.
Fracture Analysis
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Analyzing Fractures
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Fracture Analysis
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Analyzing Fractures
Brittle Fracture
Brittle fracture along the layers of unit cells is equivalent to cutting the
deck or separating it as pictured. Notice the grain or deck has not changed
its original shape meaning no plastic deformation occurred during the
fracture.
Fracture Analysis
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Ductile fractures are similar to brittle fractures in that they are usually
results of a single excessive load being applied. But in this case the load is
not applied fast enough to prevent the part from bending and deforming to
carry the load. This kind of fracture might occur in a connecting rod bolt if
the other bolt in the pair should come loose and fall out of the rod. The
remaining tight bolt is now overloaded and stretches, bends and breaks
due to the overload.
Ductile fractures are rough with dark surfaces, show lots of deformation
usually with a shear lip at the edges, occur rapidly and may have a woody
texture if the fracture runs in the direction of grain flow.