Exp No: MT3031/03

FAILURE ANALYSIS OF
METALLIC MACHINE
ELEMENTS

INSTRUCTED BY:
MR. THEMIYA
GROUP MEMBERS:
1. DHANANJAYA K.D.L.
2. ABHIRAMI T NAME: CHATHUMINDA G.A.Y.
3. ANJANA E.A.O.
COURSE: B.SC. ENGINEERING (HONS.)
4. BANDARA H.M.K.D
5. BIBULEWELA P.A.C
GROUP: A
6. CHATHUMINDA G.A.Y
7. DAHANAYAKE A.H.
INDEX NO: 210080F
8. DANINDI H.M.T.
9. DE SILVA G.A.I.
DATE OF PERFORMANCE: 28/08/2024
10. DESHAPRIYA M.P.P.
11. DHARMADASA W.H.M.A.D.
DATE OF SUBMISSION:
12. DILSHAN A.K.R.
TITLE: FAILURE ANALYSIS OF METALLIC MACHINE ELEMENTS

INTRODUCTION

The analysis of engineering failures plays a critical role in the fields of

Materials Engineering and Engineering Design, serving as an essential feedback mechanism for
improving design processes and preventing future failures. By understanding the failure mechanisms
that lead to the breakdown of machine elements, engineers can implement more robust designs and
develop effective remedial measures. The most common and effective approach in failure analysis
involves examining and testing materials to identify the root cause of failure. Various failure
mechanisms, such as fatigue failure, corrosion failure, stress corrosion cracking, ductile and brittle
fractures, hydrogen embrittlement, creep, and stress rupture, are typically identified through careful
observation of the fracture surface.
In this laboratory experiment, the focus is on conducting a failure analysis of
metallic machine elements by observing their fracture surfaces. Participants are provided with several
metallic samples that have undergone different types of failures. The objective is to identify the type
of fracture by critically examining the fracture surface, using tools such as low-power magnifying
glasses or stereomicroscopes. By analyzing the fracture features, participants can determine the
possible causes of failure and suggest potential remedial methods to enhance the reliability and
performance of engineering components
THEORY
Types of failures

o Ductile Failure
o Brittle Failure
o Fatigue Failure
o Creep Failure

Mechanisms of Material Failure

Mechanisms of material failure revolve around how cracks initiate and

propagate within a material and how these processes lead to eventual breakdown. Crack initiation
often occurs at stress concentrators, such as surface defects, voids, inclusions, or grain boundaries,
where localized stress exceeds the material’s strength. Once initiated, cracks can propagate under the
influence of applied stress or environmental conditions, such as corrosive environments or high
temperatures. The Dislocation Theory explains plastic deformation in crystalline materials through
the movement of dislocations—line defects that form half-planes within the crystal structure. As
stress is applied, these dislocations move and interact with obstacles like grain boundaries, leading to
strain hardening. When dislocation motion is restricted, the material becomes more brittle, increasing
the likelihood of failure. Fracture Mechanics further explores the conditions under which cracks
grow using parameters like stress intensity factors and fracture toughness to predict when a material
will fail. Environmental effects such as oxidation and chemical exposure, can also exacerbate crack
growth and lead to failure through mechanisms like stress corrosion cracking and highlighting the
complex interplay between material properties, stress conditions, and environmental factors in
determining failure modes.
 OBSERVATION SHEET

NAME : CHATHUMINDA G.A.Y.

TITLE : FAILURE ANALYSIS OF METALLIC MACHINE ELEMENTS
INDEX NO : 210080F
GROUP :A
DATE OF PER : 04/09/2024
INSTRUCTED BY :

01. Tensile sample 02.Gear axel

03.Gear shaft 04.Shaft I

11.Gear shaft
 06.Shaft III
05.Shaft II

07.Shaft end I 08.Pin I

10.Pin II
09.Shaft end II
RESULTS

1. Tensile sample
• Ductile Failure due to Tensile stress
2. Gear axel
• Ductile Failure due to Torsion and Fatigue
3. Gear shaft
• Due to Torsion
4. Shaft I
• Ductile Failure due to Torsion
5. Shaft II
• Brittle Failure due to Torsion
6. Shaft III
• Brittle Failure due to Torsion
7. Shaft end I
• Brittle Failure due to Fatigue
8. Pin I
• Brittle Failure due to Torsion
9. Shaft end II
• Ductile Failure due to Torsion
10. Pin II
• Fatigue Failure
11. Gear shaft
• Fatigue Failure
DISCUSSION

What are the Possible failure mechanisms for metallic machine components?

