Abstract
This work reviews the failures in the structural components of heavy road vehicles, to present a broad spectrum of failure causes in structural parts, ranging from poor manufacturing practices over design errors to the unforeseen combination of operating conditions and materials selection. The study starts with a series of examples of poorly welded parts in the structural frame of passenger buses. Three examples of failure in forged parts are included to show increasing degrees of complexity in the failure analysis: a suspension Z-bar, a heavy transmission shaft, and a torsion bar. The analyses are backed-up with finite-element models and results were compared with the location and size of defects and correlated to fractographic observation. Conclusions about the causes for failure could be formulated with a high degree of certainty, illustrating how failure analysis can be used as a tool for continuous improvement in design and manufacturing.
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