Risk and Failure Analysis for Improved Performance and Reliability PDF
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Risk and Failure Analysis for Improved Performance and Reliability SAGAMORE ARMY MATERIALS RESEARCH CONFERENCE PROCEEDINGS A vailable from Plenum Press 9th: Fundamentals of Deformation Processing Edited by Walter A. Backofen, John J. Burke, Louis F. Coffin, Jr., Norman L. Reed, and Volker Weiss 10th: Fatigue: An Interdisciplinary Approach Edited by John J. Burke, Norman L. Reed, and Volker Weiss 12th: Strengthening Mechanisms: Metals and Ceramics Edited by John J. Burke, Norman L. Reed, and Volker Weiss 13th: Surfaces and Interfaces I: Chemical and Physical Characteristics Edited by John J. Burke, Norman L. Reed, and Volker Weiss 14th: Surfaces and Interfaces II: Physical and Mechanical Properties Edited by John J. Burke, Norman L. Reed, and Volker Weiss 15th: Ultrarme-Grain Ceramics Edited by John J. Burke, Norman L. Reed, and Volker Weiss 16th: Ultrafine-Grain Metals Edited by John J. Burke and Volker Weiss 17th: Shock Waves Edited by John J. Burke and Volker Weiss 18th: Powder Metallurgy for High-Performance Applications Edited by John J. Burke and Volker Weiss 19th: Block and Graft Copolymers Edited by John J. Burke and Volker Weiss 20th: Characterization of Materials in Research: Ceramics and Polymers Edited by John J. Burke and Volker Weiss 21st: Advances in Deformation Processing Edited by John J. Burke and Volker Weiss 22nd: Application of Fracture Mechanics to Design Edited by John J. Burke and Volker Weiss 23rd: Nondestructive Evaluation of Materials Edited by John J. Burke and Volker Weiss 24th: Risk and Failure Analysis for Improved Performance and Reliability Edited by John J. Burke and Volker Weiss Risk and Failure Analgslsu IlIIpIlJ\ed Pemrmance and ReIlablllty Edited by John J.Burke Army Materials and Mechanics Research Center Watertown, Massachusetts and Volker Weiss Syracuse University Syracuse, New York PLENUM PRESS • NEW YORK AND LONDON Library of Congress Cataloging in Publication Data Sagamore Army Materials Research Conference, 24th, Raquette Lake, N.Y., 1977. Risk and failure analysis for improved performance and reliability. Includes index. 1. Materials-Testing-Congresses. 2. Reliability (Engineering)-Congresses. 3. Muni tions-Materials-Testing-Congresses. I. Burke JohnJ. II. Weiss, Volker, 1930- III. Title. TA41O.S17 1977 620.11 80-12346 ISBN 978-1-4684-7813-6 ISBN 978-1-4684-7811-2 (eBook) DOI 10.1007/978-1-4684-7811-2 Proceedings of the Twenty-fourth Sagamore Army Materials Research Conference on Risk and Failure Analysis for Improved Performance and Reliability, held at Bolton Landing, Lake George, New York, August 21-26,1977. © 1980 Plenum Press, New York Softcover reprint of the hardcover 1st edition 1980 A Division of Plenum Publishing Corporation 227 West 17th Street, New York, N.Y. 100ll All rights reserved No part of this book may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, microfilming, recording, or otherwise, without written permission from the Publisher SAGAMORE CONFERENCE COMMITTEE Chairman JOHN J. BURKE Army Materials and Mechanics Research Center Program Director VOLKER WEISS Syracuse University Secretary ARAM TARPINIAN Army Materials and Mechanics Research Center Conference Coordinator JOSEPH A. BERNIER Army Materials and Mechanics Research Center PROGRAM COMMITTEE JOHN J. BURKE Army Materials and Mechamcs Research Center M. J. BUCKLEY Air Force Materials Laboratory G.DARCY Army Materials and Mechanics Research Center H.HERGLOTZ E. I. du Pont de Nemours & Company GEORGE MAYER Army Research Office R. B. THOMPSON Rockwell International Science Center VOLKER WEISS Syracuse University S. WEISSMANN Rutgers University Arrangements at Sagamore Conference Center Helen B. DeMascio Syracuse University Preface The Army Materials and Mechanics Research Center of Water town, Massachusetts in cooperation with the Materials Science Group of the Department of Chemical Engineering and Materials Science of Syracuse University has conducted the Sagamore Army Materials Research Conference since 1954. The main purpose of these conferences has been to gather together over 150 scientists and engineers from academic institutions, industry and government who are uniquely qualified to explore in depth a subject of importance to the Department of Defense, the Army and the scientific community. This volume, RISK AND FAILURE ANALYSIS FOR IMPROVED PERFORMANCE AND RELIABILITY, addresses the areas of Techniques of Failure Analysis, Risk and Failure Analysis for Design Against Fracture, Risk and Failure Analysis for Design Against Fatigue, Elevated Temperature Effects, Environmental Effects, Systems Approach to Production Reliability Integration and Outlook - Emerging Needs and Techniques. We wish to acknowledge the dedicated assistance of Joseph M. Bernier of the Army Materials and Mechanics Research Center and Helen Brown DeMascio of Syracuse University throughout the stages of the conference planning and finally the publication of this book is deeply appreciated. Syracuse University Syracuse, New York The Editors Contents SESSION I KEYNOTE ADDRESS 1. Risk and Failure Analysis for Improved Performance and Reliability. 