TY - JOUR A1 - Wallstabe, Ronald A1 - Klinger, Christian T1 - Cause of an implant fracture: material- or fabrication failure? N2 - Intramedullary hip screws (IMHSs) are implanted for the fixture of pertrochanteric femoral fractures (thigh bone). The present work investigates the failure of an IMHS implant after the rehabilitation period which required a revision surgery where the upper femur had to be replaced by a hip endoprosthesis. Due to litigation the corresponding failure analysis was conducted at BAM Federal Institute for Materials Research and Testing and is the subject of this article. By order of the customer failure causes due to material and fabrication failures should be particularly investigated. Therefore, thorough fractographic, chemical as well as metallographic investigations were carried out. In order to assess possible fabrication failures selected dimensions of the components were compared with the technical drawings and the surface topography was analysed. The investigation revealed several causes for the fracture of the lag screw which is the implant component intended to fix the position of the femoral head. These are in descending order of relevance: (1) the screw was placed incorrectly and therefore had a smaller bending stiffness, (2) the femoral fracture zone was not stable, i.e., the lag screw 'moved out' of its proper position and (3) the laser marking on the lag screw was relatively large and led to a metallurgical notch at the now, because of the above mentioned points, severely stressed region. A material- or fabrication failure was not the root cause for the fracture of the lag screw. It was mainly due to its incorrect placement during surgery and the instability of the bone fracture. Furthermore, the implant geometry with 130° was not well-suited for the patient's anatomy. A 135°-IMHS might have been biomechanically preferable. Based on the determined failure causes and influences a relative lifetime estimation led to about 10% of the lifetime of a correctly placed 135°-IMHS assuming a sufficiently stable bone fracture zone. KW - Implant fracture KW - Intramedullary hip screw (IMHS) KW - Austenitic steel KW - Laser-marking KW - Implant placement PY - 2012 DO - https://doi.org/10.1016/j.engfailanal.2012.05.010 SN - 1350-6307 SN - 1873-1961 VL - 25 SP - 261 EP - 270 PB - Elsevier Science Publ. CY - Oxford AN - OPUS4-26238 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Klinger, Christian T1 - Experimentelle Optimierung des Schwingverhaltens und Betriebsfestigkeitsanalyse von Schienenfahrzeugkomponenten T2 - GESA-Symposium 1999 CY - Warnemünde, Deutschland DA - 1999-05-06 KW - Schwingungsverhalten KW - Schienenfahrzeug KW - Fahrzeugbauteil KW - Schwingungsfestigkeit KW - Bauteil KW - Baugruppe PY - 1999 SN - 3-18-091463-7 SN - 0083-5560 SP - 431 EP - 436 PB - VDI-Verl. CY - Düsseldorf AN - OPUS4-708 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Klinger, Christian A1 - Hortmanns, M. A1 - Ruscheweyh, H. A1 - Wohler, Hartmut T1 - Kranschäden durch windinduzierte Schwingungen KW - Kran KW - Stahlbau KW - Schwingung, Galloping KW - Wind PY - 1996 SN - 0038-9145 SN - 1437-1049 SN - 0932-6375 VL - 65 IS - 10 SP - 377 EP - 391 PB - Ernst CY - Berlin AN - OPUS4-632 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Klinger, Christian T1 - Bauteilversagen Materialfehler? T2 - BAM-Sonderkolloquium CY - Berlin, Germany DA - 2003-12-10 PY - 2003 AN - OPUS4-5221 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Klingbeil, Dietmar A1 - Klinger, Christian A1 - Kinder, J. A1 - Baer, Wolfram T1 - Investigations for indications of deliberate blasting on the front bulkhead of the ro-ro ferry MV Estonia N2 - The roll-on-roll-off passenger ferry MV ESTONIA sank during the night of 28 September 1994 in the Baltic Sea. In October 2000, divers recovered two palm-sized test pieces from the front bulkhead of the wreck. The investigators analysed these specimens to determine whether there were any indications of deliberate blasting. Since the wreck had been submerged for almost six years, it was clear that chemical traces would not be present on the surfaces of the test pieces. Therefore, the investigators performed comparative tests on shipbuilding steel to find a microstructural criterion that