Automotive

7 cases · 53 images

Crevice Corrosion in a Subsea System — Aspect Before Analysis

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Detail of the fracture in the WHEEL 1, changing direction of propagation.
71
VIEW
ML00183 / Dec.2022
Ductile Behavior of an Aluminum Wheel
M - Aluminum Silicon MagnesiumP - CastingAp - AutomotiveCd - Ductile Behavior
Cm - Aspect Before AnalysisDf - Fracture
Detailed aspect of the eye bolt fracture position, with strong plastic deformation indicating ductile overloading. The red marks in the thread surface of the bolt (in the left side of the image) correspond to the position where the nut was tight. Thread fillets adjacent to the fracture presented secondary cracks.
1125
VIEW
ML00120 / Jun.2018
Ductile Rupture of a Carbon Steel Eye Bolt
M - Low Carbon SteelP - FastenerAp - AutomotiveCd - Overload
Cm - Aspect Before AnalysisDf - Ductile Fracture
Scanning electron fractography of a chromium plated pin, close to the pin surface where the fatigue cracking started, showing intergranular morphology typical of a hydrogen embrittlement effect. It occurred because the low alloy pin was carburized, quenched and tempered, with a too high hardness structure, before the electrolytic plating.
837
VIEW
ML00081 / Aug.2017
Hydrogen Cracking of a Chromium Plated Carburized Pin
M - Low Alloy for Thermochemical TreatmentP - Chromium PlatedAp - AutomotiveCd - Hydrogen Embrittlement
Cm - Fractography by SEMDf - Brittle Fracture
Fracture occurred during fabrication of a low carbon steel automotive part, welded by SAW process in one fillet, between a superior plate (8mm thick) and an inferior plate (12 mm thick). See the schematic drawing in the next figure.
290
VIEW
ML00069 / May.2017
Liquation Cracks in SAW of Low Carbon Steel
M - Low Carbon SteelP - Fabrication WeldAp - AutomotiveCd - Welding Defect
Cm - Aspect Before AnalysisDf - Fracture
Aspect of the welded region after dye check showing several indications, later identified as hot cracks associated to the repair welding.
114
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Aspect by NDTDf - Cracks
Micrography of the weld metal presenting a martensitic island with microcracks, due to a localized increase in the manganese and silicon content, probably because an active flux was adopted in a condition where a high cleanning action was not required. A high flux-to-wire ratio (>1) could also be an issue.
795
VIEW
ML00067 / May.2017
Cold Cracks in C-Mn SAW Weld Metal
M - CMn SteelP - Fabrication WeldAp - AutomotiveCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Microcracks
The camshaft broke in a brittle way in a region where the shaft changed the geometry, close to a chilled lobe.
551
VIEW
ML00060 / Apr.2017
Brittle Fracture of a Chilled Cast Iron Camshaft
M - Chilled Cast IronP - ShaftAp - AutomotiveCd - Brittle Fracture
Cm - Aspect Before AnalysisDf - Fracture

More from these cases

ML00183 — Ductile Behavior of an Aluminum WheelM - Aluminum Silicon MagnesiumP - CastingAp - AutomotiveCd - Ductile Behavior
Detail of the crack in the WHEEL 2, changing direction of propagation exactly like the other whel.
66
VIEW
ML00183 / Dec.2022
Ductile Behavior of an Aluminum Wheel
M - Aluminum Silicon MagnesiumP - CastingAp - AutomotiveCd - Ductile Behavior
Cm - Aspect Before AnalysisDf - Cracking
WHEEL 1 fracture detail showing a small shrinkage in the left side of the photo and dimples in the right side of the photo.
73
VIEW
ML00183 / Dec.2022
Ductile Behavior of an Aluminum Wheel
M - Aluminum Silicon MagnesiumP - CastingAp - AutomotiveCd - Ductile Behavior
Cm - Fractography by SEMDf - Ductile Fracture
WHEEL 1 fracture detail showing predominantly dimples as the fracture micromechanism.
74
VIEW
ML00183 / Dec.2022
Ductile Behavior of an Aluminum Wheel
M - Aluminum Silicon MagnesiumP - CastingAp - AutomotiveCd - Ductile Behavior
Cm - Fracture Surface AspectDf - Ductile Fracture
WHEEL 1 fracture detail showing small regions of shearing.
67
VIEW
ML00183 / Dec.2022
Ductile Behavior of an Aluminum Wheel
M - Aluminum Silicon MagnesiumP - CastingAp - AutomotiveCd - Ductile Behavior
Cm - Fractography by SEMDf - Elongated Dimples
WHEEL 1 fracture detail showing small regions with smooth aspect, and brittle microcracks. But predominantly the micromechanism is by dimples.
70
VIEW
ML00183 / Dec.2022
Ductile Behavior of an Aluminum Wheel
M - Aluminum Silicon MagnesiumP - CastingAp - AutomotiveCd - Ductile Behavior
Cm - Fractography by SEMDf - Cracks

