Fundamental sources of failures: Improper Manufacturing IV and improper service conditions — Lesson 5

This lesson covers the fundamental sources of failure in manufacturing processes, focusing on improper manufacturing conditions, improper cleaning procedures, reworking methods, material selection, and assembly of components. It discusses how metals interact with environmental gases, the importance of cleaning in manufacturing, and the potential issues that can arise from improper reworking methods. The lesson also highlights the significance of material selection, explaining how the properties of materials can change over time due to wear, high temperature exposure, and corrosion. It provides an illustrative example of a nozzle failure due to improper material selection and suggests corrective actions.

Video Highlights

00:18 - Introduction to the subject of failure analysis and prevention, focusing on the fundamental sources of failure.
03:12 - Explanation of mechanical and chemical cleaning methods.
14:47 - Explanation of the impact of wear, high temperature exposure, and corrosion on component failure.
24:01 - Case study on the failure of a nozzle due to improper material selection.

Key Takeaways

- Improper manufacturing conditions can lead to component failure.
- Cleaning is crucial in manufacturing to remove impurities and ensure sound inclusion.
- Improper reworking methods can lead to issues such as the development of heat-affected zones, residual tensile stresses, and excessive hardening.
- Material selection is vital and should consider the expected failure mechanism and service conditions.
- The properties of materials can change over time due to wear, high temperature exposure, and corrosion, affecting their performance.
- Proper procedures for reworking and repair should be developed to prevent premature failure of components.