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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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