Why Stuff Falls ApartDr. McIntyre R. Louthan, Jr
Savannah River Technology Center -- Westinghouse Savannah River Co.
Dr. Louthan presented both humorous and touching illustrations about how catastrophic failures can be traced to six root causes.
1. Deficiencies in Design.
The collapse of the skybridge at the KC Hyatt was a prime example. Loadbearing hangers were split, concentrating loads above the coupling rather than distributing them as originally conceived, because 60 foot rods were "hard to handle".
2. Improper Materials Selection
An averted crisis involving the cancellation of a shipment of crane arms made from high ductile-to-brittle transition temperature steel to be shipped to the arctic was an example.
3. Defects in Material
A steering gear casing which passed a 1% AQL, but in which the lot was known to have some casting defects leading to a tragic driving plunge to death for a family was an example. Non-destructive inspection was withheld due to cost.
4. Improper Processing
A supplier supplied rolled (rather than forged) roof bolt plates for a mining application to save money. A worker was killed when the first collapse occurred.
5. Inappropriate Assembly
A major problem was averted when the manufacturer of large compressors discovered that a plater of head bolts had failed to bake out the bolts after electroplating leaving them susceptible to hydrogen embrittlement. Immediate replacement of all bolts in the field prevented a disaster.
6. Inadequate Service
Our speaker's oldest son (a graduate engineer) froze up his new van's engine when he didn't check the oil for over 13000 miles.
The be a true "professional"
Engineers need
Tough Preparation
and
Flawless Ethics
Our universities are sadly deficient in providing the second component.