Fundamental Sources of Failure: Manufacturing

This course covers the fundamental sources of failure in mechanical components and manufacturing processes, and how to prevent them. It delves into the role of extra stages in failures, the impact of imperfections in base metals, and the importance of proper manufacturing procedures. For instance, the course provides a case study on the failure of a connecting rod due to metallurgical heterogeneity and how proper heat treatment and control of microstructure can prevent such failures. It also discusses the effects of improper manufacturing, such as welding procedures not being properly established or modified, and how these can lead to reduced mechanical performance and increased sensitivity for crack nucleation. The course further explores the importance of proper control over heating rate, holding temperature, soaking time, and cooling rate in heat treatment to avoid failures.