Failure analysis of a polymer centrifugal impeller

• Failure analysis investigation of polymer impeller.
• Fracture morphologies consistent with brittle fracture.
• Fracture features include Wallner lines, mirror, mist, and hackle regions.
• Fatigue striations and drawn fibrils also observed.
• Reaming induced wear defects found on the inner diameter bore of impeller.

A failure analysis investigation was performed on a fractured polymer impeller used in a respiratory blower. Light microscopy, scanning electron microscopy and finite element analysis techniques were utilized to characterize the mode(s) of failure and fracture surfaces. A radial split down the impeller center was observed with symmetric fracture faces about the impeller bore. Fractographic analysis revealed brittle fracture features including Wallner lines, mirror, mist and hackle features stemming from the impeller bore, emanating radially outward. Crazed fibrils and faint fatigue striations suggest that intermittent load cycling led to initiation, and rapid propagation of multiple crack fronts originating along the impeller lip. Finite element analysis revealed a flexural condition induces localized stresses along the impeller lip. Significant wear features were also observed within the impeller bore, which may have contributed to premature failure of the impeller. The brittle fracture morphology and defects within the impeller bore suggest that premature failure occurred because of multiple interacting factors including: intermittently high centrifugal velocities, imbalance bore and shaft conditions, defects within the bore caused by machining, and stress concentrations along the circumference of the impeller lip.