Handbook of Materials Failure Analysis with Case Studies from the Aerospace and Automotive Industries : With case studies from the aerospace, chemical, and oil and gas industries

__Handbook of Materials Failure Analysis: With Case Studies from the Aerospace and Automotive Industries__ provides a thorough understanding of the reasons materials fail in certain situations, covering important scenarios, including material defects, mechanical failure as a result of improper design, corrosion, surface fracture, and other environmental causes. The book begins with a general overview of materials failure analysis and its importance, and then logically proceeds from a discussion of the failure analysis process, types of failure analysis, and specific tools and techniques, to chapters on analysis of materials failure from various causes. Later chapters feature a selection of newer examples of failure analysis cases in such strategic industrial sectors as aerospace, oil & gas, and chemicals. * Covers the most common types of materials failure, analysis, and possible solutions * Provides the most up-to-date and balanced coverage of failure analysis, combining foundational knowledge, current research on the latest developments, and innovations in the field * Ideal accompaniment for those interested in materials forensic investigation, failure of materials, static failure analysis, dynamic failure analysis, fatigue life prediction, rotorcraft, failure prediction, fatigue crack propagation, bevel pinion failure, gasketless flange, thermal barrier coatings * Presents compelling new case studies from key industries to demonstrate concepts * Highlights the role of site conditions, operating conditions at the time of failure, history of equipment and its operation, corrosion product sampling, metallurgical and electrochemical factors, and morphology of failure Title Page 2 Copyright 3 Contributors 4 Preface 8 Strategies for static failure analysis on aerospace structures 9 Introduction 10 Delamination Growth in Composites 10 VCCT Fundamentals 11 Experimental Benchmark and FEM Simulation 13 FEMs Comparison 14 Delamination Growth Tool 15 Correlation Between FEM Simulations and Tests 15 Mesh Size Effects 16 Comparison of Mixed-Mode Failure Criteria 16 Conclusion and Further Work in Delamination Growth Analysis 16 Debonding Onset and Growth 18 DCB Coupon: Mode I Interlaminar Fracture Toughness Test 19 FE Modeling 19 CZ Fundamentals 20 Mesh Dependency 20 Experimental Results 22 Correlation FEM Simulation-Tests 23 Conclusion and Future Work in Debonding Analysis 26 Crack Growth in Metallic Structures 26 CTOA Criterion-Experimental Obtaining of CTOAC 27 Crack Growth Tool 29 Benchmarks Description 29 FEM Modeling 30 Correlation Simulations-Tests 30 Crack Growth in Metallic Structures-Conclusion and Future Work 32 References 32 Strategies for dynamic failure analysis on aerospace structures 35 Introduction 35 Land Incidents; Low-Velocity Impacts 37 FEM Modeling and Analysis 37 Conclusion and Recommendations 39 Land Incidents; Frangibility of Airport Structures 40 Design to be Analyzed 40 Numerical Analysis Tool Used in Impact Problems 41 Model Correlation with Lateral Loading Test 43 Mechanical Properties and Failure Criterion Validation 43 Frangibility Simulation Results 44 Flight Incidents; Blade Loss of a Transport Aircraft 46 Blade-Loss Phenomenon 48 Description of the Models 49 FEM Model and Simplified Model 50 Analysis Considerations, Implicit and Explicit Method, Time Step 50 Loads and Boundary Conditions 53 Load Cases Analyzed 54 Results 55 Conclusion 57 Conclusion 59 References 60 The evolution of failure analysis at NASAs Kennedy Space Center and lessons learned 62 Introduction 62 Long-Duration Space Operations 63 Skylab 63 International Space Station 63 Failure in LEO: The Solar Alpha Rotary Joint 65 STS-117 Mission Overview 65 SARJ Hardware Overview 65 STS-117 Mission Details 66 The Problem 67 Troubleshooting During the STS-120 Mission 67 Initial KSC SARJ Investigation 68 NASA SARJ Investigation 70 Expedition 16 Sample Analysis 71 Postanalysis On-orbit Inspection 75 The Repair on STS-126, November 2008 75 What About the Port-SARJ? 76 Conclusion 76 References 77 Fleet impact resulting from a space shuttle Columbia main engine controller wire