Risk and Failure Analysis for Improved Performance and Reliability

357 Pages·1980·9.659 MB·English

by  Thomas J. Dolan (auth.), John J. Burke, Volker Weiss (eds.)

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.