Failure analysis of a dynamic brake fan assembly (ASM) and definition of prevention criteria

Wednesday, September 15, 2021: 1:20 PM
241 (America's Center)
Dr. Guiru Nash Liu , Progress Rail, Inc., LaGrange, IL
Ms. Jocelyn Buchman , Progress Rail, Inc., LaGrange, IL
A rebuilt dynamic brake fan ASM had failed catastrophically during post-rebuild performance testing. Failure analysis of the dynamic brake fan ASM was conducted using non-destructive method, optical microscope, and Scanning Electronic Microscope (SEM) and OES metals analyzer. It was found that the dynamic brake fan blade was a low cycle fatigue failure, which resulted from Cu-rich grain boundary segregation and intergranular cracking. The failure analysis results were used to define the shelf life of the dynamic brake fan blade and provide preventative maintenance criteria to eliminate future catastrophic failures.