Unit 1

Introduction, causes of failures, classification, steps in failure analysis, tools, sample selection and treatment, materials analysis, equipments, Metallography, commonly used NDT methods. Machine condition monitoring techniques and condition monitoring of gearboxes.

Unit 2

Failure mechanisms, overload failure, ductile and brittle fracture, ductile to brittle transition, stress concentration approach. Fracture mechanics approach, Fatigue mechanisms, classical fatigue prevention and prediction, fractography, damage tolerant fatigue approach. Wear failures, adhesive, abrasive, erosive, corrosive wear. Elevated temperature failures, creep, creep crack branching. Corrosion failures, types and their identification.

Unit 3

Application and case studies on Failure analysis: Failures of cast and welded components, failures of rotating components-shaft, bearing and gears.

Course Objectives

• Familiarize with various failure modes and examine the failed components
• Impart knowledge of vibration analysis for early fault detection

Course Outcomes

• CO1: Recognize and describe common engineering failure mechanisms
• CO2: Detect and diagnose the machine faults from the vibration signals
• CO3: Predict the remaining useful life of the components using fatigue, fracture and creep
• CO4: Analyse the failed engineering components

CO – PO Mapping

Textbook(s)

• Jones D. R. H., “Engineering Materials 3–Materials Failure Analysis: Case Studiesand Design Implications”, Pergamon Press, 1993.
• ASM Handbook, Vol. 11, “Failure Analysis and Prevention” Edited by, ASM Publications, 2002.

Reference(s)

• ASM Handbook, Vol. 11, “Failure Analysis and Prevention” Edited by, ASM Publications, 2002.
• Colangelo Vito J. and Heiser F., “Analysis of Metallurgical Failures”, Second Edition, John Wiley & Sons, Inc., 1987.
• Jones D. R. H.,”Failure Analysis and Case Studies”, Elsevier Publications, 1998.
• Robert Bond Randall, “Vibration-Based Condition Monitoring: Industrial, Aerospaceand Automotive Applications”, John Wiley & Sons, 2011.

Evaluation Pattern