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7075
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Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0006402
EISBN: 978-1-62708-217-4
... Abstract New aircraft wing panels extruded from 7075-T6 aluminum exhibited an unusual pattern of circular black interrupted lines, which could not be removed by scouring or light sanding. The panels, subsequent to profiling and machining, were required to be penetrated inspected, shot peened...
Abstract
New aircraft wing panels extruded from 7075-T6 aluminum exhibited an unusual pattern of circular black interrupted lines, which could not be removed by scouring or light sanding. The panels, subsequent to profiling and machining, were required to be penetrated inspected, shot peened, H2SO4 anodized, and coated with MIL-C-27725 integral fuel tank coating on the rib side. Scanning electron microscopy and microprobe analysis (both conventional energy-dispersive and Auger analyzers) showed that the anodic coating was applied over an improperly cleaned and contaminated surface. The expanding corrosion product had cracked and, in some places, had flaked away the anodized coating. The corrodent had penetrated the base aluminum in the form of subsurface intergranular attack to a depth of 0.035 mm (0.0014 in.). It was recommended that a vapor degreaser be used during cleaning prior to anodizing. A hot inhibited alkaline cleaner was also recommended during cleaning prior to anodizing. The panels should be dichromate sealed after anodizing. The use of deionized water was also recommended during the dichromate sealing operation. In addition, the use of an epoxy primer prior to shipment of the panels was endorsed. Most importantly, surveillance of the anodizing process itself was emphasized.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0046146
EISBN: 978-1-62708-217-4
... Abstract The torque-arm assembly (aluminum alloy 7075-T73) for an aircraft nose landing gear failed after 22,779 simulated flights. The part, made from an aluminum alloy 7075-T73 forging, had an expected life of 100,000 simulated flights. Initial study of the fracture surfaces indicated...
Abstract
The torque-arm assembly (aluminum alloy 7075-T73) for an aircraft nose landing gear failed after 22,779 simulated flights. The part, made from an aluminum alloy 7075-T73 forging, had an expected life of 100,000 simulated flights. Initial study of the fracture surfaces indicated that the primary fracture initiated from multiple origins on both sides of a lubrication hole that extended from the outer surface to the bore of a lug in two cadmium-plated flanged bushings made of copper alloy C63000 (aluminum bronze) that were press-fitted into each bored hole in the lug. Sectioning and 2x metallographic analysis showed small fatigue-type cracks in the hole adjacent to the origin of primary fracture. Hardness and electrical conductivity were typical for aluminum alloy 7075. This evidence supported the conclusion that the arm failed in fatigue cracking that initiated on each side of the lubrication hole since no material defects were found at the failure origin. Recommendations included redesign of the lubrication hole, shot peeing of the faces of the lug for added resistance to fatigue failure, and changing of the forging material to aluminum alloy 7175-T736 for its higher mechanical properties.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001541
EISBN: 978-1-62708-235-8
... Abstract A forging of 7075-T6 aluminum alloy, which formed a support for the cylinder of a cargo door, cracked at an attachment hole. Fluorescent penetrant inspection showed the crack ran above and below the hole out onto the machined flat surface of the flange. A 6500x electron fractograph...
Abstract
A forging of 7075-T6 aluminum alloy, which formed a support for the cylinder of a cargo door, cracked at an attachment hole. Fluorescent penetrant inspection showed the crack ran above and below the hole out onto the machined flat surface of the flange. A 6500x electron fractograph proved the crack to be a forging defect called a cold shut. Because defects of this type are usually detected when the raw forging is inspected, this occurrence was considered to be an isolated instance.
