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Fretting and Corrosion in Aircraft Components 飞机部件的微动和腐蚀
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.aero.c9001903
Jivan B. Shah
Fretting and/or fretting corrosion fatigue have been observed on such parts as main rotor counterweight tie rods, fixed-pitch propeller blades, propeller blade clamps, pressure regulator lines, and landing gear support brackets. Microcracks started from severe corrosion pits in a failed control rotor spar tube assembly made of cadmium-plated AISI 4130 Cr-Mo alloy steel. Inadequate design was responsible for the failure. A lower tine of the main rotor blade cuff failed in fatigue. The rotor blade cuff was forged of 2014-T6 aluminum alloy. Initial stages of crack growth displayed features typical of low stress intensity fatigue of aluminum alloys. The fatigue resulted from abnormal fretting owing to inadequate torquing of the main retention bolts. Aircraft maintenance engineers and owners were advised to adhere to specifications when torquing this joint.
在主旋翼配重拉杆、固定螺距螺旋桨叶片、螺旋桨叶片夹、压力调节器管路和起落架支撑支架等部件上观察到微动和/或微动腐蚀疲劳。由镀镉的AISI 4130铬钼合金钢制成的控制转子梁管组件失效后,出现了严重的腐蚀坑引起的微裂纹。设计不充分是这次失败的原因。主旋翼叶片袖带下段因疲劳失效。转子叶片袖口采用2014-T6铝合金锻造。裂纹扩展初期表现出典型的铝合金低应力强度疲劳特征。疲劳是由于主保持螺栓扭矩不足引起的异常微动引起的。飞机维修工程师和业主被建议在扭转这个接头时遵守规范。
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引用次数: 0
Use of Electron Fractography to Diagnose Hairline Cracking in an AISI 4340 Main Landing Gear Cylinder 用电子断口分析诊断AISI 4340主起落架油缸发际裂纹
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.aero.c9001540
J. A. Scott
Ground maintenance personnel discovered hydraulic fluid leaking from two small cracks in a main landing gear cylinder made from AISI 4340 Cr-Mo-Ni alloy steel. Failure of the part had initiated on the ID of the cylinder. Numerous cracks were found under the chromium plate. A 6500x electron fractograph showed cracking was predominantly intergranular with hairline indications. Leaking had occurred only 43 h after overhaul of the part. Total service time on the part was 9488 h. It was concluded that cracking on the ID was caused by hydrogen embrittlement which occurred during or after overhaul. The specific source of hydrogen which produced failure was not ascertainable.
地面维修人员发现,由美国AISI 4340 Cr-Mo-Ni合金钢制成的主起落架气缸有两个小裂缝,液压油从裂缝中泄漏。零件的故障是由气缸的内径引起的。在铬板下面发现了许多裂纹。6500x电子断口显示裂纹主要是沿晶断裂,有发际迹象。该部件在大修后仅43小时就发生了泄漏。零件的总使用时间为9488 h,内径开裂是由大修期间或大修后发生的氢脆引起的。产生故障的氢的具体来源不能确定。
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引用次数: 0
Investigation of Jet Engine Oil Scavenge Pump Failure 喷气发动机扫油泵故障的研究
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.aero.c9001575
L.D. Cologna
An oil scavenge pump was found to have failed when a protective shear neck fractured during the start of a jet engine. Visual inspection revealed that the driven gear in one of the bearing compartments was frozen as was the corresponding drive gear. Spacer wear and thermal discoloration (particularly on the driven gear) were also observed. The gears were made from 32Cr-Mo-V13 steel, hardened and nitrided to 750 to 950 HV. Micrographic inspection of the gear teeth revealed microstructural changes that, in context, appear to be the result of friction heating. The spacers consist of Cu alloy (AMS4845) bushings force fit into AA2024-T3 Al alloy spacing elements. It was found that uncontrolled fit interference between the two components had led to Cu alloy overstress. Thermal cycling under operating conditions yielded the material. The dilation was directed inward to the shaft, however, because the bushing had only a few microns of clearance. The effect caused the oil to squeeze out, resulting in metal-to-metal contact, and ultimately failure.