1. Fatigue Failure:
Fatigue failure occurs due to repeated cyclic loading, even if the applied stress is below the material's
yield strength. Over time, microscopic cracks initiate at stress concentrators like notches, sharp
corners, or surface defects, and these cracks grow with each loading cycle. Eventually, the cracks
reach a critical size, leading to sudden and catastrophic failure. Fatigue is a common failure
mechanism in rotating machinery, automotive parts, and aircraft components.

2. Corrosion Failure:
Corrosion is a chemical or electrochemical reaction between a metal and its environment, leading to
material degradation. It can weaken metallic components by reducing their cross-sectional area and
creating stress concentrators that facilitate crack initiation. Common forms include uniform corrosion,
pitting corrosion, galvanic corrosion, and crevice corrosion. Corrosion is particularly concerning in
components exposed to moisture, chemicals, or saline environments, such as pipelines, marine
structures, and chemical processing equipment.

3. Creep Failure:
Creep is the gradual, time-dependent deformation of materials under constant stress at elevated
temperatures. It occurs in three stages: primary (decreasing creep rate), secondary (steady-state
creep), and tertiary (accelerating creep leading to failure). Creep failure is a major concern for
metallic components operating at high temperatures, such as turbine blades, steam pipes, and nuclear
reactor components.

4. Ductile and Brittle Fracture:

Ductile fracture is characterized by significant plastic deformation before failure, with visible necking
and dimpling on the fracture surface. Conversely, brittle fracture occurs with little to no plastic
deformation, and the fracture surface appears flat and featureless. Brittle fracture often happens
suddenly, making it more dangerous. The fracture mode depends on material properties, temperature,
and loading rate.

5. Wear and Fretting:

Wear occurs due to mechanical interactions between contacting surfaces, leading to material loss.
Common types include abrasive wear, adhesive wear, and surface fatigue wear. Fretting wear is
caused by small oscillatory movements between contacting surfaces, leading to surface damage and
crack initiation. Components such as bearings, gears, and joints are prone to wear and fretting.

How can the type of failure be identified ?

1. Visual Inspection:
Visual inspection is the first step in failure analysis. It involves examining the failed component with
the naked eye or a magnifying glass to identify obvious signs of failure, such as fractures, cracks,
corrosion, discoloration, deformation, wear patterns, or surface defects. The appearance of the
fracture surface (e.g., rough, smooth, fibrous, or crystalline) can provide initial clues about the type of
failure—whether it is ductile, brittle, fatigue, or corrosion-related.
2. Fractography:
Fractography involves the detailed examination of fracture surfaces using optical microscopes or
scanning electron microscopes (SEM). It helps in identifying the microscopic features of the fracture
surface, such as dimples (indicative of ductile failure), cleavage facets (indicative of brittle failure),
beach marks or striations (indicative of fatigue failure), and intergranular or transgranular cracking
(indicative of stress corrosion cracking or hydrogen embrittlement).

3. Chemical and Compositional Analysis:

Chemical analysis, such as energy-dispersive X-ray spectroscopy (EDS) or X-ray fluorescence
(XRF), can determine the composition of the material and identify any changes due to corrosion,
contamination, or material degradation. Understanding the alloy composition and potential impurities
helps in determining whether corrosion or environmental degradation contributed to the failure.

5. Mechanical Testing:
Mechanical tests, such as hardness testing, tensile testing, and impact testing, can help assess the
remaining mechanical properties of the material, such as strength, toughness, and hardness.
Comparing these properties to the original specifications can help identify changes due to
embrittlement, overloading, or heat treatment anomalies.

Justify your observations and decision for the cause of failure and remedial methods
proposed.

