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Updated: Jun 13, 2026

Predicting Catalyst Extrudate Breakage Based on the Modulus of Rupture

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Published on: May 13, 2018

Factors affecting low strength breaks: fractographic analysis.

B K Tariyal¹, J M Seibert

¹Western Electric Company, Norcross, Georgia 30071, USA.

|April 15, 2010

Summary

Scanning electron microscopy identified key causes of low strength breaks in materials. Particle damage and coating issues were primary culprits, indicating process control issues.

Area of Science:

Materials Science
Mechanical Engineering
Surface Science

Background:

Low strength breaks in materials can significantly impact product reliability and performance.
Understanding the root causes of material failure is crucial for process optimization and quality control.

Purpose of the Study:

To identify and characterize the primary causes of low strength breaks using scanning electron microscopy.
To correlate specific damage mechanisms with material failure at a 345-MPa strength level.

Main Methods:

Utilized scanning electron microscopy (SEM) to examine several hundred low strength breaks.
Performed periodic statistical analysis to identify predominant failure causes over time.

Main Results:

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Identified four main causes of low strength breaks: particle damage, abrasion, coating defects, and internal inclusions.
Particle damage to the fiber surface and poorly centered coating were the predominant causes of breaks at the 345-MPa strength level.
Periodic statistics revealed shifts in dominant failure causes, suggesting out-of-control processing parameters.

Conclusions:

Material failure is often attributable to specific, identifiable surface and internal defects.
Process control is critical, as deviations can lead to an increase in specific failure modes.
Targeting particle damage mitigation and coating centering improvements can enhance material strength and reliability at the 345-MPa level.