failure during Mission STS-93 79 Space Shuttle Columbia Wiring Hardware Overview 80 Investigation 81 Conclusion 88 References 90 Fatigue failures of aeronautical items: Trainer aircraft canopy lever reverse, rescue helicopter main rotor bl... 91 Introduction 92 Fatigue fracture of an aircraft canopy lever reverse 92 Introduction 92 Results 94 Macrofractography 94 Microfractography 94 Chemical Analysis 98 Hardness Measurements 99 Microstructural Analysis 99 Microanalysis 99 FEA 100 Fatigue Life Assessment 100 Analysis of the Results 101 Conclusion 102 Failure of a helicopter main rotor blade 102 Introduction 102 Results 104 Fractography 104 Chemical Analysis 105 Hardness Measurements 105 Microstructural Analysis 105 Fatigue Life Estimation 106 Nondestructive Testing 109 Blade Maintenance 109 Conclusion 110 Fatigue fracture of a ground-attack aircraft main wheel 110 Introduction 110 Results 111 Chemical Analysis 111 Microstructural Analysis 112 Fourier Transform Infrared Spectroscopy 112 Hardness Measurements 112 Metrologic Measurements 112 Visual Observations and Macrofractography 112 Microfractography 114 Finite Element Analysis 115 Maintenance History and NDT Efficiency Assessment 117 Discussion 118 Conclusion 120 References 120 Failure investigations of helicopter tail rotor gearbox casings at Agustawestland Limited 121 Introduction 122 Background to the Problem 122 Case 1: Failure Investigation 1 (F1) 124 Procedure 125 Results 125 Discussion 126 Conclusion 129 Case 2: Failure Investigation 2 (F2) 129 Procedure 129 Results 129 Discussion 133 Conclusion 133 Case 3: Failure Investigation 3 (F3) 133 Procedure 134 Results 134 Discussion 134 Conclusion 134 Review of Mechanical Properties 135 Procedure 135 Results 135 Discussion 137 Conclusion 140 Other TRGB Fatigue Investigations 140 Other Fatigue Failure Investigations 142 Housing Design-Going Forward 142 Current Center Housing 142 Gearbox Housings on New Aircraft 143 Acknowledgments 143 References 143 Failures of Rotorcraft and Fixed-Wing Aircraft Aerospace Components 145 Introduction 145 Synopsis of a Utility Helicopter Forward Longeron Failure 146 Discussion of a Utility Helicopter Forward Longeron Failure 156 Lessons Learned from a Utility Helicopter Forward Longeron Failure 156 Synopsis of CH-47 Chinook Spiral Bevel Gear Failure 157 Discussion of CH-47 Chinook Spiral Bevel Gear Failure 160 Lessons Learned from the CH-47 Chinook Spiral Bevel Gear Failure 161 Synopsis of the MS3314 General-Purpose Bomb 1000-Pound Suspension Lug Failures 161 Discussion of the MS3314 GP Bomb 1000-Pound Suspension Lug Failures 164 Lessons Learned from the MS3314 GP Bomb 1000-Pound Suspension Lug Failures 165 Synopsis of the AM355 Main Rotor Part Failure from an Army Attack Helicopter 166 Discussion of the AM355 Main Rotor Part Failure 167 Lessons Learned from the AM355 Main Rotor Part Failure 167 Conclusion 168 References 168 Suspension and landing gear failures 170 Introduction 171 Causes of suspension systems failures 172 Metallurgical Failures 172 Design Failures 173 Processing Failures 173 Causes of Landing Gear Systems Failures 173 Metallurgical Failures 173 Processing Failures 174 Environmental Failures 174 Design Failures 174 Overload Failures 175 Cases of Suspension and Landing Gear Systems Failures 175 Processing and Design Failure of a car Suspension System Ball Joint 175 Fractographic Study 176 Metallographic Analysis 177 Finite Elements Analysis 178 Conclusion and Recommendations 179 Failure of a Landing Gear due to Overload 180 Fractographic Analysis 180 Linkage A1 180 Linkage A2 182 Estimation of Failure Load 183 Discussion 184 Failure of a Nose-Landing Gear AFT Lock-Link 184 Fractographic Analysis 184 Metallographic Analysis 187 Analysis 188 Failure of the Rear Cantilever Spring Landing Gear of a Fumigation Aircraft 188 Conclusion 191 References 191 Fatigue as a cause of failure of aircraft engine cylinder head 194 Introduction 194 Description of Failures 196 Experimental Details 199 Results 199 Visual Inspection 199 Macrofractography 200 Macrofractography of the CH I (Failure Case I) 200 Macrofractography of the CH II (Failure Case II) 202 Microfractography 204 Metallography 205 Chemical Composition 208 Hardness Measurements 211 Finite Element Analysis 211 Discussion 214 Conclusion and