Abstract
Spalled fragments from work rolls of a steel bar straightening machine were received for failure analysis. Visual inspection coupled with optical and scanning electron microscopy (SEM) were used as the principal analytical techniques for the investigation. Fractographic observations clearly revealed the presence of a characteristic fatigue crack propagation pattern (beach marks) and radial chevron marks indicating the occurrence of final overload through a brittle intergranular fracture mode. The collected evidence suggests strongly that surface-initiated cracks propagated by fatigue mechanism led to spalling, resulting therefore in severe work roll damage and subsequently high machine downtime and maintenance costs.
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