NED UNIVERSITY OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF METALLURGICAL ENGINEERING

BATCH 2021

FRACTURE MECHANICS AND FAILURE ANALYSIS

MY-410

OPEN HANDED LAB (OEL)

Evaluate the fracture surface features and cause of failure of the fractured surface.

PREPARED BY:

AIMAN AYAZ MY-21002

HAFIZA AASHI AFTAB MY-21004

MINAL KHAN MY-21009

MARIA BINTE AQEEL MY-21034

SUBMITTED TO:

DR. AMBREEN AZMAT

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 Table of Contents
List of Figures............................................................................................................................3
INTRODUCTION....................................................................................................................4
SAMPLE HISTORY OR BACKGROUND..............................................................................4
EXPERIMENTAL WORK......................................................................................................5
1. Sample Preparation.........................................................................................................5
Ultrasonic Cleaning:...........................................................................................................5
2. Fractography...................................................................................................................5
Visual Inspection:...............................................................................................................5
3. Microstructure Examination............................................................................................6
A. Sectioning and Cutting.............................................................................................6
B. Grinding...................................................................................................................7
C. Polishing..................................................................................................................7
D. Etching.....................................................................................................................8
E. Microscopy Examination.........................................................................................8
4. Hardness Testing.............................................................................................................9
RESULTS AND DISCUSSIONS...........................................................................................10
1. Fracture Surface Analysis.............................................................................................10
2. Microstructure Analysis................................................................................................11
3. Hardness Analysis.........................................................................................................11
4. Methods of Protection against Fracture........................................................................11
CONCLUSION.......................................................................................................................12
REFERENCES.......................................................................................................................12

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 List of Figures
Figure 1 Ultrasonic Cleaning.....................................................................................................5
Figure 2 Visual Inspection by Stereomicroscope.......................................................................6
Figure 3 Sample Cutting by abrasive cutting machine..............................................................6
Figure 4 Grinding Process..........................................................................................................7
Figure 5 Polishing Process.........................................................................................................7
Figure 6 Etching.........................................................................................................................8
Figure 7 Optical Microscope......................................................................................................8
Figure 8 Hardness Testing..........................................................................................................9
Figure 9 Fracture Surfaces by Stereo Microscope at 10x.......................................................10

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INTRODUCTION
Fracture mechanics is the mechanical analysis of materials containing one or more cracks to
predict the conditions when failure is likely to occur. Failure analysis is the science and
technique of understanding how materials and products fail. Whenever a component no
longer performs its intended function, it is valuable to know how and why it has failed. It
starts with an introduction to important basic questions of failure analysis and fracture
mechanics. Much more pronounced than in the design stage the benefit of fracture mechanics
in failure analysis depends on its accuracy. This is limited by both, intrinsic factors of the
method and the availability and quality of the input information.

SAMPLE HISTORY OR BACKGROUND

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 EXPERIMENTAL WORK
In this section, the fracture surface features and the cause of failure were evaluated using a
combination of ultrasonic cleaning, fractography, microstructural analysis, and hardness
testing.

1. Sample Preparation
In preparation for detailed analysis, the fracture specimens underwent a thorough cleaning.

Ultrasonic Cleaning:
Following are the steps are followed to clean the sample by ultrasonic cleaning technique.
 Before fractography, the fractured specimens were subjected to ultrasonic cleaning to
remove any debris, oil, or contaminants that could interfere with surface examination.
 The samples were immersed in an Ethanol solution and cleaned ultrasonically for 10-15
minutes. Ultrasonic waves helped dislodge particles, providing a clean fracture surface
for analysis.

Figure 1 Ultrasonic Cleaning.

2. Fractography

The fracture surfaces were examined to identify key features indicative of the failure mode.
Initially, a visual inspection was conducted using a stereomicroscope to observe any
macroscopic features.

Visual Inspection:

A preliminary visual inspection of the fracture surface was conducted using a

stereomicroscope.

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 Figure 2 Visual Inspection by Stereomicroscope.

3. Microstructure Examination

An essential step in understanding the material properties and fracture analysis is a

microstructure examination. The following steps are performed to obtain the microstructure
of the fracture sample.

 Sectioning and Cutting

 Grinding
 Polishing
 Etching
 Microscopic Analysis
A. Sectioning and Cutting

The abrasive cutting machine cuts the workpiece (welded sample). The feed rate is 50µ/sec
and the speed is 1500-2000 rev/min.

