Failure Analysis of Heat Treated Steel Components

This practical reference provides detailed focus on steel failures to help identify cause, prevent future occurrence, and improve reliability. The breadth of coverage and the numerous examples provide an invaluable resource for the designer, engineer, metallurgist, mechanical and materials engineers, quality control technicians, and heat treaters. Many examples of heat treatment failures are provided with special focus on the demands of tool Steels and Aerospace Materials. Failure Analysis of Heat Treated Steel Components......Page 1 Component Design......Page 10 Overview of the Mechanisms of Failure in Heat Treated Steel Components......Page 52 Mechanisms and Causes of Failures in Heat Treated Steel Parts......Page 96 General Aspects of Failure Analysis......Page 119 Failure in Steel Forging......Page 141 Failures from the Casting Process......Page 158 Sources of Failures in Carburized and Carbonitrided Components......Page 184 Fatigue Fracture of Nitrided Layers......Page 248 Steel Heat Treatment Failures due to Quenching......Page 261 Steel Failures due to Tempering and Isothermal Heat Treatment......Page 291 Failure Analysis in Tool Steels......Page 316 Case Studies of Steel Component Failures in Aerospace Applications......Page 356 Failure Analysis of Powder Metal Steel Components......Page 399 Induction Hardeni......Page 420 Failure Analysis of Steel Welds......Page 505 APPENDIX 1 - Metric Conversion Guide......Page 522 APPENDIX 2 - Temperature Conversion Table......Page 525 APPENDIX 3 - Steel Hardness Conversions......Page 529 APPENDIX 4 - Austenitizing Temperatures for Steels......Page 536 APPENDIX 5 - Temper Colors for Steels......Page 538 APPENDIX 6 - Physical Properties of Carbon and Low-Alloy Steels......Page 540 APPENDIX 7 - AISI to Non-AISI Steel Cross Reference......Page 550 APPENDIX 8 - Non-AISI to AISI Steel Cross Reference......Page 562 APPENDIX 9 - Iron-Carbon Equilibrium Diagram......Page 583 APPENDIX 10 - Isothermal Diagrams of Selected Steels......Page 584 APPENDIX 11 - Continuous Cooling Diagrams of Selected Steels......Page 597 Index......Page 624 This thorough reference work discusses various causes of failure with integrated coverage of process metallurgy of steels by forging, casting, welding, and various heat treatment processes. The breadth of coverage and the numerous examples provide an invaluable resource for the designer, engineer, metallurgist, mechanical and materials engineers, quality control technicians, and heat treaters. Potential failures of heat treated steel are detailed to help identify cause in preventing future occurrence and improving reliability of heat treating process and part performance. With a detailed focus on steel failures, this work can help identify root causes of failure, even if a thermal process is not specifically being considered as cause. Potential failures are covered with respect to design, material composition, component production, and thermal processing. Beginning with design aspects of component failure, chapters are devoted to several aspects of steel manufacturing including casting, forging or powder metallurgy in addition to heat treating operations. Topics include production problems such as porosity, flaws, and surface defect that may influence failures occurring during subsequent heat treatment or during use. Many examples of heat treatment failures are provided with special focus on the demands of Tool Steels and Aerospace Materials.