Failure and Fracture Analysis of a Zn-Alloy Casting
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A Zn-alloy casting failed during use, displaying a macroscopically brittle fracture. Failure analysis investigation determined the origin of fracture, located on the top corner of the component, while an extensive amount of gas porosity was identified. The subsurface porosity seems that triggered the crack initiation and the internal porosity reduced severely the fracture toughness, leading to fast and unstable crack propagation. Careful review and revision of the component casting conditions are recommended in order to prevent gas evolution and entrapment and to increase the component lifetime.
KeywordsFractography Zn-alloy casting Gas porosity
The author wishes to thank Dr. Ioannis Pantazopoulos for the provision of the fractured component and the colleagues Dr. Athanasios Vazdirvanidis and Mr. Andreas Rikos for their helpful assistance and continuous support.
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