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An aluminum alloy propeller blade that had been cold straightened to correct deformation incurred in service fractured soon after being returned to service. Visual examination revealed that crack initiation occurred at the top surface in an area containing numerous surface pits. Macroscopic appearance of the surface was of brittle fracture. X-ray stress analysis did not detect any residual stress in the top surface of the propeller blade adjacent to the fracture. However, a spanwise tensile stress of approximately 51 MPa (7.4 ksi) was indicated in the same surface of the unfailed mating blade at the location of the initial...

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