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Failures of Engineering Materials > Quiz 1 Flashcards > Flashcards

Quiz 1 Flashcards

1
Q

True or False: Failure only occurs when a component breaks.

A

False. Failure occurs whenever the component is unable to function nominally.

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2
Q

What is failure?

A

Inability of a component to function as intended.

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3
Q

Why is the study of failure important?

A

Helps to learn from mistakes to prevent future failures and for mitigation.

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4
Q

What is the main cause of failure in aircraft components?

A

Fatigue

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5
Q

What is the main cause of failure in the general engineering industry?

A

Corrosion

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6
Q

What are the four main categories/modes of failure?

A

Deformation, fracture, wear, and corrosion

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7
Q

What is deformation?

A

Any change to the shape of the material

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8
Q

What is fracture?

A

Any cracks or breaks due to stress

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9
Q

What is corrosion?

A

Deformation due to the material due to chemical reactions with the environment

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10
Q

What is wear?

A

Undesired removal of material from contacting surfaces by mechanical action (i.e. gears)

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11
Q

Define failure mode

A

Specific manner in which a failure occurs as a result of the failure mechanism

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12
Q

What are the primary causes of equipment failure?

A

Design deficiencies, material defects, manufacturing/installation defects, and service life anomalies

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13
Q

What does root cause analysis refer to?

A

Understanding of the underlying cause of failure so corrective action can be taken

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14
Q

What are the energy forms?

A

Chemical, Optical, Mechanical, Electrical, Thermal, Magnetic, Acoustic, and Nuclear (COMET MAN)

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15
Q

Which has the larger depth of field, SEM or OM?

A

SEM

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15
Q

Which microscope (SEM, TEM, or OM) has the highest resolution?

A

TEM; resolution up to 2 Angstrom

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15
Q

What do SEM, TEM, and OM stand for?

A

Scanning Electron Microscopy, Transmission Electron Microscopy, and Optical Microscope

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16
Q

Which microscope (SEM, TEM, or OM) has the highest magnification?

A

TEM; goes up to 1,000,000x magnification

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17
Q

Which technique (SEM, TEM, or OM) is most useful for fractography?

A

SEM

17
Q

What is fractography?

A

Study of the fracture surface of a material

18
Q

Which microscope (SEM, TEM, or OM) requires the easiest sample preparation?

A

SEM

19
Q

How would you prepare an OM sample?

A

Sectioning, Mounting, Grinding, Polishing, Etching

20
Q

Which microscope (SEM, TEM, or OM) has the most difficult sample preparation?

A

TEM

21
Q

Which tests can be performed to determine the mechanical properties of a sample?

A

Mechanical (compression and tension) and hardness tests

22
Q

Which tests can be performed to determine the chemical composition of metals?

A

Energy Dispersive Xray (EDX) using SEM and spectroscopy

23
Q

Which tests can be used to classify polymeric materials?

A

Fourier Transform Infrared spectroscopy (FTIR)

24
Q

Which tests might be helpful in determining manufacturing imperfections?

A

X-ray CT, ultrasonic C-scan, and SEM

25
Q

What are the steps in failure analysis?

A

0: Think
1: Collect Data
2: Preserve Fracture Surface
3: Preliminary Visual Exam
4: Non-Destructive Testing (NDT)
5: Chemical Analysis
6: Mechanical Testing
7: Macroscopic Exam
8: Microscopic Exam
9: Metallography
10: Failure Mechanisms
11: Calculations/FEA
12: Test in Service Conditions
13: Reporting

26
Q

True or False: The order of the failure analysis steps are not very important as long as all the steps are completed.

A

False

27
Q

Why do structures fail?

A

Negligence during design, construction, or operation and new application of the design

28
Q

What is failure analysis?

A

The systematic process of investigating and understanding the reasons behind the failure of a component, system, or material

29
Q

What is failure prevention?

A

Involves strategies and practices designed to avoid or minimize the occurrence of failures in systems, components, or materials

30
Q

What are types of distortion?

A

Yielding during service, creep, and buckling

31
Q

What is the most common type of corrosion?

A

Uniform corrosion due to rust on iron or steel

32
Q

What are types of fracture?

A

Monotonic and fatigue

33
Q

What is included in a case study?

A

Summary of events, documentation and analysis, discussion of ramifications, and recommendations

34
Q

What should be considered during failure analysis?

A

Physical evidence, use of engineering and scientific principles, and analytical tools

35
Q

What are the categories of root cause analysis?

A

Physical Roots (i.e. equipment), Human Roots (i.e. human factors), and Latent Roots (i.e. procedural/systemic cause)

36
Q

What is a physical root?

A

Technical explanation of why a part failed

37
Q

What is a human root?

A

Human errors that led to the physical cause – whether acts of omission or commission

38
Q

What is a latent root?

A

Deficiency in management procedures or systems that allowed human errors to go unchecked

39
Q

What is metallography?

A

The study of structure and composition of metals using microscopy

40
Q

What is a microstructure?

A

Arrangement of phases and defects within a material

41
Q

What is a crystal structure?

A

Arrangement of atoms within a unit cell

42
Q

What are types of non-destructive testing?

A

X-ray (radiography), ultrasound, dye penetrant, magnetic particle inspection (MPI), and studying cracks and porosity

Failures of Engineering Materials (2 decks)

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