1 T. J. Dolan SESSION II TECHNIQUES OF FAILURE ANALYSIS G. Bruggeman, Moderator 2. NDT - An Aid to Failure Analysis . . . . 43 H. P. Hatch 3. X-Ray Diffraction Techniques in Analysis and Prediction of Failure . . . . . . . . . . . . . . . S3 H. K. Herglotz 4. Holography for Defect Detection on Artillery Projectiles. . . . . . . . . . . . . . . . . 7S P. J. Kisatsky SESSION III RISK AND FAILURE ANALYSIS FOR DESIGN AGAINST FRACTURE T. J. Dolan, Moderator S. Ductile Fracture Analysis and Safety of Nuclear Pressure Vessels 93 F. J. Loss 6. Environmentally Assisted Fracturing Under Sustained Loading. . . ............... . 113 B·. F. Brown ix x CONTENTS SESSION IV RISK AND FAILURE ANM.YSIS FOR DESIGN AGAINST FATIGUE T. E. Davidson, Moderator 7. Fracture Mechanics Applications for Short Fatigue Cracks. .••.• • • • • • . • • . . 121 M. H. El Haddad and T. H. Topper 8. Review of Contemporary Approaches to Fatigue Damage Analysis . • • . • . . • . • 141 D. F. Socie and J. Morrow 9. A Note on Fatigue Scatter and Life Predictions • • 195 V. Weiss and A. Kuo 10. Environmentally Assisted Failures in Ordnance Components • . . • . .. ••.•••• 203 P. A. Thornton and V. J. Colangelo SESSION V ELEVATED TEMPERATURE EFFECTS P. Fopiano, Moderator 11. High Temperature Environmental Effects on Metals . 225 S. J. Grisaffe, C. E. Lowell and C. A. Stearns SESSION VI ENVIRONMENTAL EFFECTS A. McEvily, Moderator 12. Effect of Wear on Performance and Reliability 243 N. P. Suh and N. Saka 13. Corrosion Fatigue Behavior of Coated 4340 Steel for Blade Retention Bolts of the AH-l Helicopter 263 M. Levy and C. E. Swindlehurst, Jr. 14. Microcircuit Reliability Characterization 281 J. J. Naresky CONTENTS xi SESSION VII SYSTEMS APPROACH TO PRODUCTION RELIABILITY INTEGRATION D. Morlock, Moderator 15. Integration of CAD/CAM Systems for Production of Structural Components. • • •• • ..••.. 303 R. J. Sanderson SESSION VIII OUTLOOK - EMERGING NEEDS AND TECHNIQUES F. W. Schmiedeshoff, Moderator 16. Reliability Assurance of Aircraft Structures 313 H. F. Hardrath 17. Neutron Radiography Utilizing Selected Energy Interactions . . • . . . • . • . • . . . . . • 327 J. J. Antal 18. The Application of Modern Analytical Instrumentation Techniques to the Analysis of Explosive Mixes. • 341 F. C. Burns, H. F. Priest and G. L. Priest Index. 345 CHAPTER 1 RISK AND FAILURE ANALYSIS FOR IMPROVED PERFORMANCE AND RELIABILITY Thomas J. Dolan Professor Emeritus, University of Illinois Urbana, Illinois ABSTRACT The care and philosophy employed in material selection, design analyses, fabrication, and maintenance must be sufficient to limit the risk of failure. Failure analysis requires careful sorting of a variety of information to determine how and why a metal part failed, and to prevent a recurrence. To improve safety and reli ability, a philosophy of design and prototype evaluation based on the risk of failure is more sound than the stereotyped application of empiricisms, codes, specifications and factors of safety commonly used. Designers must document all conceivable failures in a system, determine by analyses the effect on system operation, and rank the risk of each potential failure according to its combined influence of severity and probability of occurrence. Design codes based upon handbook values for properties of materials are often misleading. A probability of failure exists due to the many uncertainties or variability of the basic structural reactions of a metal; significant changes in mechanical behavior occur due to processing operations, field repairs, adverse or unforeseen loadings and environment, or deterioration with time, temperature, or operating conditions. Consideration must be given to man-machine interactions to prevent accidents in complex systems. Considerable latitude in use and misuse of equipment must be foreseen in order to predict and evaluate the resistance to each possible mode of failure. Careful consideration of the complete life cycle is necessary for selecting optimum materials that will withstand the modifications due to processing and service history, yet provide minimum risk of failure with improved safety and reliability.
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