一架喷气式发动机在启动过程中,一个保护剪切颈断裂,导致一个油清除泵失效。目视检查显示,在一个轴承室的从动齿轮是冻结的,因为是相应的驱动齿轮。还观察到垫片磨损和热变色(特别是在从动齿轮上)。齿轮由32Cr-Mo-V13钢制成,淬火并氮化至750至950 HV。齿轮齿的显微检查揭示了微观结构的变化,在上下文中,似乎是摩擦加热的结果。垫片由Cu合金(AMS4845)衬套组成,与AA2024-T3铝合金间距元件配合。结果表明,两组分之间不受控制的配合干涉导致了Cu合金的超应力。在操作条件下进行热循环生成该材料。然而,膨胀是直接向内的轴,因为衬套只有几微米的间隙。这种作用导致油被挤出,导致金属与金属接触,最终失效。
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引用次数: 0
Corrosion Cracking of Aircraft Components 飞机部件的腐蚀开裂
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.aero.c9001745
Jivan B. Shah
A 2000-T6 aluminum alloy bracket failed in a coastal environment because corrosive chlorides got between the bracket and attachment bolt. The material used for the part was susceptible to stress corrosion under the service conditions. Cracking may have been aggravated by galvanic action between aluminum alloy bracket and steel bolt. To preclude or minimize recurrences, fittings in service should be inspected periodically by dye penetrant for signs of cracking on the end face and within the fitting hole and protected with a suitable coating to exclude damaging chlorides. Also, a 2000-T6 aluminum alloy swivel fitting experienced intergranular corrosion fracture as the result of stress-accelerated corrosion. Corrosion began because of a loose fit between the aluminum swivel fitting and steel tube assembly, which caused fretting. Inadequate maintenance and/or abnormal service operation may have loosened the fitting.
2000-T6铝合金托架在沿海环境中失效,原因是腐蚀性氯化物进入了托架和连接螺栓之间。该部件所用材料在使用条件下易受应力腐蚀。铝合金支架与钢螺栓之间的电偶作用可能加剧了开裂。为了防止或尽量减少再次发生,使用中的管件应定期用染料渗透剂检查端面和管件孔内的开裂迹象,并涂上适当的涂层以防止损坏的氯化物。此外,2000-T6铝合金旋转接头由于应力加速腐蚀而发生晶间腐蚀断裂。腐蚀开始是因为铝旋转接头和钢管组件之间的配合松动,导致微动。不适当的维护和/或不正常的维修操作可能会使管件松动。
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引用次数: 0
Microbially Influenced Corrosion of Aluminum Alloy Aircraft Fuel Tanks 微生物对铝合金飞机油箱腐蚀的影响
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.aero.c0091809
Aluminum 7075 aircraft wing tanks failed in the 1950s. Investigation (visual inspection, biological analysis, and chemical analysis) supported the conclusion that MIC was the cause of the failures. Water condensed into the fuel tanks during flight led to microbial growth on the jet fuel. Pitting attack occurred under microbial deposits on the metal surface in the water phase or at the water-fuel interface. Previously, exposure of aluminum 7075 to cultures of various isolates showed that 27 bacterial isolates and 3 fungi could seriously corrode the aluminum alloy over several weeks. No recommendations were made.
铝制7075飞机机翼油箱在20世纪50年代失败。调查(目视检查、生物分析和化学分析)支持MIC是失败原因的结论。在飞行过程中,水凝结到燃料箱中,导致喷气燃料上的微生物生长。在水相金属表面或水-燃料界面微生物沉积下发生点蚀。此前,将铝7075暴露于各种菌株的培养物中表明,27种细菌分离株和3种真菌可以在数周内严重腐蚀铝合金。没有提出任何建议。
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引用次数: 0
Fatigue Failure of an Aluminum Alloy Assembly at Spot Welds Because of Improper Heat Treatment 铝合金点焊件热处理不当导致的疲劳失效
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.aero.c0047072
Postflight inspection of a gas-turbine aircraft engine that had experienced compressor stall revealed that the engine air-intake bullet assembly had dislodged and was seated against the engine-inlet guide vanes at the 3 o'clock position. The bullet assembly consisted of an outer aerodynamic shell and an inner stiffener shell, both of 1.3 mm (0.050 in.) thick aluminum alloy 6061-T6, and four attachment clips of 1 mm (0.040 in.) thick alclad aluminum alloy 2024-T42. Each clip was joined to the outer shell by 12 spot welds and was also joined to the stiffener. Analysis (visual inspection, dye-penetrant inspection, and 10x/150x micrographs of sections etched with Keller's reagent) supports the conclusion that the outer shell of the bullet assembly separated from the stiffener because the four attachment clips fractured through the shell-to-clip spot welds. Fracture occurred by fatigue that initiated at the notch created by the intersection of the faying surfaces of the clip and shell with the spot weld nuggets. The 6061 aluminum alloy shell and stiffener were in the annealed (O) temper rather than T6, as specified. Recommendations included heat treating the shell and stiffener to the T6 temper after forming.