exclusively characterises a blast. The shipyard Jos. L. Meyer, Germany, had built the ESTONIA and supplied shipbuilding steel plates similar to that used for building the vessel in 1979/1980. The comparative tests comprised mechanical tests, shot peening tests and blasting tests using different explosives. Testing demonstrated that blasting always formed twinned ferrite grains in the microstructure over the whole cross-section of each of the 8 mm thick comparative plates. Although one of the original test pieces of the ESTONIA showed deformation twins, this was only confined up to 0.4 mm underneath the surfaces and not spread over the whole cross-section. Comparative shot peening tests produced the very same pattern of subsurface deformation twins. Therefore, the twins detected in the microsection of the test pieces of the ESTONIA wreck traced back to the shot peening process performed by the shipyard in 1979/1980 and not to a deliberate blast. KW - Investigations on parts of a ship wreck KW - Comparative blasting tests KW - Metallographic analyses of shipbuilding steel KW - Derivation of microstructural criteria for blasting KW - Deformation twins PY - 2014 DO - https://doi.org/10.1016/j.engfailanal.2014.03.016 SN - 1350-6307 SN - 1873-1961 VL - 43 IS - Special Issue 'A Tribute to Prof. A. Martens' SP - 186 EP - 197 PB - Elsevier Science Publ. CY - Oxford AN - OPUS4-31291 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Klinger, Christian T1 - Wer den Schaden hat... - Schadensanalyse als interdisziplinäre Aufgabe T2 - Abendvortrag auf der Tagung "Werkstoffprüfung 2009" CY - Bad Neuenahr, Germany DA - 2009-12-03 PY - 2009 AN - OPUS4-20730 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Klinger, Christian T1 - Fraktographie für die Schadensanalyse T2 - Gründungssitzung der AG Fraktographie, BAM CY - Berlin, Germany DA - 2010-09-03 PY - 2010 AN - OPUS4-22815 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Bettge, Dirk A1 - Klinger, Christian A1 - Ell, Matthias A1 - Klingbeil, Dietmar A1 - von Oppel, Kay A1 - Singh, Kai A1 - Eberle, Arno A1 - Engelhardt, Monika A1 - Bogel, Bärbel A1 - Saliwan Neumann, Romeo T1 - Schadensanalyse an Rohrbögen von Dampferzeugeranlagen T2 - VGB-Fachtagung "Dampferzeuger, Industrie und Heizkraftwerke 2006" CY - Würzburg, Deutschland DA - 2006-09-04 KW - Schadensanalyse KW - Brüche KW - Dampferzeuger KW - Transportschaden PY - 2006 PB - VGB PowerTech e.V. CY - Essen AN - OPUS4-12817 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Häcker, Ralf A1 - Klinger, Christian A1 - Kahlcke, Ole A1 - Schriever, Sina ED - Grellmann, W. T1 - Zwischen Zeitstand und Relaxation - Einfluss der Proben- und Prüfmaschinensteifigkeit auf die Lebensdauer unter konstanter Belastung N2 - Zur Abschätzung der Lebensdauer eines bei höherer Temperatur langzeitbelasteten Bauteils wurden Zeitstandversuche, Relaxationsversuche und weitere Versuche mit unterschiedlichen Umgebungssteifigkeiten durchgeführt. Die Zeitstandversuche, deren Versuchsführung eine unendlich niedrige Umgebungssteifigkeit simuliert, liefern geringere Lebensdauern (Bruchzeiten) im Vergleich zu Versuchen mit endlich hohen, technisch relevanten Steifigkeiten bei vergleichbarer Probensteifigkeit (Geometrie), wobei die Lebensdauern mit steigender Umgebungssteifigkeit zunehmen. Die längsten Lebensdauern zeigen Relaxationsversuche mit einer unendlich hohen Umgebungssteifigkeit aufgrund ihrer Versuchsregelung. Für die Übertragung der an Proben gewonnenen Ergebnisse auf das Bauteil wurde das Steifigkeitsverhältnis Z zwischen der Steifigkeit der 'Probe' und der der 'Umgebung' definiert und angewandt. Das Steifigkeitsverhältnis des kritischen Bereichs im Bauteil und das der Werkstoffprobe in der Prüfmaschine sollten möglichst ähnlich sein. Dann lassen sich bei der Übertragung auf das Bauteil realistisch höhere Lebensdauern abschätzen als nur mit Kenntnis der Ergebnisse der Zeit-standversuche. T2 - DVM-Tagung Werkstoffprüfung 2011 - Neue Entwicklungen in der Werkstoffprüfung - Herausforderungen an die Kennwertermittlung CY - Berlin, Germany DA - 01.12.2011 KW - Zeitstandverhalten KW - Steifigkeit KW - Relaxationsversuch KW - Lebensdauer KW - Bauteilprüfung PY - 2011 SN - 978-3-9814516-1-0 SN - 1861-8154 N1 - Serientitel: DVM-Bericht – Series title: