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Jur T.A.,Engineering Design and Testing Corporation
Journal of Failure Analysis and Prevention | Year: 2013

The analysis concerns back-to-back losses of a spincaster used in the manufacture of rolls for rolling mills. Both losses involved the fatigue fractures of parts used to secure the mold for the roll being cast in position while spinning. The fractures are analyzed as to cause so as to avoid yet another occurrence. Further, since the loss incidents were accompanied by loud noises and by molten metal flying about, interpretation of the fracture also involved dispelling the notion that there was an "explosion." © 2012 ASM International.

Rose A.M.,Engineering Design and Testing Corporation
Journal of Failure Analysis and Prevention | Year: 2010

From drying your hair in the morning to using your computer at work to watching a DVD on your big screen TV at night, transformers are involved in the many things we do every day. As the name implies, transformers transform electricity from one voltage to another. In the early days of electricity, it was costly to move electricity from Point A to Point B. As a result, people who wanted electricity had to live very close to a power plant. At the 1893 World's Fair, George Westinghouse and Nikola Tesla introduced alternating current, or AC power, to the world. Up until this time, Thomas Edison's direct current, or DC power, was the only form of electricity in the United States. Among the many positive attributes of AC power, engineers discovered that if the power could be converted (or transformed) to use higher voltage and lower current, then it would be cost-effective to transport the electricity over longer distances from a power plant to a home or business. This discovery and the invention of the transformer led to the power distribution system as we know it today. Transformers are the backbone of our electrical transmission and distribution system. Of these, high- and medium-voltage transformers are the most complex and the most expensive pieces of equipment in this system. Consequently, it is important that transformers be properly constructed and maintained to ensure a long service life. © 2010 ASM International.

Jur T.A.,Engineering Design and Testing Corporation | Harris R.D.,Engineering Design and Testing Corporation
Journal of Failure Analysis and Prevention | Year: 2014

A paper manufacturing machine experienced an in-service fracture of one of the machine's felt guide rolls. An engineering analysis of the fractured roll was conducted to determine the cause. Consideration was given to resonant vibration of the roll with respect to operation of the machine at or near the natural frequency of the roll. However, analysis demonstrated that vibration was not an issue. Rather, the roll fracture was attributed to a high cycle fatigue fracture mechanism associated with a plug weld at a threaded fastener used to attach a large balance weight to the inside of the roll. The balance weight was, in turn, installed to compensate for variation in the wall thickness of a pipe product used to make the roll. The cause of the roll fracture was defective manufacture. © ASM International 2014.

Stewart G.,Engineering Design and Testing Corporation | Harris R.,Engineering Design and Testing Corporation
Materials Science and Technology Conference and Exhibition 2010, MS and T'10 | Year: 2010

Determining the scope of damages and repairs or replacements required after a commercial or industrial fire is the first step in restoration of the property. Knowledge of the properties of various engineering materials is an essential tool of the engineer conducting a scope of damage evaluation. Field observations combined with knowledge of material properties and the behavior of those materials with exposure to various temperatures allows the investigating engineer to determine the local temperature exposure experienced by different structures and equipment items. Armed with this knowledge of the local temperatures, knowledge of the properties of the materials of construction allows an immediate assessment of the likelihood of damages to specific components, even those not immediately accessible, without detailed disassembly and examination. This allows rapid segregation of items that are likely repairable from those that are probably not, leaving only any items still in question for detailed disassembly and examination. Copyright © 2010 MS&T'10®.

Jur T.,Engineering Design and Testing Corporation | Windham R.,Engineering Design and Testing Corporation
Materials Science and Technology Conference and Exhibition 2010, MS and T'10 | Year: 2010

Following a hurricane at a seaport, four cranes were found in a mass of deformed steel at the end of the dock. The cranes had all been tied down prior to the storm. Assuming effective tie down procedures and that there was no pre-storm loss of integrity, the cranes should have stayed in place. It so happened that the cranes belonged to two different shipping companies. The extent of the loss made it important to identify which of the cranes broke loose first, thereby allowing assignment of responsibility for the damage. By a careful study of the damaged condition of the cranes, a reconstruction confirmed assignment of responsibility. Copyright © 2010 MS&T'10®.

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