Call Today: (972) 934-0493

Gusset Weld Failure

A square tube failed where a gusset plate weld had been placed. The tube fracture surface is shown below in Photograph A.

Overall view of failed square tube fracture surface.
Photograph A  Overall view of failed square tube fracture surface.

The fracture surface displays an area of old rusted fracture at the 6 o'clock location. The area of old fracture is characterized by a concentration of red-brown rust indicating a longer standing fracture.

The tube fracture increased in size from the old rusted origin area by cyclic fatigue and/or cyclic overload stress. The appearance of intermittent zones of fatigue and/or cyclic overload is observed on the vertical legs of the tube fracture shown in Photograph A.

The fracture surface grew or extended around the tube until final fracture occurred in the between 11 o'clock and 1 o'clock.

A gusset weld, which contained what was believed to be weld cracks, had been placed on the mating tube at the 6 o'clock location. The fracture initiated, at the time of initial welding, at the 6 o'clock location. Cyclic fatigue permitted the initial manufacturing defect to propagate circumferentially until final failure occurred.

Contact Us

J.E.I. Metallurgical, Inc.

5514 Harbor Town
Dallas, Texas 75287

Phone: (972) 934-0493
Fax: (469) 737-3938

Location Map

Follow Me On