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Root Cause Failure Analysis

The document discusses root cause failure analysis (RCFA) and provides an example of one that was conducted. RCFA is a systematic investigation to determine the underlying cause of a failure. In one example, white cast iron liners cracked during installation for mining wear due to residual tensile stresses from welds in their fabrication. Defects were also found in the brazing between the iron and steel backing plate. Improvements to fabrication procedures and quality assurance were recommended.

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193 views1 page

Root Cause Failure Analysis

The document discusses root cause failure analysis (RCFA) and provides an example of one that was conducted. RCFA is a systematic investigation to determine the underlying cause of a failure. In one example, white cast iron liners cracked during installation for mining wear due to residual tensile stresses from welds in their fabrication. Defects were also found in the brazing between the iron and steel backing plate. Improvements to fabrication procedures and quality assurance were recommended.

Uploaded by

saurabhsubhu
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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RCFA For Mining Industry

Root Cause Failure Analysis (RCFA) is the systematic inves- from large residual tensile stresses from welds between a steel
tigation of the construction, application, and history of a failed I-beam and the steel backing plate during fabrication by the
component, equipment or system to determine the failure manufacturer. These stresses were the result of the joint design,
mechanism and underlying cause. RCFA may be employed for welding procedure and execution of the weld. Furthermore, there
legal, insurance, safety, environmental or production reasons. were many defects which originated in the brazing operation
Once a failure occurs, one can determine the basic cause(s) and between the steel backing plate and white cast iron. Improve-
recommend changes necessary to reduce or eliminate the risk ments were recommended in fabrication procedures (minimize
of reoccurrence. heat input, smaller weld bead, control of inter-pass temperature,
welding sequence) and quality assurance during fabrication.
The XPS Materials Technology Laboratory, located in the XPS
Centre in Falconbridge, is the only failure analysis and materials Please contact Wilson Pascheto and his team of materials
testing laboratory in Northern Ontario. Having investigated over technology experts at [email protected]
1,000 cases, the XPS Materials Technology group has extensive

WELD CAUSING STEEL I BEAM


TENSILE STRESS

} MILD STEEL BACKING

Cracking of White Cast Iron Liners

experience in metallurgical root cause failure analysis in machin-


ery use in mine sites, concentrators, smelters, leach plants,
DFLG SODQWV DQG HOHFWURO\WLF UH¿QHULHV 2XU ¿HOG DQG ODERUDWRU\ WHITE
experience allows us to make and implement practical recom- MILD STEEL BACKING
mendations to mitigate failures together with site expertise and
CAST IRON
VXSSOLHUV,QWKLVUHJDUGRXU¿HOGH[SHULHQFHLQSDUWLFXODUJLYHV
XVDVLJQL¿FDQWDGYDQWDJHRYHUPDQ\RWKHUPHWDOOXUJLFDOIDLOXUH
analysis labs. Recommendations may include changes in mate-
rials of construction or design, fabrication or construction proce-
dures, quality assurance during fabrication and/or construction, DEFECTIVE BRAZING LAYER
inspection plans during operation as well as maintenance and
operating procedures.

In one example, white cast iron liners mounted onto mild steel WHITE CAST IRON
backing plates cracked during the installation process for a min-
ing wear application. Through RCFA, XPS Materials Technology
engineers and technicians determined that the failure resulted
Defective Brazing Layer from White Cast iron to the Mild Steel Backing

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