对一台经历过压气机失速的燃气涡轮飞机发动机的飞行后检查发现,发动机进气子弹组件已经脱落,并在发动机进气导叶的3点钟位置上。子弹组件包括一个外部气动外壳和一个内部加强壳,都是1.3毫米(0.050英寸)厚的6061-T6铝合金,以及四个1毫米(0.040英寸)厚的2024-T42铝合金附件夹。每个夹子通过12个点焊连接到外壳上,也连接到加强筋上。分析(目视检查、染料渗透检查和凯勒试剂蚀刻的10倍/150倍显微照片)支持这样的结论,即子弹组件的外壳与加强板分离,因为四个附件夹在壳与夹的点焊中断裂。断裂是由疲劳引起的,这种疲劳是由夹件和壳体表面与点焊块的交叉处产生的缺口引起的。6061铝合金外壳和加强筋采用退火(O)回火,而不是按照规定采用T6回火。建议包括热处理外壳和加强板到T6回火成形后。
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引用次数: 0
Failure Analysis of Silica Phenolic Nozzle Liners 二氧化硅酚醛喷嘴衬套失效分析
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.aero.c9001491
M. Katcher
Two silica phenolic nozzle liners cracked during proof testing. The test consisted of pressuring the nozzles to 14.1 MPa (2050 psia) for 5 to 20 s. It was concluded that the failure was due to longitudinal cracking in the convergent exhaust-nozzle insulators, stemming from the use of silica phenolic tape produced from flawed materials that went undetected by the quality control tests, which at the time, assessed tape strength properties in the warp rather than the bias direction. Once the nozzle manufacturer and its suppliers identified the problem, they changed their quality control procedures and resumed production of nozzle liners with more tightly controlled fiber/fabric materials.
两个二氧化硅酚醛喷嘴衬套在证明测试中破裂。试验包括将喷嘴加压至14.1 MPa (2050 psia) 5至20 s。结论是,故障是由于汇聚式排气喷嘴绝缘子的纵向开裂,这是由于使用了由有缺陷的材料生产的硅酚醛胶带造成的,而质量控制测试没有发现这些材料,当时的质量控制测试评估的是翘曲方向而不是偏倚方向的胶带强度特性。一旦喷嘴制造商及其供应商发现了这个问题,他们就改变了质量控制程序,并使用更严格控制的纤维/织物材料恢复了喷嘴衬套的生产。
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引用次数: 0
Analysis of Sub-Critical Cracking in a Ti-5Al-2.5Sn Liquid Hydrogen Control Valve Ti-5Al-2.5Sn液氢控制阀亚临界开裂分析
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.aero.c9001558
D. Meyn, R. Bayles
A liquid hydrogen main fuel control valve for a rocket engine failed by fracture of the Ti-5Al-2.5Sn body during the last of a series of static engine test firings. Fractographic, metallurgical, and stress analyses determined that a combination of fatigue and unexpected aqueous stress-corrosion cracking initiated and propagated the crack which caused failure. The failure analysis approach and its results are described to illustrate how fractography and fracture mechanics, together with a knowledge of the crack initiation and propagation mechanisms of the valve material under various stress states and environments, helped investigators to trace the cause of failure.
在一系列静态发动机点火试验的最后阶段,火箭发动机的液氢主燃料控制阀因Ti-5Al-2.5Sn阀体断裂而失效。断口学、冶金学和应力分析确定,疲劳和意外的水性应力腐蚀裂纹的结合引发并扩展了导致失效的裂纹。本文描述了失效分析方法及其结果,以说明断口学和断裂力学,以及对阀门材料在各种应力状态和环境下裂纹萌生和扩展机制的了解,如何帮助研究人员追踪失效原因。
{"title":"Analysis of Sub-Critical Cracking in a Ti-5Al-2.5Sn Liquid Hydrogen Control Valve","authors":"D. Meyn, R. Bayles","doi":"10.31399/asm.fach.aero.c9001558","DOIUrl":"https://doi.org/10.31399/asm.fach.aero.c9001558","url":null,"abstract":"A liquid hydrogen main fuel control valve for a rocket engine failed by fracture of the Ti-5Al-2.5Sn body during the last of a series of static engine test firings. Fractographic, metallurgical, and stress analyses determined that a combination of fatigue and unexpected aqueous stress-corrosion cracking initiated and propagated the crack which caused failure. The failure analysis approach and its results are described to illustrate how fractography and fracture mechanics, together with a knowledge of the crack initiation and propagation mechanisms of the valve material under various stress states and environments, helped investigators to trace the cause of failure.","PeriodicalId":326464,"journal":{"name":"ASM Failure Analysis Case Histories: Air and Spacecraft","volume":"95 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125177047","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Failure of a Main Landing Gear on a Light Airplane 轻型飞机主起落架故障
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.aero.c9001018
C. Howard Craft
Initial investigation showed that a landing gear failure was the result of a hard landing with no evidence of contributory factors. The objective of reexamination was to determine whether there was any evidence of metallurgical failure. The landing gear was primarily an AISI type 6150 Cr-V steel flat spring attached at the top end to the fuselage and at the bottom end to the axle. Failure occurred at the clamping point near the top end of this spring. The failure showed evidence of severe brinelling at one corner in the clamping area. The fracture surfaces were clean, fresh, and indicative of a shock type of failure pattern. Closer examination, however, showed a fatigue crack at one corner. At this point, there was definite evidence of progression and oxidation. It was concluded that the corner in question was subjected to repeated brinelling resulting from normal landing loads, probably accentuated by looseness in the clamping device. The resulting residual tensile stress lowered the effective fatigue strength at that point against drag and side loads.
