This bed frame was not returned for inspection but the customer did send a picture of the bed's broken weld.By looking at the picture it was determined that the bracket where the foot high-low actuator mounts onto the backbone of the bed frame separated.A new bed frame was shipped to the customer.This problem has been assigned capa (b)(4), and a follow-up report will be submitted upon completion of the corrective action.Metallurgical analysis report, dated 11/04/2011, on two removed sections from the bed-frame where he weld broke state (1) both fractures had occurred at the heat affected weld zone at the toe of the attachment welds; (2) there was significant distortion of the 1x2 inch rectangular tube typical of high bending moment stress; (3) the welding process employed (b)(4) was not suitable for the materials and thicknesses being joined; (4) weld size was excessive; (5) heat input was excessive; (6) technique was poor resulting in excessive weld (s)platter and leaving from one to two inches of electrode (wirer) at weld terminations; (7) weld penetration into the attachments was satisfactory however penetration into the attachments was satisfactory however penetration into the tube was minimal; and (8) examination of the wear pattern on the lever holes suggest a straight tension loading and the clevis holes suggest a straight tension loading and the clevis holes indicate a push-pull load which is approximately 15 degrees off of horizontal.
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