1. Fractures typically occur at stress raisers such as
keyways or geometrical changes, but can also initiate
from surface damage such as fretting or off centre
loads like bending. Various investigative techniques
are employed to determine the root cause including
visual assessment, Scanning Electron Microscopy
(SEM), optical microscopy and mechanical testing.
Assessment of the fracture mechanism reveals many
factors relating to failure such as the type of load
acting upon the shaft, i.e. reversed bending,
unidirectional bending, overload and can provide
information regarding the approximate number of
cycle to failure. This can even identify problems with
other components in the system such as bearings or
couplings.
For further information contact Eirwyn Davies or call
01925 843417.
Operating within ESR Technology, the Forensic Engineering & Materials department has an experienced team of engineers and
scientists that has been solving failure analysis challenges for over 40 years.
Shaft Failure Investigations
ESR Technology Provides Support to GrowHow UK
ESR’s world-class
engineers & scientists
provide expertise in:
• Failure Investigations
• Condition Monitoring
• Design Audits & Reviews
• Material Assessment &
Selection
• Tribological Advice & Testing
• Bearing Design
• Expert Witness
• Vibration Analysis
ESR’s facilities include:
• SEM (Environmental)
• EDX Analysis
• Metallographic Prep &
Analysis
• Optical Microscopy
• Surface Topography
• Metrology
ESR Technology Main Office
ESR Technology Ltd, Whittle House,
410 The Quadrant, Birchwood Park,
Warrington, Cheshire WA3 6FW
+44 (0)1925 843 400
www.esrtechnology.com
Engineering or Materials
Problem?
Contact us @
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using UNSUBSCRIBE in the subject.
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please email using SUBSCRIBE in the subject.
paul.roffey@esrtechnology.com
eirwyn.davies@esrtechnology.com
rory.taylor@esrtechnology.com
Forensic Engineering & Materials
Newsletter - Spring 2013
www.esrtechnology.com
Other News:
Principal Engineer, Dr John
Beard, recently celebrated 30
years at ESR Technology
Rory Taylor, a Senior Mechanical
Engineer as ESR, recently
achieved chartered status with the
Institute of Mechanical Engineers.
Dr Paul Roffey recently published
“Fatigue testing of Forth Road
Suspension Bridge wires” in
Engineering Failure Analysis.
Tim Gould recently joined ESR,
Tim has both failure analysis and
casting technology experience .
ESR Technology have provided forensic
engineering support to GrowHow UK Ltd on a
recent plant shutdown. This has helped inform
their decision making on future maintenance.
GrowHow are the UK's leading supplier of nitrogen
based chemicals, ammonium nitrate & compound
fertilisers. On-site metallurgical replication was
performed on both pipe work and vessels to identify
possible features such as creep assessment, thermal
degradation and possible cracking.
Portable hardness testing was used to obtain
further material information. Mechanical testing was
carried out in some cases to aid material
identification and aid welding procedures on vessel
additions. Some of the materials used in such
plants include basic carbon steels, high temperature
stainless steels and nickel alloys.
Mike Sadler-Johns, a GrowHow Engineer
commented; “ESR has provided a very professional
service during our site shutdown. The results
obtained from the metallographic and inspection
work are excellent and contribute significantly to our
decision making and to future inspections plans for
our equipment”. If you require on-site metallurgy, or
would like more information contact Paul Roffey or
call 01925 843 490.
Keyway
Final overload
region
Rotating shafts are used in a variety of machines
including motors, drives and pumps. Fractured shafts
are often simply attributed to fatigue and replaced.
However, detailed examination of the initiation location
can provide important information as to the cause of the
failure. Only when the root cause of failure can be
determined can changes be made to prevent future
failures, saving time and money.

2. NCT has been at the forefront of applied tribology (friction, wear & lubrication) for over 40 years working. We work to improve the
reliability and performance of industrial equipment or products.
NCT provides evaluation of
lubricants and/or material
combinations using:
• Plint TE77 HFRR
• Hydraulic Power HFRR
• Plint TE53 Multi-Purpose
Test Rig
• Plint TE80 4-Ball Test Rig
• Falex Pin-in-Vee Block Test
• Pin-on-Disc Tests
• Erosion & Abrasion Tests
• Galling Tests
• Scratch Tests
• 50kN capacity Fatigue Tests
• 20kN capacity Tensile Tests
• 5kN capacity Fatigue Rig
• Rolling Contact Fatigue Test
• Gear Test Rig
ESR Technology Main Office
ESR Technology Ltd, Whittle House,
410 The Quadrant, Birchwood Park,
Warrington, Cheshire WA3 6FW
+44 (0)1925 843 400
www.esrtechnology.com
If you would like to unsubscribe to this newsletter please email
using UNSUBSCRIBE in the subject.
Alternatively, if you would like to subscribe to this newsletter
please email using SUBSCRIBE in the subject.
Machine, Bearing,
Friction, Wear or
Lubrication Problem?
Contact us @
paul.tweedale@esrtechnology.com
hugues.renondeau@esrtechnology.com
+44 (0) 1925 843476
National Centre of Tribology (NCT)
Newsletter - Spring 2013
www.esrtechnology.com
NCT has added a Test Sequencer module to its
TIAB Digital Hydraulic Controller (DHC). This
enables complex repeatable test sequences to be
created and run on existing or purpose build test
rigs (e.g. ‘rainflow’ testing). It’s first use is on a
custom built rig (photo right) to measure static and
dynamic friction as a function of the angular position
of friction plates. The latter are enclosed in a sealed
hydraulic fluid reservoir with axial loads of up to
4.4KN applied to them. The hydraulically driven
crank is used to precisely actuate the friction plates
under load, with friction data measured via a piezo-
electric torque cell (see typical plot right) . Test step
sequencing allows extensive frictional data logging
in a very controlled and repeatable manner for the
representative loading imposed. Characterisation of
this behaviour over many cycles of operation is of
paramount importance for these friction plates as
they are to be used in a safety-critical systems.
For more info email Hugues Renondeau
ESR Technology Improves its Hydraulic Testing Capabilities
-2
-1.5
-1
-0.5
0
0.5
0
200
400
600
800
1000
1200
0 5 10
Position(mm)
Torque(N.cm)
Time(s)
Torque
Position
Crank arm
Normal load
Specimens &
torque cell
ESR Technology is investing in NCT’s core facilities
with the purchase of a Nanovea ST400 non-contact
3D profilometer. This significantly extends our 2D
and 3D profilometry capabilities. 2 sensors (with
different standoffs and ranges) using ‘White Light
Axial Chromatism’ and 150 x 150 mm stages will
allow us to comprehensively assess the surfaces of
the engineering components that we investigate.
The Mountains 3D software suite provides surface
roughness (2&3D to ISO & ASTM), flatness,
waviness, wear scar volume, dimensional analysis,
grain counting, and more to be determined.
For more info email Hugues Renondeau
New 3D Non-Contact Profilomter
3D image and analysis courtesy of Mi-Net and Nanovea