Microstructural damage due to dull tool Grinding burn Electrochemical machining intergranular attack Electrical discharge machining recast layer cracki Residual stress cracking due to overheating Metalworking Processes Cracking, tears, or necking due to forming/deep drawing Laps due to thread rolling/spinning Tool marks and scratches from forming Surface tears due to poor surface preparation prior to working Residual stress cracking due to flowforming Luders lines due to forming strain rate Microstructural damage due to shearing, blanking, piercing Overheating damage during spring winding Laps and cracks due to shot penin Stress-corrosion cracking due to use of improper die lubricants Heat Treatment Grain growth Incomplete phase transformation Quench crack Decarburization Untempered martensite Temper embrittlement and similar embrittlement conditions nadequate precipitation Sensitized microstructure Inhomogeneities in microstructure Loss of properties due to overheating during post-plating bake Welding Lack of fusion Brittle cracking in heat-affected zone(HAz) Sensitized haz Residual stress cracking Slag inclusions Cratering of fusion zone at endpoint Filler metal contour out of specification · Hot cracking Cracking at low exposure temperatures Hydrogen embrittlement due to moisture contamination Liquid metal embrittlement from plating contamination Cleaning/ Finishing Corrosion due to inadequate cleaning prior to painting Intergranular attack or hydrogen embrittlement due to acid cleaning Hydrogen embrittlement due to plating Stress corrosion from caustic autoclave core leaching of castings Assembly at Factory/nstallation at Site Misalignment ong parts· Microstructural damage due to dull tool · Grinding burn · Electrical discharge machining recast layer cracking · Electrochemical machining intergranular attack · Residual stress cracking due to overheating Metalworking Processes · Cracking, tears, or necking due to forming/deep drawing · Laps due to thread rolling/spinning · Tool marks and scratches from forming · Surface tears due to poor surface preparation prior to working · Residual stress cracking due to flowforming · Lüders lines due to forming strain rate · Microstructural damage due to shearing, blanking, piercing · Overheating damage during spring winding · Laps and cracks due to shot peening · Stress-corrosion cracking due to use of improper die lubricants Heat Treatment · Grain growth · Incomplete phase transformation · Quench cracks · Decarburization · Untempered martensite · Temper embrittlement and similar embrittlement conditions · Inadequate precipitation · Sensitized microstructure · Inhomogeneities in microstructure · Loss of properties due to overheating during post-plating bake Welding · Lack of fusion · Brittle cracking in heat-affected zone (HAZ) · Sensitized HAZ · Residual stress cracking · Slag inclusions · Cratering of fusion zone at endpoint · Filler metal contour out of specification · Hot cracking · Cracking at low exposure temperatures · Hydrogen embrittlement due to moisture contamination · Liquid metal embrittlement from plating contamination Cleaning/Finishing · Corrosion due to inadequate cleaning prior to painting · Intergranular attack or hydrogen embrittlement due to acid cleaning · Hydrogen embrittlement due to plating · Stress corrosion from caustic autoclave core leaching of castings Assembly at Factory/Installation at Site · Misalignment · Missing/wrong parts