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This manufacturing defect acted as a stress raiser and resulted in fatigue crack initiation. Metallographic examination revealed micro-cracks on the edges of an open hole located in an area of high stress concentration. This section of frame experiences multi-axial loading conditions including out-of-plane bending, twisting and shear under road loads. The fracture observed was on the frame web within the torque rod connection to the rear drive axle of the vehicle. A failure analysis investigation was performed on a fractured heavy duty truck frame rail obtained during endurance track testing.
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