Recommendations 215 References 216 Analysis of an engine bevel pinion failure 218 Introduction 218 Background Information About the Failure 220 Investigations 222 Visual and Stereo-Binocular 222 Fractured Piece of the Bevel Pinion 222 Pinion Housing 225 Vertical Quill Shaft 226 Microhardness and Optical Microscopy 227 Scanning Electron Microscopy 227 Analysis of Failure Cause 228 Conclusion 230 Recommendation 230 Acknowledgments 230 References 230 Failure due to synergistic fracture and pitting corrosion of ruptured bolts in a LARZAC engine of Alpha Jet 232 Introduction 232 Laboratory Evaluation of the Damaged Bolts 234 Failure Analysis Summary 234 Physical and Visual Evaluation of the Bolts Samples 234 Surface Examination Using SEM Images 234 Chemical Composition Examination 235 Conclusion 236 Recommendations 238 Reference 238 A failure-processing scheme based on Kalman prediction and the reliability analysis for 25kVA generators used... 239 Introduction 239 25kVA Generator 241 Kalman Filter and the Simulation System 242 Kalman Filter 242 State-Space Models of the Generator 244 Continuous State-Space Model 244 Discrete State-Space Model 245 Aging Model 246 Simulations and Results 246 Parameters 246 Number of Simulation Samples 247 Results: Comparison Between Kalman Prediction and MCS 248 Failure Processing Scheme 255 Discussions 257 Reliability Analysis 257 Conclusion 259 References 261 Fatigue failure in aircraft structural components 263 Introduction 263 Failure Analysis of an Aircraft Propeller 265 Propeller After Failure 266 Failure Mechanism of the Propeller Blade 268 Discussion on the Failure of Propeller Blade 271 Failure Analysis of a Flap Actuator Rod 272 Failure Mechanism of the Actuator Rod 273 Discussion on the Failure of Actuator Rod 276 Conclusion 278 References 278 Chemical analysis techniques for failure analysis: Part 1, common instrumental methods 280 Introduction 281 Basic Operating Principles, Applications, and Limitations of Common Techniques 281 Electronic Transitions: The Underlying Physical Phenomena Responsible for Many of the Techniques 282 Absorption Spectroscopies 283 Emission Spectroscopies 284 Generic Spectrometer 286 Raman Spectroscopy, Mass Spectrometry, and Chromatography 287 Raman Spectroscopy 287 Mass Spectrometry 288 Chromatography 290 A Brief Review of Specific Techniques 291 Atomic Emission Spectroscopy 291 Gas Chromatography/Mass Spectrometry 293 Mass Spectrometry 293 Gas Chromatography 294 FTIR Spectroscopy 296 Raman Spectroscopy 299 EDS and WDS 301 XPS and Auger Electron Spectroscopy (AES) 304 Miscellaneous Techniques 305 Karl Fisher Titration 305 Secondary Ion MS (SIMS) 305 XRF Spectroscopy 305 Residual Gas Analyzers 306 Ultra Violet/Visible (UV/Vis) Spectroscopy 306 Near Infrared (NIR) Spectroscopy 306 Liquid Chromatography/Mass Spectrometry (LC/MS) 306 Ion Chromatography (IC) 306 AA Spectroscopy (AA) 306 References 307 Chemical analysis techniques for failure analysis: Part 2, examples from the lab 309 Introduction 309 Outgassing-Gaseous Materials Leading to Failures 310 Sulfur-Containing Gases Leading to Silver Corrosion 310 Condensable Materials Analysis 315 Contamination at Electrical Contacts 320 An Example of an Electrically Resistive Failure Resulting from Contamination at Contact Surfaces 321 Intermittents and Opens During Operation of a Slip Ring 324 A Surface Appearance Question 329 Investigation of Discolored Wafers 329 Failures as a Result of Cleaning 331 Shorting Connectors 331 A Metallurgical Example 334 Conclusion 337 References 338 Characterization of steel cut-edge properties for improved life predictions for preventing automotive structu... 