+15 more from this case →

ML00120 — Ductile Rupture of a Carbon Steel Eye BoltM - Low Carbon SteelP - FastenerAp - AutomotiveCd - Overload
Micrography as polished of the longitudinal section of the bolt at the fracture position. The fracture (top of the figure) is rough, characteristic of a ductile fracture.
196
VIEW
ML00120 / Jun.2018
Ductile Rupture of a Carbon Steel Eye Bolt
M - Low Carbon SteelP - FastenerAp - AutomotiveCd - Overload
Cm - As polished micrographyDf - Fracture
Micrography as polished of the longitudinal section of the bolt at the first thread fillet below the fracture, presenting a cracking at the bottom of the fillet.
194
VIEW
ML00120 / Jun.2018
Ductile Rupture of a Carbon Steel Eye Bolt
M - Low Carbon SteelP - FastenerAp - AutomotiveCd - Overload
Cm - NItal Etched MacroDf - Crack
Micrography of a longitudinal section of the bolt at the thread fillet adjacent to the fracture, presenting a ductile cracking from the bottom of the fillet, propagating with a strong plastic deformation. The deformation lines of the cold formed process (thread cold rolling) are also deformed by the cracking propagation.
141
VIEW
ML00120 / Jun.2018
Ductile Rupture of a Carbon Steel Eye Bolt
M - Low Carbon SteelP - FastenerAp - AutomotiveCd - Overload
Cm - Nital Etched Micrography by OMDf - Ductile Crack
Micrographic detail of a longitudinal section of the bolt at the bottom of the thread fillet adjacent to the fracture, presenting a ductile cracking propagating with a plastic deformation. The deformation lines of the cold formed process are also deformed by the cracking propagation and there are some other small secondary cracks at 90° from the principal cracking.
133
VIEW
ML00120 / Jun.2018
Ductile Rupture of a Carbon Steel Eye Bolt
M - Low Carbon SteelP - FastenerAp - AutomotiveCd - Overload
Cm - Nital Etched Micrography by OMDf - Ductile Crack
ML00081 — Hydrogen Cracking of a Chromium Plated Carburized PinM - Low Alloy for Thermochemical TreatmentP - Chromium PlatedAp - AutomotiveCd - Hydrogen Embrittlement
The aspect of the pin fracture surface shows that a fatigue crack propagated from the pin surface at the edge of a lubrication hole in the chromium plated pin.
83
VIEW
ML00081 / Aug.2017
Hydrogen Cracking of a Chromium Plated Carburized Pin
M - Low Alloy for Thermochemical TreatmentP - Chromium PlatedAp - AutomotiveCd - Hydrogen Embrittlement
Cm - Aspect Before AnalysisDf - Fatigue Fracture
Micrographic detail of an intergranular secondary crack (adjacent to the broken surface) propagating from the hard chromium layer.
75
VIEW
ML00081 / Aug.2017
Hydrogen Cracking of a Chromium Plated Carburized Pin
M - Low Alloy for Thermochemical TreatmentP - Chromium PlatedAp - AutomotiveCd - Hydrogen Embrittlement
Cm - Nital Etched Micrography by OMDf - Intergranular Cracking
Scanning electron fractography of the pin in the fatigue subcritical crack growth, showing striation and regions of smashing .
40
VIEW
ML00081 / Aug.2017
Hydrogen Cracking of a Chromium Plated Carburized Pin
M - Low Alloy for Thermochemical TreatmentP - Chromium PlatedAp - AutomotiveCd - Hydrogen Embrittlement
Cm - Fractography by SEMDf - Fatigue Striation
Fractographic detail of the fatigue striation in the subcritical crack growth.
37
VIEW
ML00081 / Aug.2017
Hydrogen Cracking of a Chromium Plated Carburized Pin
M - Low Alloy for Thermochemical TreatmentP - Chromium PlatedAp - AutomotiveCd - Hydrogen Embrittlement
Cm - Fractography by SEMDf - Fatigue Striation
Fractography of the final fracture of the pin, presenting dimples (ductile fracture), after the nucleation and subcritical propagation of fatigue fracture.
36
VIEW
ML00081 / Aug.2017
Hydrogen Cracking of a Chromium Plated Carburized Pin
M - Low Alloy for Thermochemical TreatmentP - Chromium PlatedAp - AutomotiveCd - Hydrogen Embrittlement
Cm - Fractography by SEMDf - Dimples
ML00069 — Liquation Cracks in SAW of Low Carbon SteelM - Low Carbon SteelP - Fabrication WeldAp - AutomotiveCd - Welding Defect
Schematic drawing presenting the fracture occured during fabrication of a low carbon steel automotive part.
82
VIEW
ML00069 / May.2017
Liquation Cracks in SAW of Low Carbon Steel
M - Low Carbon SteelP - Fabrication WeldAp - AutomotiveCd - Welding Defect
Cm - Identification drawingDf - Fracture
The macrography presents the position of the fracture in the superior plate (8 mm thickness).
61
VIEW
ML00069 / May.2017
Liquation Cracks in SAW of Low Carbon Steel
M - Low Carbon SteelP - Fabrication WeldAp - AutomotiveCd - Welding Defect
Cm - NItal Etched MacroDf - Fracture
The macrography presents the position of the fracture in the fillet weld side.
67
VIEW
ML00069 / May.2017
Liquation Cracks in SAW of Low Carbon Steel
M - Low Carbon SteelP - Fabrication WeldAp - AutomotiveCd - Welding Defect
Cm - NItal Etched MacroDf - Fracture
Micrography of the fracture at the superior plate (8 mm thickness). The fracture occurred in the coarse grain heat affected zone.
60
VIEW
ML00069 / May.2017
Liquation Cracks in SAW of Low Carbon Steel
M - Low Carbon SteelP - Fabrication WeldAp - AutomotiveCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Fracture
Micrography of the fracture at the fillet weld margin. The fracture occurred in the coarse grain heat affected zone of the superior plate (8 mm thickness).
54
VIEW
ML00069 / May.2017
Liquation Cracks in SAW of Low Carbon Steel
M - Low Carbon SteelP - Fabrication WeldAp - AutomotiveCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Fracture