DVM-Bericht IS - 643 SP - 267 EP - 272 AN - OPUS4-24932 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Tiebe, Carlo A1 - Zunkel, Astrid A1 - Klein, Ulrich A1 - Schlischka, Jörg A1 - Klinger, Christian T1 - Materialuntersuchungen zur Schadensanalyse an einem explodierten Umlaufkühler N2 - Ein Durchlaufkühler ist im Betrieb explodiert. Die zerborstenen Gehäuseteile aus Kunststoff führten zu einem Austreten der Kühlflüssigkeit am Betriebsort sowie zu einem Personenschaden mit Knalltrauma. Bei Funktionsprüfungen am beschädigten Gerät traten unerwartet, aber reproduzierbar Knalleffekte auf der Kupfer-Kühlschlange auf. Ein möglicher Mechanismus konnte im Labor durch Synthese von Kupferazid auf Kupferproben und Auslösung vergleichbarer Knalleffekte nachgestellt werden. Damit ist die Plausibilität des beschriebenen Schadensereignisses mit diesem oder einem ähnlich reagierenden Stoff belegt. Ein eindeutiger Nachweis darüber, dass beim aufgetretenen Schadensfall dieselbe chemische Reaktion stattgefunden hat ist nicht möglich, da die Belag-Überreste aus dem explodierten Kühlgerät für eine Analyse nicht mehr in ausreichender Menge verfügbar waren. T2 - Erfahrungsaustausch für Sachverständige in der Anlagenüberwachung der Industrie (ESA 2021) CY - Online meeting DA - 20.04.2021 KW - Umlaufkühler KW - Schadensanalyse KW - Materialuntersuchungen KW - Gutachten KW - Kupferazid PY - 2021 AN - OPUS4-52484 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Tiebe, Carlo A1 - Zunkel, Astrid A1 - Klein, Ulrich A1 - Schlischka, Jörg A1 - Klinger, Christian T1 - Materialuntersuchungen an einem explodierten Umlaufkühler N2 - Ein Umlaufkühler ist im Betrieb explodiert. Splitter des zerborstenen Gehäuses aus Kunststoff wurden mit dem Kühlwasser in die Umgebung geschleudert, am Betriebsort entstand Personenschaden. Bei Funktionsprüfungen am beschädigten Gerät traten unerwartet - aber reproduzierbar - Knalleffekte bei Berührung der Außenoberfläche der Kupfer-Kühlschlange auf. Ein möglicher Mechanismus konnte im Labor durch Synthese von Kupferazid auf Kupferproben und Auslösung vergleichbarer Knalleffekte nachgestellt werden. Damit ist die Plausibilität des beschriebenen Schadensereignisses mit diesem oder einem ähnlich reagierenden Stoff belegt. Ein eindeutiger Nachweis darüber, dass bei dem aufgetretenen Schadensfall dieselbe chemische Reaktion stattgefunden hat, war nicht möglich, da die Belag-Überreste aus dem explodierten Kühlgerät für eine Analyse nicht mehr in ausreichender Menge verfügbar gewesen sind. KW - Kupferazid KW - Umlaufkühler KW - Explosion KW - Gutachten KW - Schadensanalyse KW - Materialuntersuchung PY - 2022 SN - 2191-0073 VL - 12 IS - 7/8 SP - 15 EP - 21 PB - VDI Fachmedien CY - Düsseldorf AN - OPUS4-55570 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - GEN A1 - Portella, Pedro Dolabella A1 - Bettge, Dirk A1 - Klinger, Christian A1 - Baer, Wolfram T1 - Über das Versagen von Strommasten im Münsterland (Nov. 2005) - der Beitrag der Metallographie und der Fraktographie T2 - 43. Metallographie-Tagung CY - Aachen, Deutschland DA - 2009-09-16 PY - 2009 SN - 978-3-88355-376-4 VL - 41 SP - 21 EP - 30 PB - Werkstoff-Informationsges. CY - Frankfurt/M. AN - OPUS4-20061 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Klinger, Christian T1 - Thomasstahl in Freileitungsmasten: Schadensanalyse der Mastumbrüche Münsterland 2005 und Empfehlungen T2 - 3. ETP-Konferenz CY - Düsseldorf, Germany DA - 2007-07-03 PY - 2007 AN - OPUS4-15204 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Klinger, Christian T1 - Schadensanalyse an umgebrochenen Strommasten im Münsterland 2005 T2 - Werkstoffprüfung 2006 CY - Bad Neuenahr, Germany DA - 2006-12-07 PY - 2006 AN - OPUS4-13895 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Klinger, Christian T1 - Thomas-Stahl in Freileitungsmasten: "Strommastenschäden Münsterland 2005" - Untersuchungen, Ergebnisse und Maßnahmen T2 - Jahrestagung IHE Zittau, Instandhaltung in der Energiewirtschaft CY - Dessau-Roßlau, Germany DA - 2010-10-26 PY - 2010 AN - OPUS4-22819 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Klinger, Christian T1 - Failure analysis on broken power towers in the region Münsterland (Germany) November 2005 T2 - International Conference Engineering Failure Analysis CY - Cambridge, England DA - 2010-07-04 PY - 2010 AN - OPUS4-22785 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Klinger, Christian T1 - Schadensanalyse an umgebrochenen Strommasten im Münsterland 2005 T2 - SVMT Jahrestagung CY - Dübendorf, Switzerland DA - 2007-03-07 PY - 2007 AN - OPUS4-22817 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Klinger, Christian T1 - Schadensanalysen der BAM am Beispiel der Strommastumbrüche Münsterland 2005 T2 - Tag der offenen Tür im BMWi CY - Berlin, Germany DA - 2007-08-25 PY - 2007 AN - OPUS4-22821 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Klinger, Christian A1 - Mehdianpour, Milad A1 - Klingbeil, Dietmar A1 - Bettge, Dirk A1 - Häcker, Ralf A1 - Baer, Wolfram T1 - Failure analysis on collapsed towers of overhead electrical lines in the region Münsterland (Germany) 2005 N2 - End of November 2005 strong south-west wind and heavy snowfall were predominant in the region Münsterland, north-western part of Germany. This led to accretion of a considerable quantity of wet snow to overhead electrical lines in form of snow rolls on the conductors. Eighty-two transmission towers failed catastrophically, most of them by buckling, however some by brittle fracture. As a consequence nearly 250,000 people have been cut off from electrical power supply for several days with major media attention. This paper describes the forensic analysis in order to investigate the failure cause. Therefore extensive materials investigations, mechanical testing of original components and specimens thereof, estimations for the real wind and snow loads and their combinations, structural analyses as well as detailed evaluations on the basis of previous investigations, literature and regulations were conducted. It was revealed that some of the examined components were manufactured from Thomas steel which was partially in embrittled condition. The investigated towers fulfilled the design codes valid at the time of erection. However the present line loads of the wet snow rolls on the conductors exceeded by far the ones given in the design codes valid at that time. The load case leading to failure was reconstructed by the derived positions of loads mainly caused by unequal and asymmetric distribution of snow rolls on left and right electrical system. The loads and corresponding stresses acting on the structure before failure were estimated. By comparison with the fracture forces from mechanical testing of original members of the collapsed tower the component that primarily failed was localised. The primary fracture occurred on a diagonal member under tension made of Thomas steel which was weakened by embrittlement. The failure cause was a combination of heavy weather conditions (storm, approx. 0 °C and wet snowfall leading to heavy snow rolls on conductors), asymmetric loading conditions and the usage of Thomas steel which was partially embrittled. Finally, recommendations for avoiding future failures are given. KW - Transmission towers KW - Thomas steel KW - Embrittlement KW - Snow loads KW - Ice loads PY - 2011 DO - https://doi.org/10.1016/j.engfailanal.2011.07.004 SN - 1350-6307 SN - 1873-1961 VL - 18 IS - 7 SP - 1873 EP - 1883 PB - Elsevier Science Publ. CY - Oxford AN - OPUS4-24517 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Zerbst, Uwe A1 - Madia, Mauro A1 - Klinger, Christian A1 - Bettge, Dirk A1 - Murakami, Y. T1 - Defects as a root cause of fatigue failure of metallic components. II: Non-metallic inclusions N2 - This second part of the review on defects as root cause of fatigue failure comprises the origin, the nature and the effects of non-metallic inclusions. Topics addressed are the different kinds of inclusions formed during the manufacturing process, various types of mis-match causing local stresses and, as a consequence, fatigue crack initiation, and effects of characteristics such as size, morphology, localization, spatial distribution and orientation of the defects on the fatigue behavior. Methods for inclusion counting and sizing are discussed along with statistical aspects necessary to be considered when evaluating structural components. KW - Non-metallic inclusions KW - Mis-match KW - Inclusion size KW - Inclusion cluster KW - Statistics PY - 2019 DO - https://doi.org/10.1016/j.engfailanal.2019.01.054 