UNCLASSIFIED

Nationaal Lucht- en Ruimtevaartlaboratorium National Aerospace Laboratory NLR

Executive summary

Failure analysis of metallic materials: a short course

Report no. NLR-TP-2010-550 Author(s) S.A. Barter S.P. Lynch R.J.H. Wanhill Report classification UNCLASSIFIED Date February 2011 Knowledge area(s) Vliegtuigmateriaal- en schadeonderzoek

Problem area Analysis of aircraft service failures is a demanding discipline, requiring a wide range of knowledge and expertise. There is no substitute for experience, and the key to successful failure analyses is teamwork that includes knowledge transfer. Recognising this, the NLR and DSTO have pooled their experience of some notable failures in aircraft metallic components and structures to provide a short (1-day) teaching course.

Description of work The teaching course is concerned principally with aerospace metallic materials, and is in two parts. Part I covers general procedures, causes and types of failures, failure diagnosis, and a final summary of the required specialist knowledge and techniques. Part II consists of nine case histories drawn from DSTO and NLR experience. Both parts are presented in PowerPoint format.

Descriptor(s) failure analysis metals aerospace

This report is a joint research activity of the NLR (Amsterdam, the Netherlands) and DSTO (Melbourne, Australia). UNCLASSIFIED

UNCLASSIFIED

Failure analysis of metallic materials: a short course

Nationaal Lucht- en Ruimtevaartlaboratorium, National Aerospace Laboratory NLR Anthony Fokkerweg 2, 1059 CM Amsterdam, P.O. Box 90502, 1006 BM Amsterdam, The Netherlands Telephone +31 20 511 31 13, Fax +31 20 511 32 10, Web site: www.nlr.nl

UNCLASSIFIED

Nationaal Lucht- en Ruimtevaartlaboratorium National Aerospace Laboratory NLR

NLR-TP-2010-550

Failure analysis of metallic materials: a short course

S.A. Barter1, S.P. Lynch1 and R.J.H. Wanhill

1

DSTO, Melbourne

This report is a joint research activity of the NLR (Amsterdam, the Netherlands) and DSTO (Melbourne, Australia). The contents of this report may be cited on condition that full credit is given to NLR and the authors. This publication has been refereed by the Advisory Committee AEROSPACE VEHICLES.

Customer Contract number Owner Division NLR Distribution Classification of title Approved by:
Author

National Aerospace Laboratory NLR -National Aerospace Laboratory NLR Aerospace Vehicles Unlimited Unclassified February 2011
Reviewer Managing department

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Summary
Analysis of aircraft service failures is a demanding discipline, requiring a wide range of knowledge and expertise. There is no substitute for experience, and the key to successful failure analyses is teamwork that includes knowledge transfer. Recognising this, the NLR and DSTO have pooled their experience of some notable failures in aircraft metallic components and structures to provide a short (1-day) teaching course. The teaching course is concerned principally with aerospace metallic materials, and is in two parts. Part I covers general procedures, causes and types of failures, failure diagnosis, and a final summary of the required specialist knowledge and techniques. Part II consists of nine case histories drawn from DSTO and NLR experience. Both parts are presented in PowerPoint format.

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Contents
Part I Introduction General Procedures for Failure Analysis Causes and Types of Failure Failure Diagnosis: Fracture Modes Required Specialist Knowledge and Techniques 7 9 12 30 34 47

Part II: Case Histories Aermacchi MB-326H wing spar (1990) General Electric CF6-50 G40 turbine blades (1977-79) De Havilland Canada DHC-4 Caribou / Pratt & Whitney R2000 components (1970-84) Boeing 747-258F engine + pylon losses (1992) Fokker F50 / Pratt & Whitney 125B bearing (2002) Arospatiale Alouette III helicopter tail lug (1990) Boeing F/A-18 trailing edge flaps (1993) General Dynamics F-16 / Pratt & Whitney F100-PW-220 RCVV lever arm pin (1992) Westland Lynx SH14D helicopter rotor hub (1998)

48 49 55 59 64 72 78 81 92 97

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