Failure Analysis of a Fractured Stick End Casting: An ASM Materials Camp Investigation
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CASE HISTORY—PEER-REVIEWED
Failure Analysis of a Fractured Stick End Casting: An ASM Materials Camp Investigation Erik M. Mueller . Rachel Eckert . Adam Boesenberg . Nicole Hudak . Krish Gupta . Zachary Dickinson . Miabella Doerr . Tao Dodeja . Eric Echanove
Submitted: 10 June 2020 / Accepted: 7 July 2020 Ó ASM International 2020
Abstract Students attending ASM Materials Education Foundation camps are taught about and engage in a variety of materials science and engineering concepts—including failure analysis. As part of the weeklong camp, high school students perform failure analysis on actual fractured components and present their results at the end of the camp. In this case, the students of one group were tasked with determining the failure of a stick end from a commercial pasta drying system. This paper will detail their results, obtained by performing optical and electron microscopy, as well as chemical and mechanical testing. Their analysis determined that poor manufacturing practices and a lack of maintenance led to continued failure of these parts in service.
Introduction
Keywords Fatigue Aluminum–silicon Casting Die casting Food industry Shrinkage porosity Education
Named after William Hunt Eisenman, the first managing director of ASM International, the Eisenman Materials Camp for students is the largest and most elaborate student camp sponsored by the ASM Materials Education Foundation each year [1]. At this weeklong camp, high school students from 11th and 12th grades work in groups on failure analysis projects ranging from household tools, industrial components, and transportation accidents. Under the supervision of volunteer mentors from industry, academia, and government laboratories, the students employ techniques including electron microscopy, mechanical testing, and heat treating to find the root cause of a failure along with recommendations to correct the problem. They present these results in a professional setting to the leaders of ASM International. This publication details the findings,
E. M. Mueller (&) Materials Laboratory Division, NTSB, L’Enfant Plaza East, SW, Washington, DC 20594, USA e-mail: [email protected]
K. Gupta Purdue University, 610 Purdue Mall, West Lafayette, IN 47907, USA
R. Eckert A. Boesenberg Ames Laboratory, U.S. Department of Energy, 2415 Pammel Dr, Ames, IA 50011, USA
Z. Dickinson Gannon University, 109 University Square, Erie, PA 16541, USA
R. Eckert Department of Materials Science and Engineering, Iowa State University, 528 Bissel Rd, Ames, IA 50012, USA
M. Doerr Lakewood High School, Lakewood, OH, USA
A. Boesenberg Center for Industrial Research and Service, Iowa State University, 1805 Collaboration Place, Ames, IA 50010, USA
T. Dodeja Solon High School, Solon, OH, USA E. Echanove Notre Dame Cathedral High School, Chardon, OH, USA
N. Hudak Ohio State University, Columbus, OH 43210, USA
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J Fail. Anal. and Preven.
conclusions, and recommendations of one of the groups from the 2019 Eisenman Materials Camp. An international past
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