339 Cut-Edge Characteristics Properties 339 Cut-Edge Fatigue Crack Initiation and Growth 346 Prestrain Fatigue Life Performance 352 Fatigue Life Prediction 356 Conclusion 360 References 361 Failure analysis cases of components of automotive and locomotive engines 362 Case 1: Brittle Cracking of Gear-Teeth Due to Segregation of Excessive Inclusions 363 Background 363 Observation Results 363 Visual Observations 363 SEM Observations 365 Metallurgical Examination 366 Failure Causes Analysis 367 Conclusion 367 Recommendations 368 Case 2: Fatigue Fracture of Fuel Injection Pipe Because of Surface Machining Dent 368 Background 368 Observation Results 368 Failure Causes Analysis 371 Conclusion 371 Case 3: Fatigue Cracking of Carburized Plunger-Sleeves Due to Raw Material Defect and Improper Heat Treatment 371 Background 371 Observation Results 372 Observations on Surface Damage 372 Observations on Fracture Surface 372 Microcomposition Analysis on Inclusions on the Fracture Surface 374 Microstructure Examination 375 Oxidation and Carburizing Simulation Tests in Laboratory 377 Failure Causes Analysis 378 Conclusion 379 Recommendations 379 Case 4: Intergranular Fracture of Carburized Splined-Shaft Due to Case Internal Oxidation and Defective Design 379 Background 379 Observation Results 380 Fractographic Observation 380 Microstructure Examination 383 Failure Causes Analysis 385 Conclusion 386 Recommendations 387 References 387 Failure mechanisms and modes analysis of vehicle exhaust components and systems 389 Introduction 390 Trend Overview of Exhaust Development and Materials Requirements 392 Typical Failure Mechanisms and Modes in Vehicle Exhaust Systems 395 Mechanical Fatigue 397 Thermal Fatigue 398 Corrosion 399 Tensile 402 Impact 402 Oxidation 402 Urea Corrosion 403 Erosion-Corrosion 404 Failure Modeling and Data Analysis 404 Fatigue Failure Modeling 404 Crack Growth Approach 406 Total Life Approach 408 Statistical and Probabilistic Data Analysis 409 Example: Probabilistic Distribution of Thermal-Fatigue Test Data 411 Materials Performance Ranking and Selection 413 Material Ranking in Cyclic Oxidation and V-Specimen Thermal-Cycling Resistance 413 Cycling Oxidation Tests 413 V-Shape Specimen Thermal-Cycling Tests 414 A Ranking Formula for Cyclic Oxidation and V-Shape Specimen Thermal Cycling 414 Material Ranking in Corrosion Resistance 415 Pitting or Crevice Depth 415 Pitting Corrosion Potential 415 Pitting Corrosion Resistance Ranking with PREN 417 Case Studies 418 Case 1: Muffler Bracket Fatigue Failure 418 Case 2: Probabilistic Thermal-Fatigue Life Assessment 421 Conclusion 425 References 426 Failure of structural parts for large road vehicles 429 Introduction 429 Experimental Procedures 430 Case Studies 431 Welded Hollow Structural Sections 431 Z-Bar of Air Suspension 434 Transmission Axle 436 Torsion Bar 440 Discussion 441 Conclusion 442 Acknowledgments 442 References 442 Failure of steel couplings used in railway transport 444 Introduction 444 Problem Definition 446 Material and Geometry of the Railway Coupling 447 Material Characterization 449 Metallographic Analysis 449 Quantitative Analysis of Casting Defects 450 Fatigue Tests: Generate Life Fatigue Curve 452 Service Acquisition and Data Treatment 454 Strain Gauge Acquisition 454 Uniaxial Behavior 455 Service Stress Analysis 457 Life Prediction Approaches 460 Life Prediction Using Palmgren-Miner Rule Modified by Haibach 460 Life Prediction Using Palmgren-Miner Rule and Goodman Equation 461 Results and Discussion 463 Conclusion 463 References 464 Failure analysis and prevention in powertrain systems 466 Introduction 466 Failure Analysis of a Broken Intake Valve [2] 469 Failure History 469 Results and Discussions 471 Mechanical Investigations 471 Material Investigations 473 Remarkable Notes 476 Failure Analysis of a Cracked Cylinder Head [13,14] 476 Failure History 476 Results and Discussions 477 Observation Results 477 Measurements 477 Material Investigations 479 Mechanical Investigations 482 Remarkable Notes 484 References 486 Index 488 A 488 B 488 C 489 D 490 E 490 F 491 G 492 H 492 I 493 K 493 L 493 M 493 N 494 O 494 P 494 R 495 S 495 T 496 U 497 V 498 W 498 X 498 Z 498 Content: Front Matter,Copyright,Contributors,PrefaceEntitled to full textPart 1: Failure Analysis in Aircraft and Aerospace StructuresChapter 1 - Strategies for static failure analysis on aerospace structures, Pages 3-28, Javier S. Millán, Iñaki Armendáriz, Juan García-Martínez, Roberto González Chapter 2 - Strategies for dynamic failure analysis on aerospace structures, Pages 29-55, Iñaki Armendáriz, Javier S. Millán, José M. Encinas, José Olarrea Chapter 3 - The evolution of failure analysis at NASA’s Kennedy Space Center and lessons learned, Pages 57-73, Maria C. Wright, Victoria L. Long, Steven J. McDanels Chapter 4 - Fleet impact resulting from a space shuttle Columbia main engine controller wire failure during Mission STS-93, Pages 