+3 more from this case →

ML00070 — Automotive Light Alloy Wheel Repaired By WeldingM - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Hot cracks in the fusion zone. The eutectic regions were melted and cracked in an interdendritic morphology.
37
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Micrography by SEMDf - Cracks
Detail of the hot cracks in the fusion zone. The eutectic regions were melted and cracked in an interdendritic morphology. Keller etch.
50
VIEW
ML00070 / Jan.2019
Automotive Light Alloy Wheel Repaired By Welding
M - Aluminum Silicon MagnesiumP - RimAp - AutomotiveCd - Removed From Service
Cm - Micrography by SEMDf - Cracks
ML00067 — Cold Cracks in C-Mn SAW Weld MetalM - CMn SteelP - Fabrication WeldAp - AutomotiveCd - Welding Defect
Aspect of the fracture in the middle of the fillet weld between the superior plate (Low carbon 8 mm thick no longer there) and the inferior plate (C-Mn 12 mm thick), in an overlap geometry.
77
VIEW
ML00067 / May.2017
Cold Cracks in C-Mn SAW Weld Metal
M - CMn SteelP - Fabrication WeldAp - AutomotiveCd - Welding Defect
Cm - Aspect Before AnalysisDf - Fracture
Micrography of the fractured region in the center of the fillet weld metal, that is hard due to the increase in the Mn and Si contents.
43
VIEW
ML00067 / May.2017
Cold Cracks in C-Mn SAW Weld Metal
M - CMn SteelP - Fabrication WeldAp - AutomotiveCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Fracture
Micrography of the weld metal in a cracked region.
41
VIEW
ML00067 / May.2017
Cold Cracks in C-Mn SAW Weld Metal
M - CMn SteelP - Fabrication WeldAp - AutomotiveCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Cracks
Micrographic detail of the weld metal in a cracked region.
77
VIEW
ML00067 / May.2017
Cold Cracks in C-Mn SAW Weld Metal
M - CMn SteelP - Fabrication WeldAp - AutomotiveCd - Welding Defect
Cm - Nital Etched Micrography by OMDf - Cracks
ML00060 — Brittle Fracture of a Chilled Cast Iron CamshaftM - Chilled Cast IronP - ShaftAp - AutomotiveCd - Brittle Fracture
Micrography transverse to the fracture, showing that the region that broke presented in the shaft thickness a large amount of brittle structures (ledeburite), that suggest a too large extension of the chill effect.
53
VIEW
ML00060 / Apr.2017
Brittle Fracture of a Chilled Cast Iron Camshaft
M - Chilled Cast IronP - ShaftAp - AutomotiveCd - Brittle Fracture
Cm - Nital Etched Micrography by OMDf - Fracture
Micrographic detail of the structure in a section transverse to the fracture, showing that the brittle region in the shaft is associated to a large amount of ledeburite.
43
VIEW
ML00060 / Apr.2017
Brittle Fracture of a Chilled Cast Iron Camshaft
M - Chilled Cast IronP - ShaftAp - AutomotiveCd - Brittle Fracture
Cm - Nital Etched Micrography by OMDf - Fracture
Camshaft in the broken region, close to a lobe where the cast iron was chilled.
48
VIEW
ML00060 / Apr.2017
Brittle Fracture of a Chilled Cast Iron Camshaft
M - Chilled Cast IronP - ShaftAp - AutomotiveCd - Brittle Fracture
Cm - Aspect Before AnalysisDf - Fracture