Case 251 ยท Public preview
An Interfacial Chemical Reaction Can Produce Both Metallic Lead and Gas
Glass repeatedly lost adhesion from nickel-plated metal frames after processing, with a group of samples reported as completely defective.
SEMEDSElemental mappingMetallographic microsectioningGood-to-defective comparison
What the evidence preview establishes
Fracture occurred through a reaction layer near the glass-to-nickel interface. Reduction of lead oxide glass produced metallic lead and released oxygen gas, although the role of phosphorus in the nickel remained unresolved.
Why this case matters
When glass adhesion fails, examine the fracture path and interface chemistry together. Reaction products and gas-generating reduction can weaken an interface, but the presence of a reaction layer alone does not prove which process variable controls failure.
Full evidence reserved for MEMBER and STOREThe complete case includes the evidence sequence, four interpreted figures, alternative explanations, limitations, and practical application guidance.