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Failure Analysis of Spring

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FZV is a Mechanical Engineer, Metallurgist, Nuclear Engineer, Engineering Failure Analysis, Accident Reconstruction Consultant with world-class expertise in surface engineering, corrosion, wear, surface modification, failure analysis, microstructure, diffusion bonding, zirconium alloys, nickel alloys, underground waste storage tanks, materials vendors, and laser processed zirconium.

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Summary A company experienced two failures of their spring during testing and requested that a failure analysis be performed. Two springs were supplied (see Figure 1 in PDF), one failed prematurely and the other successfully completed 2 million cycles. The failed spring possessed circumferential notches beneath the coating. Both springs are approximately 10% below the strength requirement of ASTM A228.

Analysis Testing included dimensional inspection, visual examination, metallography, microhardness testing, chemical analysis, Scanning Electron Microscopy (SEM), and computer modeling.

Results A simple stress analysis shows that the highest levels of stress are in the location where failure did occur. This demonstrates that there were no unknown forces acting on the spring that might have contributed to failure.

To read the entire case study, please download the PDF. This case study is available as a PDF (due to inclusion of formulas and the limitations of HTML to represent them). Please use this link to view/download the complete case study.

Read other articles by this KKAI Associate:

Failure Analysis of Gas Compressor Head Bolts

Investigation of Corrosion of Stainless Steel Piping

Mechanical Engineer, Metallurgist, Nuclear Engineer, Engineering Failure Analysis, Accident Reconstruction Consultant, surface engineering, corrosion, wear, surface modification, failure analysis, microstructure, diffusion bonding, zirconium alloys, nickel alloys, underground waste storage tanks, materials vendors, and laser processed zirconium.
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Kevin Kennedy & Associates, Inc.
Rapid Response Engineering® Solutions
3905 Vincennes Road, Suite 320
Indianapolis, Indiana 46268
(317) 536-7000 voice
(317) 536-7220 fax

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