GB/T 38803-2020 PDF in English
GB/T 38803-2020 (GB/T38803-2020, GBT 38803-2020, GBT38803-2020)
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Specification for failure analysis of steel wire ropes
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Standards related to (historical): GB/T 38803-2020
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GB/T 38803-2020: PDF in English (GBT 38803-2020) GB/T 38803-2020
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 77.140.65
H 49
Specification for failure analysis of steel wire ropes
ISSUED ON: JUNE 02, 2020
IMPLEMENTED ON: DECEMBER 01, 2020
Issued by: State Administration for Market Regulation;
Standardization Administration of the People’s Republic of
China.
Table of Contents
Foreword ... 3
1 Scope ... 4
2 Normative references ... 4
3 Terms and definitions ... 5
4 General principles and personnel capability requirements ... 6
5 General procedures ... 7
6 Failure analysis method ... 10
7 Failure analysis report ... 13
8 Residual samples of failure analysis ... 14
Specification for failure analysis of steel wire ropes
1 Scope
This Standard specifies the terms and definitions, general principles and
personnel capability requirements, general procedures, analysis methods,
analysis reports and residual sample storage for failure analysis of steel wire
ropes.
This Standard is applicable to the failure analysis of steel wire ropes for various
purposes. It can be used as a reference for the failure analysis of steel wire and
steel wire rope products.
Note: This Standard provides guidance for the failure analysis of steel wire
ropes due to manufacturing defects, or handling, storage, installation
damage, or broken wire, broken strand, fracture, corrosion, overload.
Under normal circumstances, because the failed steel wire rope has
been subjected to complex stresses such as load, bending, extrusion,
and rotation, and the appearance, size, mechanical and technological
properties of the steel wire rope and the steel wire in the rope have
changed, so, the test results of its appearance, size, mechanical and
technical properties shall not be used as the basis for judging whether
the steel wire rope is qualified.
2 Normative references
The following documents are indispensable for the application of this document.
For dated references, only the dated version applies to this document. For
undated references, the latest edition (including all amendments) applies to this
document.
GB/T 228.1, Metallic materials - Tensile testing - Part 1: Method of test at
room temperature
GB/T 238, Metallic materials - Wire - Reverse bend test
GB/T 239.1, Metallic materials - Wire - Part 1: Simple torsion test
GB/T 1839, Test method for gravimetric determination of the mass per unit
area of galvanized coatings on steel products
GB/T 2972, Test method for uniformity of zinc coating on zinc-coated steel
wire by the copper sulphate dip
The technical activity and management activity of taking necessary detection
and analysis methods to comprehensively analyze the failed steel wire ropes,
to find the failure cause, according to certain working procedures.
3.3 Macroscopic inspection
Inspect the macroscopic characteristics of the steel wire rope visually or
through a magnifying glass no greater than 10 times.
3.4 Microscopic inspection
Inspect the microstructure, morphology, crystal structure and other microscopic
characteristics of the steel wire in the steel wire rope by tools such as
metallographic microscope or scanning electron microscope.
4 General principles and personnel capability
requirements
4.1 General principles
The failure analysis of steel wire ropes shall be undertaken by an organization
with independent legal personality and relevant technical capabilities.
When the client requires the trustee to issue a report for the failure analysis of
steel wire ropes with third-party impartiality, the trustee shall have relevant
qualifications and technical capabilities. The organization that undertakes the
failure analysis of steel wire ropes shall follow the following principles:
a) Comply with relevant national laws, regulations and rules; be fair, just,
objective and scientific;
b) Establish standardized, rigorous and complete failure analysis procedures;
c) Make the analysis method scientific and rigorous, the analysis process
thorough and comprehensive, the evidence conclusive, and the
conclusion accurate;
d) Record the phenomena that is observed in the analysis process and the
test data in detail; save the necessary image data;
e) If a simple method can be used to find out the cause of the failure, avoid
complex and tedious analysis and testing.
4.2 Personnel capability requirements
5.3 Site survey
If necessary, and the conditions for site survey are available, the organization
responsible for failure analysis shall select personnel who are familiar with the
use and maintenance of steel wire ropes to conduct site survey.
The site survey shall conduct necessary inspection, inquiry, data retrieval,
measurement, photographing, and recording of the following items:
a) Failure time, place, use environment, failure process and abnormal
phenomena before the failure;
b) Feature survey and description of the steel wire ropes on site;
c) Technical documents such as steel wire rope product quality certificate,
acceptance inspection report, installation record;
d) Steel wire rope product use and design specifications or regulations;
e) Records of daily use, inspection, maintenance of steel wire ropes;
f) Physical specifications, models and failure signature of steel wire ropes;
g) Characteristic parameters and status quo of the reel, pulley, back-up roll,
connection and other devices in contact with the steel wire rope.
