Table of Contents

Cover image

Title page

Copyright

Preface

Acknowledgements

Dedication

Chapter 1: Introduction

1.1 Product failure

1.2 Properties of polymers

1.3 Failure modes

1.4 Methods of investigating product failure

1.5 Public information sources

Chapter 2: Examination and analysis of failed components

2.1 Introduction

2.2 Processing methods and defects

2.3 Mechanical testing

2.4 Techniques for recording product failures

2.5 Forensic microscopy

2.6 Types of product defect

2.7 Molecular analysis of polymer properties

2.8 Integrity of results

2.9 Conclusions

Chapter 3: Polymeric medical devices

3.1 Introduction

3.2 Failed catheter

3.3 Failure of connectors

3.4 Failure of a breast tissue expander

3.5 Failure of sutures

3.6 Failure of breathing tubes

3.7 Conclusions

Chapter 4: Polymer storage tanks

4.1 Introduction

4.2 The Boston molasses disaster

4.3 Failure of polypropylene storage tanks

4.4 Failure of fibreglass storage tanks

4.5 Reconstructing the events leading to failure

4.6 Dealing with the aftermath

4.7 Setting new standards

Chapter 5: Small polymeric containers

5.1 Introduction

5.2 Failure of battery containers

5.3 Failure of buckets

5.4 Exploding batteries

5.5 Failed truck battery cases

5.6 Failures in miner lamp battery casings

5.7 Improving design to prevent failure

5.8 Conclusions

Chapter 6: Polymeric pipes and fittings

6.1 Introduction

6.2 Fracture of PVC water piping

6.3 Failure of PVC water pumps

6.4 Failures in gas pipelines

6.5 Failures in ABS pipes and fittings

6.6 Compressed gas explosion

6.7 Failures in polybutylene pipes and acetal resin fittings

6.8 Conclusions

Chapter 7: Polymeric seals

7.1 Introduction

7.2 Failure of elastomeric seals in brakes

7.3 The Challenger disaster

7.4 Failed elastomeric seals in a semi-conductor factory

7.5 Failures in TPE radiator washers

7.6 Failures in silicone mastics

7.7 Conclusions

Chapter 8: Tools and ladders

8.1 Introduction

8.2 Failure of polypropylene hobby knives

8.3 Failure of polystyrene components in hobby knives

8.4 Failure of handles in angle grinders

8.5 Failure of security caps for gas cylinders

8.6 Failure of an ABS handle

8.7 Failure of chairs manufactured from polypropylene

8.8 Failure of swimming pool steps

8.9 Failed polyamide fittings in ladders

8.10 Conclusions

Chapter 9: Components in transport applications

9.1 Introduction

9.2 Failure of tailpack in a motorbike accident

9.3 Failure of drive belts

9.4 Failure of tyres

9.5 Failed Rilsan nylon fuel pipes

9.6 Stress corrosion cracking of nylon connectors

9.7 Conclusions

Chapter 10: Consumer products

10.1 Introduction

10.2 Failure of Noryl plugs

10.3 Failure of Noryl busbar plugs

10.4 Residual current devices (RCDs)

10.5 Failure of kettle switches

10.6 Failure of fittings on luggage carriers

10.7 Failure of ABS joints on bike carriers

10.8 Failure of HDPE baby cot latches

10.9 Conclusions

Chapter 11: Conclusions

11.1 Introduction: causes of product failure

11.2 Poor manufacturing methods

11.3 Poor design

11.4 Poor choice of materials

11.5 Environmental stresses

11.6 Access to information

Index