Shaft Failure

Metallurgical failure analysis was requested after a company experienced several identical shaft failures. Macro and microscopic examination revealed that metal bending fatigue was to blame for the failures.  The metal fatigue was due to an inadequate filet radius at a diameter change in the subject shaft. The inadequate radius was due to a manufacturing error.

 
Photograph A  Overall view of failed shaft.

 
Photograph B  Close-up view of the two halves
 of the failed shaft.

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