Figure 3 Sample Cutting by abrasive cutting machine.

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B. Grinding

Grinding aims to remove roughness from the cutting process and to achieve flatness of the
ground surfaces. Grinding is done using a rotating disc covered with silicon carbide paper
and water. There are numbers of grades of paper with 180, 240, 400, 600, 800, 1000 and
1200.

Figure 4 Grinding Process.

C. Polishing

Metal polishing and polishing of other materials have to remove the deformations introduced
during grinding and provide a highly reflective finish, so the samples can be examined on the
microscope. Smooth or fine polishing is done with velvet cloth with Aluminum Oxide 0.05-
micron suspension.

Figure 5 Polishing Process.

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D. Etching

Metallographic etching of the metal surface is done to make visible the crystalline structure
of the metal and to produce optical contrast between the various constituents. Some common
etching agents we use in our metallographic lab are Nital, Aqua Regia, Picryl, etc. We have
etched it with Nital (1-5% HNO3 nitric acid + 95-99% Ethyl Alcohol).

Table 1 Composition of Etchant (Nital).

Element Composition (%)

HNO3 1-5

Ethyl Alcohol 95-99

Figure 6 Etching.

E. Microscopy Examination

Optical microscopy provides information about the overall microstructure, including grain
size.

Figure 7 Optical Microscope.

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4. Hardness Testing

Rockwell Hardness Test is performed on samples. The “C” Scale is used. Rockwell Test load
is 150kg and the indenter is Diamond.

Figure 8 Hardness Testing.

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 RESULTS AND DISCUSSIONS
In this section, the analysis of fractured samples was discussed, focusing on their structural

characteristics, fracture surface morphology, crack propagation, hardness, and overall failure

geometry. The purpose of this analysis is to understand the effects of material properties and

processing parameters on these key fracture features, which are critical for assessing the

material's performance and the causes of failure.

1. Fracture Surface Analysis

The fracture surfaces of the samples were analyzed to identify the modes of failure and
potential causes. The following analysis provides insights into the nature of the fracture and
the underlying factors contributing to material failure.

A B

C D
Figure 9 Fracture Surfaces by Stereo Microscope at 10x.

Image A: The surrounding surface is marked by rough textures and pitting, which may
indicate corrosion. The pits could act as stress concentrators, facilitating crack initiation and
propagation. There is a prominent crack measuring around 2867 µm, suggesting rapid crack
growth originating from the circular defect.

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Image B: This image shows a crack extending 8021 µm in length, with an angular orientation
of approximately 72.32 degrees relative to the sample's surface. The fracture angle may
indicate a mixed-mode failure, combining elements of tensile and shear stresses.
Image C: The fracture surface in this image is marked by a relatively long, straight crack
measuring around 8575 µm. The uniform and smooth appearance of the surrounding area
suggests minimal ductility, supporting a brittle fracture mode.
Image D: The image shows a large crack that extends 3200 µm in width and 7818 µm in
length. The crack runs through a granular region, indicating a brittle fracture. The granular
texture around the crack suggests that the fracture surface propagated along cleavage planes,
typical of materials failing in a brittle manner. The presence of parallel lines along the crack
path indicates the likely influence of pre-existing material defects or quenching-induced
stresses, making the material more susceptible to brittle failure under stress.
The findings indicate high-stress failure, likely exacerbated by quenching-induced internal
stresses and pre-existing defects.
2. Microstructure Analysis

3. Hardness Analysis

4. Methods of Protection against Fracture

Here are some effective methods for protection against fracture:

 Achieve the right balance of hardness and toughness.
 Reduce residual stresses after processing.
 Use tougher materials or grain-refined alloys.
 Apply techniques like carburizing or nitriding.
 Avoid sharp corners to reduce stress concentration.
 Use coatings to prevent corrosion and wear.
 Detect early cracks using NDT methods.
 Ensure even load distribution and prevent overloads.
 Minimize weld-related stresses.
 Include fail-safes to prevent catastrophic failure.

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CONCLUSION

REFERENCES

1. Comparison Table:
Temperatur Observations
e
35°C Negligible corrosion observed.
650°C Stable oxide layer, low weight loss.
750°C Thick oxide, cracks, high weight loss.

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