75-86, Steven J. McDanels Chapter 5 - Fatigue failures of aeronautical items: Trainer aircraft canopy lever reverse, rescue helicopter main rotor blade and fighter-bomber aircraft ground-attack main wheel, Pages 87-116, Manuele Bernabei, Laura Allegrucci, Mikael Amura Chapter 6 - Failure investigations of helicopter tail rotor gearbox casings at Agustawestland Limited, Pages 117-140, Fiona Belben Chapter 7 - Failures of Rotorcraft and Fixed-Wing Aircraft Aerospace Components, Pages 141-165, Victor K. Champagne, Marc S. Pepi Chapter 8 - Suspension and landing gear failures, Pages 167-190, Edgar A. Ossa, Marco Paniagua Chapter 9 - Fatigue as a cause of failure of aircraft engine cylinder head, Pages 191-214, Branimir Krstic, Bosko Rasuo, Dragan Trifkovic, Igor Radisavljevic, Zoran Rajic, Mirko Dinulovic Chapter 10 - Analysis of an engine bevel pinion failure, Pages 215-228, Swati Biswas, Mudigere D. Ganeshachar, Varada N. Satish Kumar, Jivan Kumar, Sangli N. Narendra Babu Chapter 11 - Failure due to synergistic fracture and pitting corrosion of ruptured bolts in a LARZAC engine of Alpha Jet, Pages 229-235, Ahmed Z. Farahat, Abdel S.H. Makhlouf Chapter 12 - A failure-processing scheme based on Kalman prediction and the reliability analysis for 25 kVA generators used on IDF, Pages 237-260, Shang-Kuo Yang Chapter 13 - Fatigue failure in aircraft structural components, Pages 261-277, Selim Gürgen, Melih C. Kuşhan, Seyid F. Diltemiz Chapter 14 - Chemical analysis techniques for failure analysis: Part 1, common instrumental methods, Pages 279-307, William J. Wolfgong Chapter 15 - Chemical analysis techniques for failure analysis: Part 2, examples from the lab, Pages 309-338, William J. Wolfgong Chapter 16 - Characterization of steel cut-edge properties for improved life predictions for preventing automotive structural failure, Pages 341-363, Daniel J. Thomas Chapter 17 - Failure analysis cases of components of automotive and locomotive engines, Pages 365-391, Zhiwei Yu, Xiaolei Xu Chapter 18 - Failure mechanisms and modes analysis of vehicle exhaust components and systems, Pages 393-432, Zhigang Wei, Thomas Goehring, Melany Mioduszewski, Limin Luo, Adam Kotrba, Marek Rybarz, Kay Ellinghaus, Markus Pieszkalla Chapter 19 - Failure of structural parts for large road vehicles, Pages 433-447, Víctor H. Jacobo, Edgar I. Ramírez, Rafael Schouwenaars, Armando Ortiz Chapter 20 - Failure of steel couplings used in railway transport, Pages 449-470, Teresa L.M. Morgado Chapter 21 - Failure analysis and prevention in powertrain systems, Pages 471-492, Mohammad Azadi Index, Pages 493-503

Handbook of Materials Failure Analysis: With Case Studies from the Aerospace and Automotive Industries provides a thorough understanding of the reasons materials fail in certain situations, covering important scenarios, including material defects, mechanical failure as a result of improper design, corrosion, surface fracture, and other environmental causes.

The book begins with a general overview of materials failure analysis and its importance, and then logically proceeds from a discussion of the failure analysis process, types of failure analysis, and specific tools and techniques, to chapters on analysis of materials failure from various causes. Later chapters feature a selection of newer examples of failure analysis cases in such strategic industrial sectors as aerospace, oil & gas, and chemicals.

• Covers the most common types of materials failure, analysis, and possible solutions
• Provides the most up-to-date and balanced coverage of failure analysis, combining foundational knowledge, current research on the latest developments, and innovations in the field
• Ideal accompaniment for those interested in materials forensic investigation, failure of materials, static failure analysis, dynamic failure analysis, fatigue life prediction, rotorcraft, failure prediction, fatigue crack propagation, bevel pinion failure, gasketless flange, thermal barrier coatings
• Presents compelling new case studies from key industries to demonstrate concepts
• Highlights the role of site conditions, operating conditions at the time of failure, history of equipment and its operation, corrosion product sampling, metallurgical and electrochemical factors, and morphology of failure