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Catastrophic failure of a fan in a diesel engine cooler
Authors:B. V. Krishna  R. K. Sidhu
Affiliation:(1) Materials Science & Technology Division, Thapar Centre for Industrial Research and Development, Thapar Technology Campus, Bhadson Road, P.O. Box 68, 147 001 Patiala, Punjab, India
Abstract:
The fan used to cool a diesel engine fractured catastrophically after approximately 100 h of operation. The fan failed at a spider, which was resistance spot welded to a shim placed between two circular spiders of 3 mm thickness. The detailed analysis of the fracture indicated that the premature failure of the fan was due to inadequate bonding between the sheets at the weld nugget. The fracture was initiated from the nugget-plate interface. The inadequate penetration and lack of fusion between the steel sheets during resistance spot welding led to poor weld strength and the fracture during operation. The propensity to crack initiation and failure was accentuated by improper cleaning of the surfaces prior to welding and to inadequate nugget-to-sheet edge distance.
Keywords:failure analysis  heat penetration  nugget-to-edge distance  resistance spot welding  weld strength
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