SN - 1350-6307 VL - 98 SP - 228 EP - 239 PB - Elsevier Ltd. AN - OPUS4-47459 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Zerbst, Uwe A1 - Madia, Mauro A1 - Klinger, Christian A1 - Bettge, Dirk A1 - Murakami, Y. T1 - Defects as a root cause of fatigue failure of metallic components. I: Basic aspects N2 - According to the definition of the ASM handbook [1,3], a defect is "an imperfection. that can be shown to cause failure by a quantitative analysis and that would not have occurred in the absence of the imperfection". The topic of the present three-part review is a discussion of defects which can cause failure in cyclically loaded structures. The features discussed comprise material defects such as non-metallic inclusions, pores or micro-shrinkages, etc. and geometric defects such as surface roughness and secondary notches which have their origin in manufacturing, and defects such as surface damage due to scratches, impact events or contact fatigue as well as corrosion pits which arise in service. In this first part, the discussion is prefaced by an introduction to basic aspects which are essential for a deeper understanding of the characteristics and mechanisms how the defects influence fatigue crack initiation and propagation. These include the life cycle of a fatigue crack from initiation up to fracture, crack arrest, multiple crack initiation and coalescence, and the material and geometrical properties affecting these. KW - Defects KW - Fatigue crack propagation stages KW - Crack arrest KW - Multiple cracks PY - 2019 DO - https://doi.org/10.1016/j.engfailanal.2019.01.055 SN - 1350-6307 VL - 97 SP - 777 EP - 792 PB - Pergamon-Elsevier Science Ltd CY - Oxford, England AN - OPUS4-47372 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Zerbst, Uwe A1 - Madia, Mauro A1 - Klinger, Christian A1 - Bettge, Dirk A1 - Murakami, Y. T1 - Defects as a root cause of fatigue failure of metallic components. III: Cavities, dents, corrosion pits, scratches N2 - This third part of the review on defects as root cause of fatigue failure addresses cavities (pores, micro-shrinkages, unmelted regions), defective microstructures and microcracks as material defects and defects due to local damage during manufacturing, service and maintenance such as dents, scratches and localized corrosion. In addition, damage due to contact fatigue and the effect of surface roughness are discussed in the context of fatigue failure. Also addressed is the competition between different kinds of defects in controlling the initiation and early growth of fatigue cracks. KW - Pores KW - Micro-shrinkages KW - Impact damage KW - Contact fatigue KW - Corrosion pits KW - Scratches PY - 2019 DO - https://doi.org/10.1016/j.engfailanal.2019.01.034 SN - 1350-6307 VL - 97 SP - 759 EP - 776 PB - Pergamon-Elsevier Science Ltd CY - Oxford, England AN - OPUS4-47373 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Zerbst, Uwe A1 - Klinger, Christian T1 - Material defects as cause for the fatigue failure of metallic components N2 - The paper provides an overview on material defects which may serve as fatigue crack initiation sites and can cause final fatigue failure of a component. These comprise nonmetallic inclusions in Steel and aluminum alloys, cavities such as pores, micro-shrinkages and un-welded regions in cast, sinter and additively manufactured alloys, graphite nodules, shrinkages and other items in modular cast iron, regions of defective microstructure, microcracks and secondary notches such as undercuts and surface roughness. Besides their origin, the effect and mechanisms on fatigue crack initiation and propagation are discussed. The considerations are proceeded and accompanied by a Brief discussion of some Basic aspects such as the stages of crack propagation along their length scale, the overcoming of crack arrest and the question when a secondary notch can be treated as a crack. KW - Material defects KW - Fatigue strength and life KW - Non-metallic inclusions KW - Pores KW - Shrinkages KW - Graphite modules KW - Surface roughness PY - 2019 DO - https://doi.org/10.1016/j.ijfatigue.2019.06.024 SN - 0142-1123 SN - 1879-3452 VL - 127 SP - 312 EP - 323 PB - Elsevier AN - OPUS4-49127 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -