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Applied Failure Analysis

Greg Rentfrow Empire Machinery Mesa, Arizona

Failure Analysis
The thoughtful review of product and environmental facts which leads to the identification of root causes of product problems.

Failure Analysis
8 Steps of Failure Analysis
1. Define the problem 2. Organize the fact gathering 3. Observe and record the facts 4. Think logically with the facts 5. Identify the most probable Root Cause 6. Communicate responsibility 7. Make repairs as directed 8. Follow up

Failure Analysis
All failures must be carefully analyzed. To prevent reoccurrence. No matter how large or small, something different must be done.

Failure Analysis

History Check files,folders and reports. Both your`s and our`s


Some failures can be traced back to a previous incidence that occurred long before the final failure. Fracture road signs will tell.
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Make Changes
Design Service Procedures Machine Monitoring Maintenance practices Training

Failure Analysis
D9L Landfill application. Severe corrosion. Scavenge sump. Failed all engine main bearings. Root cause: No or Poor maintenance Did not clean belly pan!! Fix: Made change to belly pan mounts.

Failure Analysis

Failure Analysis

Organize
Dont destroy the facts Gather and label ALL parts Take an oil sample / oil quality? Save the filters and screens Gather machine service history Talk with operator / mechanics

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Failure Analysis
History folder Wear types Fracture types Load types Temperatures Electronic control module information

Observe & Record

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Wear Types
Abrasive - 90% Adhesive-Fastest Corrosion Erosion Fretting corrosion Contact Stress Fatigue (Normal at high hours with heavy loads) What you should see at PCR, part was left in service until maximum life.
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Terminology
Stress raisers(normal) physical irregularity, geometry change, snap ring groove, keyway, bearing radius, spline area transition, (Abnormal) nick from torch, dent from handling damage, wear at a snap ring groove.) Initiation site (start of fracture) Final fracture (end of fracture) Shear lip (end of ductile fracture) Fast crack (brittle or ductile) Slow crack (fatigue)
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Failure Analysis
Fracture Types

Brittle Ductile Fatigue

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Fatigue Fracture
Light to dark Smooth to rough Ratchet marks Beach marks
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Ratchet marks indicate that very high stresses (loads) were present at the initiation site to start a Fatigue fracture at a normal high stress area( root fillet).

Failure Analysis
Bending Fatigue

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Fatigue Fracture
Beach Marks usually radiate away from the initiation site, but not always as seen here on this hydraulic cylinder rod.

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Brittle Fractures
Fast (one time overload) Crystalline (sparkles) No plastic deformation

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Failure Analysis
Brittle Fracture

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Failure Analysis
Brittle Fracture

Chevrons

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Failure Analysis
Ductile Fractures

Fast Large shear lips Dark Rough & woody Plastic deformation

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Failure Analysis
Fractures

Ductile

Plastic deformation Necking

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Failure Analysis
Factors Affecting Ductile Fractures

Medium - low hardness High temperatures Low stress concentration Low load rate

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Think Logically
How does it work? How does it load?

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What Do You See?

Beware of Preconceived Ideas

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Failure Analysis
Root Cause

Identify root cause Redefine problem

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Failure Analysis
6. Communicate with the
responsible party

7. Make repairs

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Failure Analysis
Follow-up Maintenance practices Operating techniques

Final Steps

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Failure Analysis
Use the monitoring systems to your advantage

Caterpillar Monitoring System CMS ET VIMS VIDS

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Repair Before Failure


Your Past Experience!!!
CTS SOS OMG CSA Customer Track Service Scheduled Oil Samples Overhaul Maintenance Guide Customer Support Agreements

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Failure Analysis
Repair before failure.maximize profit margin

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Failure Analysis
Preventive Maintenance Predictive Maintenance PM could also mean Preserving money Peace of mind

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Our Goal
Is to provide Excellence in Service & Equipment to Keep`em Productive while Reducing cost.

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Applied Failure Analysis


CUSTOMER FACTORY

DEALER
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