1 Introduction |
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1 | (24) |
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1 | (2) |
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3 | (4) |
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1.2.1 Fault Tree Analysis |
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4 | (3) |
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1.3 Product Design and Manufacture |
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7 | (3) |
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10 | (2) |
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11 | (1) |
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12 | (1) |
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12 | (2) |
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13 | (1) |
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14 | (7) |
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15 | (2) |
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1.6.2 Evidence and Trial Procedure |
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17 | (2) |
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1.6.3 The Role of Forensic Engineers |
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19 | (1) |
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20 | (1) |
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1.7 Engineering Materials |
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21 | (1) |
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22 | (3) |
2 Materials in Distress |
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25 | (36) |
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25 | (5) |
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2.1.1 Cause of Demise - Engineering example |
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27 | (3) |
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2.2 Manufacturing Defects |
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30 | (5) |
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2.2.1 Defects by Omission |
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31 | (2) |
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33 | (2) |
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2.3 Failures under Mechanical Overload |
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35 | (8) |
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2.3.1 Polymeric Materials |
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39 | (2) |
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41 | (2) |
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43 | (9) |
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52 | (6) |
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2.5.1 Stress Corrosion Cracking of Metals |
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55 | (3) |
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2.5.2 Environmental Cracking of Plastics |
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58 | (1) |
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58 | (3) |
3 Establishing the Load Transfer Path |
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61 | (24) |
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3.1 Loads, Forces and Design |
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61 | (1) |
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3.2 Abnormal Externally Applied Force -- Stepladder |
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62 | (4) |
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3.3 Establishing the Load Transfer Path |
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66 | (7) |
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3.4 Effect of Faults and Weaknesses |
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73 | (3) |
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3.5 Cause of Failure of Axle Bracket in Racing Motorcycle Sidecar |
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76 | (9) |
4 A "Toolbox" for Forensic Engineers |
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85 | (46) |
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85 | (1) |
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4.2 An Initial Approach to a Failure |
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86 | (3) |
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4.2.1 Significance of Initial Observations |
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87 | (2) |
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4.3 Assessing the Situation |
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89 | (1) |
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90 | (15) |
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4.4.1 Photography and Sample Handling |
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91 | (1) |
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4.4.2 Product and Material Standards |
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92 | (1) |
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4.4.3 Macroscopic Examination |
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93 | (1) |
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4.4.4 Examination under Magnification: Optical Microscopic Inspection |
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94 | (1) |
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4.4.5 Metallographic Sectioning |
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94 | (6) |
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4.4.6 Scanning Electron Microscopy (SEM) |
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100 | (5) |
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105 | (10) |
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105 | (2) |
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107 | (1) |
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4.5.3 Moh's Hardness Test |
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107 | (1) |
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4.5.4 Vickers Hardness Test |
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107 | (1) |
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4.5.5 Brinell Hardness Test |
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108 | (1) |
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4.5.6 Rockwell Hardness Test |
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109 | (1) |
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4.5.7 Tensile Strength and Hv |
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109 | (2) |
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111 | (2) |
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113 | (2) |
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4.6 Indirect Strain Measurement |
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115 | (6) |
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115 | (2) |
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4.6.2 Crack Detection Methods |
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117 | (1) |
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4.6.3 Other Crack Detection Techniques |
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118 | (3) |
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4.7 Chemical and Thermal Analysis |
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121 | (7) |
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4.7.1 Differential Scanning Calorimetry (DSC) |
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121 | (3) |
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4.7.2 Infrared Spectroscopy |
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124 | (2) |
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126 | (1) |
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127 | (1) |
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4.7.5 Integrity of Analysis |
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127 | (1) |
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128 | (2) |
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130 | (1) |
5 Failure Due to Manufacturing Faults |
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131 | (40) |
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131 | (2) |
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5.2 Failure of Freight Containers |
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133 | (11) |
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5.3 Failures of Gears in Oil Pump |
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144 | (2) |
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146 | (5) |
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5.5 Failure of Threaded Iron Pipe Coupling |
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151 | (1) |
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5.6 Replacement Gears for Gearbox of Heavy Trucks |
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152 | (3) |
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155 | (3) |
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5.8 Rivet Failure in Multipurpose Tool |
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158 | (1) |
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5.9 Scaffolding Guard Rail |
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159 | (6) |
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5.10 Gas Molding Problems |
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165 | (6) |
6 Fluid Transport |
