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Journal of Failure Analysis and Prevention

, Volume 4, Issue 6, pp 15–18 | Cite as

Failure analysis of gray iron pump housings

  • E. E. Vernon
  • M. E. Stevenson
  • J. L. McDougall
  • L. McCall
Case Histories

Abstract

Hydrostatic pressure testing of several large gray iron castings resulted in brittle overload failures. Subsequent failure analysis on two of the failed components revealed casting imperfections associated with the failure origins. In each case, the root cause of failure was related to the casting mold. The first incident involved an imperfection that resulted in a stress concentration that reduced the normally large critical flaw size to the microstructural level. A microstructural gradient adjacent to the fracture of the second casting was the result of an inadequate mold design that allowed for rapid cooling at a thin-walled region of the casting. Material selection was a concern of the manufacturer and was also investigated.

Keywords

brittle overload failure casting imperfection cooling rate microstructural gradient Type C graphite 

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References

  1. 1.
    “Design Considerations,” Casting, vol. 15, ASM Handbook, ASM International, Metals Park, OH, 1988.Google Scholar
  2. 2.
    “Microstructure of Cast Irons,” Atlas of Microstructures of Industrial Alloys, vol. 7, Metals Handbook, 8th ed., American Society for Metals, Metals Park, OH, 1972.Google Scholar
  3. 3.
    W.F. Smith: Structure and Properties of Engineering Alloys, 2nd ed., McGraw-Hill, New York, NY, 1993.Google Scholar
  4. 4.
    J.R. Davis, ed.: Cast Irons, ASM Specialty Handbook, ASM International, Materials Park, OH, 1996.Google Scholar

Copyright information

© ASM International 2004

Authors and Affiliations

  • E. E. Vernon
    • 1
  • M. E. Stevenson
    • 1
  • J. L. McDougall
    • 1
  • L. McCall
    • 1
  1. 1.Metals & Materials Engineers, LLCSuwanee

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