Failure of a Bucket-Wheel Stacker Reclaimer: Metallographic and Structural Analyses

• Published in: Journal of failure analysis and prevention Vol. 12; no. 4; pp. 402 - 407
• Main Authors: ARAUJO, L. S, DE ALMEIDA, L. H, BATISTA, E. M, LANDESMANN, A
• Format: Journal Article
• Language: English
• Published: Materials Park, OH ASM International 01.08.2012; Springer Nature B.V
• Subjects: Applications; Applied sciences; Collapse; Engineering techniques in metallurgy. Applications. Other aspects; Exact sciences and technology; Failure; Flanges; Heat affected zone; Iron ores; Metals. Metallurgy; Mining; Stackers; Structural analysis; Weld defects; Scanning electron microscopy; Wheel; Brittle fracture; Metallography; Plastic deformation; Steel; Mining; Structural collapse; Welded joint; Bucket; Failure analysis; Bucket-wheel stacker reclaimer; Heat affected zone; Microstructure; Fractography; Fracture mode; Structural analysis
• ISSN: 1547-7029; 1864-1245
• DOI: 10.1007/s11668-012-9575-z

The structural collapse of an iron-ore bucket-wheel stacker reclaimer at the beginning of operation was investigated by means of mechanical tests, microstructural characterization, and computational structural analysis. The mechanical failure was a consequence of a brittle fracture by cleavage. The crack followed the heat-affected zone of a welded joint connecting a rectangular hollow section member and a plate flange. The main factors contributing to failure were related with a combination of design-in and manufacturing-in factors like high load-strength ratio at the point of failure, local stress concentration as a result of geometry restrictions, and weld defects. This particular section was responsible for the load transfer between the front tie member and the boom extremity, and its failure was the main cause of the catastrophic failure of the equipment.[PUBLICATION ABSTRACT]