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Failure of Tubular Frame in the Field - Case Study

Welding 3Challenge:

Eliminate the cracking of the welded tubular joint.


Conducted failure analysis and specified alternate material and weld process.


The customer produced a tubular frame used to support air conditioning units mounted on semi-trucks. This frame developed cracks in the welded joint which allowed the frame to deform in the field.


Eliminated field failures. A sample was provided to Hornet for analysis. A combination of material change, design, and welded process reduced stress incurred in the field and eliminated the failure mode.

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