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171 | (44) |
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171 | (1) |
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171 | (3) |
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172 | (1) |
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6.2.2 Corrosion and Environmental Degradation |
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172 | (1) |
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173 | (1) |
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174 | (10) |
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6.3.1 Failure of an Oil Delivery Pipe |
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175 | (2) |
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6.3.2 Vehicle Brake Pipe Failure |
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177 | (4) |
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6.3.3 Stainless Steel Pipe Clamp Corrosion |
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181 | (3) |
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184 | (1) |
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184 | (10) |
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6.4.1 Reasons for Failure |
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186 | (1) |
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6.4.2 The Fracture Surface |
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187 | (2) |
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189 | (2) |
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191 | (1) |
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6.4.5 Stress Corrosion Cracking |
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192 | (1) |
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192 | (1) |
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193 | (1) |
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194 | (1) |
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194 | (5) |
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6.5.1 Cracking and Abrasion |
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196 | (1) |
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197 | (1) |
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6.5.3 Murphy Infants v. Fiat Spa |
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198 | (1) |
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199 | (1) |
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6.6 SCC of Diesel Fuel Pipe Connector |
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199 | (6) |
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6.6.1 Remains of the Pipe |
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200 | (2) |
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6.6.2 Stress Corrosion Cracking |
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202 | (2) |
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6.6.3 Loading of the Return Pipe |
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204 | (1) |
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204 | (1) |
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205 | (7) |
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208 | (1) |
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6.7.2 Experimental Analysis |
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208 | (2) |
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210 | (2) |
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212 | (1) |
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212 | (3) |
7 Failure of Storage Vessels |
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215 | (40) |
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7.1 Leakage of a Galvanized Tank |
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216 | (2) |
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7.1.1 The Failed Header Tank |
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217 | (1) |
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218 | (10) |
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7.2.1 Material Requirements |
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218 | (1) |
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7.2.2 Failure Investigation |
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219 | (2) |
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221 | (2) |
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223 | (3) |
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226 | (1) |
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7.2.6 Mechanical Analysis |
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226 | (1) |
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227 | (1) |
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7.3 Battery Case Failures |
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228 | (8) |
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7.3.1 Miners Backpack Cases |
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228 | (3) |
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7.3.2 Fire in the Hong Kong Subway |
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231 | (2) |
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233 | (3) |
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236 | (3) |
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7.5 Failure of Underground Storage Tanks |
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239 | (2) |
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7.6 Failure of Large Storage Tanks |
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241 | (12) |
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7.6.1 The Material Evidence |
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243 | (2) |
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245 | (2) |
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247 | (1) |
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248 | (1) |
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248 | (2) |
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250 | (1) |
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7.6.7 Inspection of Other Tanks |
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251 | (1) |
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7.6.8 Other Tank Failures |
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252 | (1) |
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253 | (1) |
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254 | (1) |
8 Accidents in the Workplace |
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255 | (32) |
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8.1 Explosion in a Foundry |
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255 | (6) |
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255 | (2) |
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257 | (1) |
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258 | (2) |
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260 | (1) |
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8.2 Accident with a Pressure Die-Casting Machine |
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261 | (3) |
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261 | (2) |
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263 | (1) |
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264 | (9) |
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8.3.1 Eye Injury While Replacing Clutch Plate |
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265 | (2) |
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267 | (3) |
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8.3.3 Printer's Drying Frame |
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270 | (3) |
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273 | (13) |
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8.4.1 The Material Evidence |
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273 | (2) |
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275 | (1) |
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275 | (1) |
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8.4.4 Coefficient of Friction |
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276 | (1) |
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277 | (1) |
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8.4.6 Stability Experiments |
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278 | (3) |
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281 | (1) |
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282 | (2) |
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8.4.9 Ladder Accidents and Design Improvements |
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284 | (2) |
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286 | (1) |
9 Failure of Medical Implements |
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287 | (32) |
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287 | (1) |
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9.2 The Body as a working Environment |
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288 | (1) |
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9.3 Design and Performance Criteria |
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288 | (2) |
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289 | (1) |
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289 | (1) |
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290 | (7) |