初步调查显示,起落架故障是硬着陆的结果,没有证据表明是其他因素造成的。复检的目的是确定是否有冶金失效的证据。起落架主要是一个AISI型6150 Cr-V钢扁平弹簧,连接在机身的顶部和轴的底部。故障发生在靠近弹簧顶端的夹紧点。故障显示在夹紧区域的一个角落有严重的布氏损伤的证据。断裂表面干净,新鲜,表明是一种冲击型的断裂模式。然而,更仔细的检查显示,在一个角落有疲劳裂纹。在这一点上,有明确的证据表明进展和氧化。得出的结论是,由于正常的着陆载荷,可能由于夹紧装置的松动而加剧了所讨论的角受到反复的压边。由此产生的残余拉伸应力降低了该点抗阻力和侧载荷的有效疲劳强度。
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引用次数: 0
Damaged Propeller Blades 螺旋桨叶片损坏
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.aero.c9001747
Jivan B. Shah
This report covers case histories of failures in fixed-wing light airplane and helicopter components. In a 2025-T6 or 2219 aluminum alloy propeller blade that failed near the tip, cracks started on the leading edge at surface damage in the critical area-the zone between 4 and 10 in. from the tip of the blade. Incorrect dressing and inadequate pre-flight inspection were the two main causes. Two other types of propeller blade fatigue failures resulted mainly from propeller straightening operations, usually performed after previous blade bending damage. To eliminate blade tip failures, all surface-damaged material should be removed and polished smooth before further flight. The blade should be correctly dressed. Also, the tachometer should be calibrated to ensure the engine/propeller combination is not operated in the critical speed range at normal cruising speeds.
本报告涵盖了固定翼轻型飞机和直升机部件故障的历史案例。在2025-T6或2219铝合金螺旋桨叶片中,在尖端附近发生故障时,在临界区域(4 - 10英寸)的前缘表面损伤处开始出现裂纹。从刀刃的尖端。不正确的着装和不充分的飞行前检查是两个主要原因。另外两种类型的螺旋桨叶片疲劳失效主要是由于螺旋桨矫直操作造成的,通常是在先前的叶片弯曲损伤之后进行的。为了消除叶尖故障,所有表面损坏的材料应在进一步飞行前去除并抛光光滑。刀刃应正确修整。此外,转速表应进行校准,以确保发动机/螺旋桨组合在正常巡航速度下不在临界速度范围内运行。
{"title":"Damaged Propeller Blades","authors":"Jivan B. Shah","doi":"10.31399/asm.fach.aero.c9001747","DOIUrl":"https://doi.org/10.31399/asm.fach.aero.c9001747","url":null,"abstract":"\u0000 This report covers case histories of failures in fixed-wing light airplane and helicopter components. In a 2025-T6 or 2219 aluminum alloy propeller blade that failed near the tip, cracks started on the leading edge at surface damage in the critical area-the zone between 4 and 10 in. from the tip of the blade. Incorrect dressing and inadequate pre-flight inspection were the two main causes. Two other types of propeller blade fatigue failures resulted mainly from propeller straightening operations, usually performed after previous blade bending damage. To eliminate blade tip failures, all surface-damaged material should be removed and polished smooth before further flight. The blade should be correctly dressed. Also, the tachometer should be calibrated to ensure the engine/propeller combination is not operated in the critical speed range at normal cruising speeds.","PeriodicalId":326464,"journal":{"name":"ASM Failure Analysis Case Histories: Air and Spacecraft","volume":"2011 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131808406","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
期刊
ASM Failure Analysis Case Histories: Air and Spacecraft
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