Failure analysis of frontal load-bar equipment

This article presents a case study of a fractured load-bar. Material and fracture surface were characterized by magnetic particle inspection, optical microscopy, scanning electron microscopy, hardness and chemical analysis. Results showed that, although the material was according to the project specification, component failures were due to thermal fatigue promoted by the Joule thermal effect, resulting from energy dissipation on the load-bar inner surface, which contacts the vehicle-supporting mechanism.