Improved productivity through failure analysis: Case studies in precision forging of aerospace components

In this study, usefulness of failure analysis in improving productivity through selection of better materials and heat treatments that delay or prevent the on set of fracture in precision forging of aerospace components is illustrated. Examples have been taken from failed cold working dies, hot forging dies and broaches. Detailed metallographic analysis of the microstructures and fractures has pinpointed the sources and mechanisms of failure. This, in turn, has indicated the means of preventing such failures in service and, in improving die life and performance, by using advanced materials and optimizing heat treatments and surface engineering treatments.