Utility projects across the country were grinding to a halt when tunneling machines built by Akkerman, Inc., were failing. At a rate of 5 to 10% of their machines breaking down in the field, escalating customer dissatisfaction due to downtime affecting their projects' scheduling, and potential warranty costs, were growing concerns for the company.

The carbon-steel hydraulic pistons that drive the machine were breaking from what initially was thought to be fatigue. However, fatigue breakage would give telltale warning signs that would show up during scheduled inspections. These failures were happening instantaneously, and had the visual appearance of having been the result of fatigue.

Microscopic examination showed that the failures weren't caused by fatigue, but by cleavage fracture, which causes almost instantaneous failure.

Chemical analysis showed that the pistons were made out of 1045 carbon steel that had been processed to specifications, but a slightly different processing would make the parts tougher.

Akkerman switched to material processed according to M. E. Williams recommendations, and have not had a single failure in two years. The new material ended up costing less than $1 more per part, a bargain, considering the massive costs of replacing the $1,000 pistons.