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Preclude failure: A philosophy for materials selection and simulated service testing

Honor lecture covers the important role played by proper materials selection, design, analyses, fabrication and maintenance in the preclusion of failures

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Abstract

Failure of products in service under foreseeable conditions often subject manufacturers to legal liability when personal injuries occur; hence, the care used (or the philosophy employed) in material selection, design, analyses, fabrication and maintenance must be sufficient to preclude failure. Failure analysis requires careful sorting of a wide variety of information to determine how and why a metal part failed in service or in testing and to determine what can be done to prevent a recurrence. Valuable knowledge is available in the literature from documentation of prior failures that may be used to develop logical approaches to the design and development of new components. A philosophy of design and prototype evaluation based on the prevention of failure is more sound and workable than the stereo-typed application of empiricisms, codes, specifications and factors of safety now commonly used. Reliance on design for static loadings and for factors of safety based on tensile strength as a criterion are frequently erroneous and dangerous. If a part does not fulfill its intended function satisfactorily, it “fails” by: (a) excessive deformation, (b) fracture, (c) surface disintegration, and (d) deterioration of properties. A variety of failures will be discussed to emphasize the factors that must be considered in selection of an optimum material and in prescribing an effective method of simulated-service testing. Considerable latitude in use and misuse of equipment must be foreseen in order to predict possible modes of failure. A broad consideration of service environment is necessary for correcting faulty design and selecting proper materials which will withstand modifications due to processing, fabrication, maintenance or repair operations that lead to failure.

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Authors and Affiliations

  1. Department of Theoretical and Applied Mechanics, University of Illinois, Urbana, Ill.

    Thomas J. Dolan (Head)

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  1. Thomas J. Dolan
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Dolan, T.J. Preclude failure: A philosophy for materials selection and simulated service testing. Experimental Mechanics 10, 1–14 (1970). https://doi.org/10.1007/BF02320080

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