A “Toolbox” for Forensic Engineers

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Failure Due to Manufacturing Faults 147 Figure 5.11 Failed manhole step (left) beside deliberately broken one (right). Figure 5.12 Fractures of the accident step. climbing in or out. The castings were hot-dip galvanized before being dispatched to a builders merchant, who had sold several hundred to a subcontractor constructing manholes in a sewer system. The broken footrest end of the accident step, along with the remains of two other steps from the subcontractor’s unused stock that had been broken deliberately as a test after the accident, were submitted for examination. Figure 5.11 shows the accident footrest on the left and one of the tested steps on the right, viewed from the underside. The short piece of limb above the accident step is from another of the tested footrests, to illustrate the length of the limbs that had been left set in the brickwork. Figure 5.12 is the accident step, viewed slightly from above, showing the fractures. There is a large casting blowhole in the flange at the right-hand side and a smaller one at the outside edge that is part of the fracture, as can be seen in the closer view depicted in Figure 5.13. It occupies approximately 5% of the total crosssectional area of both fractured limbs. These blowholes had been formed by
148 Forensic Materials Engineering: Case Studies Figure 5.13 Closer view of fractures. Notice the large blowhole is not in the fractured area. The smaller one (arrowed) represents approximately 10% of the total fracture area of both limbs. Figure 5.14 Etched microstructure of flake graphite cast iron (magnification 75¥). gases evolved at the interface between the metal and the sand mold when the liquid iron was poured. Holes formed by gases being released within the body of liquid metal during solidification would be much smaller and distributed uniformly throughout the cross section. The foundry can therefore be blamed for releasing a casting containing visible blowholes, but the total cross-sectional area of only the one limb is reduced by 5% or so; hence they would have minimal effect on the bending strength. As there is not the slightest suggestion this could be a fatigue failure, these faults cannot be responsible for the sudden fracture that occurred the first time the footrest came under load.
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Library of Congress Cataloging-in-P
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Preface Case studies of product fai
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could not be simpler in shape, they
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Acknowledgments We thank The Open U
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The Authors Peter R. Lewis, Ph.D.,
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Laboratories of Imperial College of
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3 Establishing the Load Transfer Pa
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6.5.2 A Problem in Eire 197 6.5.3 M
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9.4.2 Failure in Femoral Stem of To
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13.3.7 Design Development Sequence
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Materials in Distress 2.1 Introduct
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Materials in Distress 27 It is usef
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Materials in Distress 29 (A) Unload
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Materials in Distress 31 1. Flowing
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Materials in Distress 33 to compens
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Materials in Distress 35 Fracture o
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Materials in Distress 37 Force A Fr
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Materials in Distress 41 somewhat b
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Materials in Distress 43 Figure 2.8
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Materials in Distress 49 Stress Amp
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Materials in Distress 53 solutions.
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Accidents in the Workplace 255 8 De
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Accidents in the Workplace 257 ensu
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A “Toolbox” for Forensic Engineers

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