1. Tensile Sample
• Cause: Ductile failure occurs when the material undergoes significant plastic deformation
before breaking. This is common in materials subjected to tensile stress beyond their yield
strength.
• Remedy: Ensure that the tensile stress applied remains within the material's allowable limits by
selecting materials with higher yield strength or improving design to distribute stress more
evenly.
2. Gear Axel
• Cause: The combination of torsional stress and fatigue from repeated loading and unloading
can lead to ductile failure. This typically happens when the material experiences cyclic loading.
• Remedy: Improve material selection by choosing one with higher fatigue strength. Consider
stress-relief processes like shot peening, or redesign the part to minimize torsional loading.
3. Gear Shaft
• Cause: Torsional failure occurs when the material cannot resist twisting forces, leading to
shear failure.
• Remedy: Use materials with better shear strength or increase the cross-sectional area of the
shaft to reduce the applied stress.
4. Shaft I
• Cause: Similar to the gear shaft, ductile failure due to torsion indicates that the shaft
experienced significant twisting beyond its ductility limits.
• Remedy: Improve material ductility or reduce the torsional load through design changes such
as adding supports or reducing the torque applied.
5. Shaft II
• Cause: Brittle failure under torsion occurs when a material fractures without significant plastic
deformation. This may happen if the material is brittle or subjected to low temperatures or high
strain rates.
 • Remedy: Use materials with higher toughness, avoid sharp stress concentrations (like notches),
and ensure the operating environment avoids low temperatures that may lead to brittle
behavior.
6. Shaft III
• Cause: Similar to Shaft II, this indicates that the shaft material failed without deformation,
likely due to poor toughness or a notch effect.
• Remedy: Follow the same remedial methods as Shaft II — improve material toughness and
reduce stress concentrators in the design.
7. Shaft End I
• Cause: Brittle fatigue failure happens when the material endures cyclic stresses over time,
causing cracks to propagate and lead to sudden fracture.
• Remedy: Improve fatigue life through surface treatments like case hardening or polishing to
reduce crack initiation. Also, redesign to reduce cyclic stresses.
8. Pin I
• Cause: Brittle failure under torsion in a pin suggests insufficient toughness or resilience in the
material.
• Remedy: Use a more ductile material or consider reducing the applied torsional stress by
adjusting the design.
9. Shaft End II
• Cause: Similar to Shaft I, this failure indicates the shaft end was subjected to high torsional
stress leading to plastic deformation and eventual failure.
• Remedy: Use materials with higher ductility and torsional strength, or improve the design to
reduce torsional load.
10. Pin II
• Cause: Fatigue failure occurs due to repetitive stress cycles over time, weakening the pin until
it breaks.
• Remedy: Implement better material selection for higher fatigue resistance, reduce stress
concentrators, and ensure the applied loads are below fatigue limits. Consider periodic
inspections for early detection of cracks.
11. Gear Shaft
• Cause: Fatigue failure in the gear shaft implies that repeated loading and unloading cycles
caused micro-crack formation that eventually led to failure.
• Remedy: Use materials with better fatigue resistance, optimize the design to reduce stress
concentrations, and regularly inspect for signs of fatigue cracking.
Write a short essay on possible failure mechanisms in other materials like polymer,
ceramics and composites.

• Failure Mechanisms in Polymers

Polymers, including thermoplastics and thermosets, can fail through mechanisms like creep, stress
cracking, and thermal degradation. Creep occurs under sustained loads at elevated temperatures,
leading to gradual deformation due to their viscoelastic nature. Environmental stress cracking (ESC)
happens when polymers are exposed to tensile stress and a chemically aggressive environment,
resulting in brittle fractures without much plastic deformation. Fatigue failure may occur under cyclic
loading, and exposure to high temperatures or UV radiation can lead to thermal and photo-
degradation, causing chemical breakdown and embrittlement.

• Failure Mechanisms in Ceramics

Ceramics are hard, brittle materials that primarily fail by brittle fracture due to their inability to
deform plastically, which means cracks, often initiated at flaws, propagate rapidly under tensile
stress. Thermal shock is another critical failure mechanism; ceramics subjected to rapid temperature
changes can develop internal stresses leading to cracking. Creep can also be an issue for structural
ceramics at high temperatures. Although ceramics resist wear, abrasive wear can occur when they are
in contact with harder materials, degrading the surface.

• Failure Mechanisms in Composites

Composites, made from a matrix and reinforcement, have complex

failure mechanisms due to their heterogeneous nature. Delamination, or layer separation, often results
from impact or out-of-plane stresses and significantly reduces mechanical properties. Matrix cracking
and fiber breakage occur under mechanical loading, compromising the material's structural integrity.
Interfacial debonding, where the bond between matrix and reinforcement weakens, is another critical
mode that reduces strength. Environmental degradation, such as moisture absorption or UV exposure,
can weaken the fiber-matrix bond, leading to premature failure.
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[3] Wikipedia Contributors, “Metallurgical failure analysis,” Wikipedia, May 16, 2024.
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