5.4 Samples and their protection
The client takes samples by himself; or the trustee performs site survey and
takes samples. When intercepting or collecting samples for failure analysis, the
following matters shall be paid attention to:
a) Before intercepting the sample for failure analysis of the steel wire rope,
carefully check the steel wire rope; select the representative failure part
and intercept the sample; there shall be sufficient distance between the
interception position and the failure part;
b) When it is necessary to conduct analysis and testing of steel wire rope
twisting parameters, physical and chemical properties, intercept a sample
of sufficient length at the end of the steel wire rope or away from the failure
part;
c) When the steel wire rope, strand or steel wire has multiple damages or
fractures, check carefully and identify; select representative samples;
d) In order to avoid secondary damage or corrosion to the sample for failure
analysis of the steel wire rope, take effective protective measures during
sampling, loading and unloading and transportation.
Perform macroscopic observation classification and statistics of morphology
and characteristics of typical damages or defects such as structural damage,
wear, corrosion, extrusion, wire breakage, and fracture of failed steel wire ropes;
record typical damages or defects.
5.5.3.2 Microscopic inspection
Perform microscopic morphology observation and analysis of typical damages
or defects such as structural damage, wear, corrosion, extrusion, wire breakage,
and fracture of failed steel wire ropes, including defect characteristics and
fracture sources; record typical damages or defects.
5.5.3.3 Micro-area composition analysis
Perform micro-area composition analysis of typical damages or defects such
as damage, corrosion, wire breakage, and fracture of failed steel wire ropes;
record typical damages or defects.
5.5.3.4 Metallographic structure inspection
Test and record the metallographic structure, inclusions of the typical damaged
or defective samples such as wear, corrosion, extrusion, wire breakage, and
fractures of failed steel wire ropes and the non-damaged or defective samples.
6 Failure analysis method
6.1 Appearance, size and failure signature inspection and measurement
6.1.1 Appearance quality of steel wire ropes
Appearance quality of steel wire ropes, such as appearance, oiling, structure,
twisting method, twisting defects, shall be detected visually.
6.1.2 Feature size of steel wire ropes
Wire rope length, diameter, lay length and out-of-roundness, strand gap and
chord height, wire diameter (including central wire), rope core size shall be
measured with wide-jaw vernier calipers, micrometers or feeler gauges, in
accordance with the methods that are specified in the relevant product
standards.
6.1.3 Steel wire rope damage and defect
Wire rope wear, corrosion, extrusion, wire breakage, skipped wire, intersected
wire, broken strand, broken rope, wavy, cage deformity, rope core or strand
protrusion, kinking, bending, rope diameter reduction or increase, and such
The uniformity test of galvanized coatings on split steel wire shall be carried out
in accordance with the regulations of GB/T 2972.
The adhesion test of galvanized coatings on split steel wire shall be carried out
in accordance with the regulations of GB/T 2976.
Note: The wrapping diameter of the adhesion test of galvanized coatings on
split steel wire can be the diameter of the steel wire itself; the wrapping
number can be 8 circles, or can be carried out according to customer
requirements.
6.2.4 Rope core and grease properties
The determination lubricant content, moisture content and physical and
chemical properties of the rope core and grease shall be carried out in
accordance with the regulations of YB/T 4182 or NB/SH/T 0387.
6.3 Damage and defect inspection and analysis
6.3.1 Macroscopic inspection
The morphology and characteristics of typical damages or defects such as
structural damage, wear, corrosion, extrusion, wire breakage, and fractures of
steel wire ropes shall be observed by visual inspection, stereo microscope or
other tools.
6.3.2 Microscopic inspection
The microscopic morphology inspection of typical damages or defects, such as
structural damage, wear, corrosion, extrusion, wire breakage, fracture and the
fracture source of steel wire ropes shall be performed in accordance with the
regulations of JY/T 010.
6.3.3 Micro-area composition analysis
The micro-area composition analysis of typical damages or defects such as
damage, corrosion, wire breakage, and fractures of steel wire ropes shall be
performed in accordance with the provisions of GB/T 17359.
6.3.4 Metallographic structure inspection
The inspection of metallographic microstructure for the steel wire in the steel
wire rope shall be carried out in accordance with the regulations of GB/T 13298.
The determination of nonmetallic inclusions for the steel wire in the steel wire
rope shall be carried out in accordance with the regulations of GB/T 10561.
6.4 Other test methods
......
Source: Above contents are excerpted from the PDF -- translated/reviewed by: www.chinesestandard.net / Wayne Zheng et al.
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