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UNCLASSIFIED
Executive summary
UNCLASSIFIED
Nationaal Lucht- en Ruimtevaartlaboratorium
National Aerospace Laboratory NLR
This report is a joint research activity of the NLR (Amsterdam, the Netherlands) and
DSTO (Melbourne, Australia).
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
Descriptor(s)
failure analysis
metals
aerospace
Failure analysis of metallic materials: a short course
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 theirexperience 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 fromDSTO and NLR experience. Both
parts are presented in PowerPoint
format.
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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
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Contents
Part I 7
Introduction 9 General Procedures for Failure Analysis 12 Causes and Types of Failure 30 Failure Diagnosis: Fracture Modes 34 Required Specialist Knowledge and Techniques 47
Part II: Case Histories 48
Aermacchi MB-326H wing spar (1990) 49 General Electric CF6-50 G40 turbine blades (1977-79) 55 De Havilland Canada DHC-4 Caribou / Pratt & Whitney R2000 components (1970-84) 59 Boeing 747-258F engine + pylon losses (1992) 64 Fokker F50 / Pratt & Whitney 125B bearing (2002) 72 Arospatiale Alouette III helicopter tail lug (1990) 78 Boeing F/A-18 trailing edge flaps (1993) 81 General Dynamics F-16 / Pratt & Whitney F100-PW-220 RCVV lever arm pin (1992) 92 Westland Lynx SH14D helicopter rotor hub (1998) 97
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Part I
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Part II: Case Histories
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