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I inspected the “thin” areas as you mentioned, and they completely meet our specs.
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What spec? Did you spec putting the thinnest material and the smallest radius exactly where the top will receive its highest torque loading? Or did someone design a pretty top, and some flow designer come along later and cut out the back side of the radius, with absolutely no thought of the structure.
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Pressure tests at 40 PSI resulted in no problems on 100’s of blocks (the pressure we test at). We also did some destructive testing this morning on 20 of these housings, using a heavy hammer and hitting the top of the housing (inlet & outlet), which places a direct stress on the alleged “weak” spots, and NONE failed. The entire housing will eventually disintegrate when hit hard enough, but we found absolutely no signs of stress related failures.
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Neither of the above is realistic, or puts a direct stress on the weak spot. Nothing alledged, they are the weakest spots, casting errors and machining errors will determine which is actually the weakest. Rocking 7/16 tubing back and forth to get it over the 1/2+ fitting will put a lot a lot of torque side to side, (the design makes back and forth unlikely) from weak spot to weak spot. It takes a lot of force to get the 7/16 tubing on.
Will one break the first time, unlikely, but how many mountings did you "spec" it for? Would you reveal the the "spec" for the thickness of material at that point? The "tolerance"? What was the load (ft-lbs) "specified", how many repetitions?
No, I didn't think so. If anyone thought about it it would have an 1/8" minimum radius, because it would have cost nothing to do it right.