Many years ago when I first started my career in a rotating equipment maintenance organization, I was spending the day with a senior metallurgist, which was part of my orientation process as a new technical employee. He was well known to not have the best “bedside manner” and it was clear he was not thrilled to have a young mechanical engineer by his side for the day. As I walked into the materials lab, looking for something to start a conversation, I picked up a small broken ANSI pump shaft and asked if he knew why this shaft had failed? His response I vividly remember to this day – he said, “Son, I have not analyzed that failure yet, but if it is a shaft out of a piece of rotating equipment and is broken into two pieces, there is about a 90% chance that it is a fatigue failure”. While...
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