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9.4.1 Fatigue Failure of Prosthetic Hip Components |
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290 | (2) |
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9.4.2 Failure in Femoral Stem of Total Hip Prosthesis |
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292 | (1) |
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9.4.3 Manufacturing Contamination of Acetabular Hip Shells |
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293 | (2) |
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9.4.4 Corrosion of a Polished Titanium Alloy Femoral Stem |
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295 | (2) |
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297 | (6) |
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9.5.1 Fracture of a TPE Catheter |
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297 | (1) |
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9.5.2 Fracture of a Breast Tissue Expander |
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298 | (5) |
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9.6 Examination of Needle Recovered from Upper Thigh |
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303 | (2) |
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305 | (1) |
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9.7 A Defective Breathing Tube |
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305 | (2) |
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306 | (1) |
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9.8 Failure of Surgical Tweezers |
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307 | (6) |
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9.8.1 In-Plane Cracking of Surgical Tweezers |
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307 | (3) |
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9.8.2 Production Failure of Titanium (Ti-6Al-4V) Ophthalmic Tweezers |
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310 | (3) |
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313 | (2) |
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9.10 Failure of Nerve Probe during Surgical Procedure |
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315 | (2) |
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316 | (1) |
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317 | (2) |
10 Component Failure in Road Traffic Accidents |
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319 | (30) |
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10.1 Steering Arm from Truck |
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320 | (8) |
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320 | (3) |
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323 | (2) |
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10.1.3 Alternative Explanation |
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325 | (1) |
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10.1.4 Further Examples of Steering Shaft Failures from Motor Vehicle Accidents |
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326 | (2) |
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328 | (3) |
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331 | (4) |
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10.3.1 Brake Failure by Fatigue |
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332 | (3) |
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10.3.2 Failure of a Plastic Pipe |
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335 | (1) |
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335 | (5) |
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10.4.1 Failure Mechanisms |
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336 | (2) |
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10.4.2 Motorcycle Accident |
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338 | (2) |
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340 | (9) |
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340 | (4) |
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344 | (5) |
11 Fraudulent Insurance Claims |
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349 | (16) |
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350 | (2) |
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11.2 Perforated Oil Filter |
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352 | (2) |
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11.3 Major Engine Damage, Allegedly Due to Loss of Oil |
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354 | (4) |
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11.4 Three-Car Road Accident |
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358 | (7) |
12 Criminal Cases |
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365 | (14) |
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365 | (3) |
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368 | (2) |
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370 | (2) |
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372 | (1) |
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373 | (2) |
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12.6 Remelting Beer Barrels |
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375 | (4) |
13 Intellectual Property Cases |
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379 | (50) |
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379 | (2) |
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380 | (1) |
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380 | (1) |
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381 | (12) |
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382 | (3) |
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385 | (1) |
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386 | (1) |
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387 | (2) |
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13.2.5 The Trial (Schneider v Taylor) |
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389 | (1) |
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389 | (1) |
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12.2.7 Alternative Interpretation |
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390 | (2) |
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13.2.8 Standard Dimensions |
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392 | (1) |
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392 | (1) |
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393 | (1) |
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393 | (21) |
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13.3.1 History of Development |
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394 | (1) |
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13.3.2 The Hover Principle |
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395 | (1) |
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395 | (2) |
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13.3.4 Wheeled Rotary Mowers |
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397 | (1) |
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397 | (1) |
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13.3.6 The Rasenkatz Patent |
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398 | (1) |
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13.3.7 Design Development Sequence |
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399 | (6) |
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13.3.8 Pretrial Litigation |
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405 | (1) |
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405 | (1) |
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406 | (1) |
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13.3.11 Main Trial (Black & Decker v. Flymo I) |
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406 | (1) |
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407 | (1) |
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408 | (1) |
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13.3.14 Wording of Claim 1 |
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409 | (2) |
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411 | (2) |
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413 | (1) |
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13.4 Electromechanical Devices |
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414 | (11) |
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13.4.1 Residual Current Devices |
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414 | (1) |
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13.4.2 Power Breaker v. Volex et al. |
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414 | (1) |
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415 | (3) |
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13.4.4 Modeling the Technical Effect |
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418 | (2) |
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420 | (3) |
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13.4.6 The Trial (Patents County Court) |
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423 | (2) |
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425 | (1) |
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425 | (1) |
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426 | (3) |
Index |
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