Wire Breaks And Failure Analysis

PagePreface 1

Types of Wire Breaks 2

Causes of Breaks 3

Prevention of Breaks 4

Wire Break Classification 5

Possible Source of Inclusions 6

I Process Related Problems 7

Annealing Problems: Arcing• Molten Ends 8

Cut Ends 9

Mechanical Damage 10-11

Scriber Marks 12

Welding Related Wire Breaks

• Hot Welds 13

• Cold Welds 14

Wire Drawing Problems

• Bulging 15

• Chatter 16

• Crowsfeet 17

• Cups, Cones, and Cuppy Wire 18

• Drawing Slivers 19

• Misalignment 20

• Packed or Plugged Die (compacted fines) 21

• Shaving 22

• Surface Tearing and Galling 23

• Tensiles 24

• Torsion Breaks 25

II Rod Related Problems 26

Casting Problems• High Oxygen 27

• Icicles / Slag 28

• Macroporosity 29-30

• Off Center Macroporosity 31

Hot Rolling Problems

• Slivers / Seams 32-33

• Roll Protrusions and Overfills 34

• Oxides and Hot Cracks 35

III Inclusions 36

Inclusion Absent 37

Inclusion Present

• Magnetic Inclusions 38-39

• Non-Magnetic Inclusions 40IV Look-Alikes 41-43V Field Service Related Defects 44

Corrosion 45

Fatigue 46

Hydrogen Embrittlement 47

Over Heating 48

Oxidation 49