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in Failure of Rifle Receivers Caused by Exfoliation (Ref 1)
> ASM Failure Analysis Case Histories: Failure Modes and Mechanisms
Published: 01 June 2019
Fig. 1 Forged aluminum alloy 7075-T6 receiver from an M16 rifle that failed by exfoliation corrosion. (a) Rifle receiver. 0.7×. Similar receivers were forged from three different materials to investigate the effects of processing on exfoliation resistance ( Table 1 ). Section A-A: (b), (c
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in Failure by Stress-Corrosion Cracking of an Ejection Seat Swivel
> ASM Failure Analysis Case Histories: Air and Spacecraft
Published: 01 June 2019
Fig. 1 Opened crack (a) in aluminum alloy 7075-T651 ejection seat swivel fixture that failed by SCC. Note crack propagation markings that suggest the crack initiated on the inside wall of the fixture and woody appearance of the fracture. (b) Higher-magnification view of fracture surface from
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in Corrosion of Aluminum Alloy 7075-T6 Wing Panel
> ASM Failure Analysis Case Histories: Air and Spacecraft
Published: 01 June 2019
Fig. 1 Aluminum alloy 7075-T6 aircraft wing panel (a) showing unusual surface appearance. (b) SEM of the panel surface showing cracked anodized coating. 160x. (c) SEM showing the anodized coating flaking away and corrosion deposit under the coating. 85x. (d) Cross section of corrosion site
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Published: 01 June 2019
Fig. 1 Cracked aluminum alloy 7075-T6 aircraft pylon strut (a) with arrows indicating cracks. (b) SEM of crack C from (a) showing the mud crack pattern indicative of a corrosion mechanism. 820x
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in Fatigue Fracture of an Aluminum Alloy 7075-T73 Landing-Gear Torque Arm
> ASM Failure Analysis Case Histories: Air and Spacecraft
Published: 01 June 2019
Fig. 1 Aluminum alloy 7075-T73 landing-gear torque-arm assembly that was redesigned to eliminate fatigue fracture at a lubrication hole. (a) Configuration and dimensions (given in inches). (b) Fracture surface showing fatigue beach marks. Approximately 2×
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in Mechanisms and Appearances of Ductile and Brittle Fracture in Metals
> Failure Analysis and Prevention
Published: 01 January 2002
Fig. 46 Crack propagation in shear bands in a 7075-T6 plate specimen. Shear banding has occurred on four planes of high shear stress (two containing the width direction and two containing the thickness direction). Crack initiation has occurred in multiple locations, including the edge
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in Mechanisms and Appearances of Ductile and Brittle Fracture in Metals
> Failure Analysis and Prevention
Published: 01 January 2002
Fig. 86 Fracture on essentially one plane of high shear stress in a 7075-T6 cylindrical tensile specimen. There is a small flat region in the center of the specimen (not visible in photograph) that does not extend to the surface of the specimen. No fracture surface markings exist to indicate
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Published: 01 January 2002
Fig. 14 Beach marks on a fatigue fracture in aluminum alloy 7075-T73 forging. The light-colored reflective bands are zones of fatigue crack propagation. At high magnifications, thousands of fatigue striations can be resolved within each band. The dull, fibrous bands are zones of crack
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Published: 01 January 2002
Fig. 20 Fatigue-fracture zones in aluminum alloy 7075-T6 plates. (a) Fatigue crack that grew as a flat-face fracture with a shallow convex crack front. (b) Change in orientation of fatigue fracture from plane strain (arrow A) to plane stress (arrow B).
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Published: 01 January 2002
Fig. 7 Fractured lug of an alloy 7075-T6 forging. Arrows show sites at machined hole where stress-corrosion cracks originated because of stress acting across the short transverse grain direction. Keller's reagent. 2×
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Published: 30 August 2021
Fig. 39 Fracture weld joint on alloy 7075 collar side of the swing arm structure
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in Problems Associated with Heat Treated Parts
> Analysis and Prevention of Component and Equipment Failures
Published: 30 August 2021
Fig. 28 Effect of burning on ductility in a 7075 aluminum alloy. (a) Properly heated. (b) Embrittled due to liquid phases formed in grain boundary. Profile of fracture surface of tensile specimens pulled to failure
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Published: 30 August 2021
Fig. 2 (a) Cracked HL 22-8 aluminum alloy 7075-T6 fasteners. (b) Typical cracked fastener head. (c) Typical head cracks produced by installing fasteners in misaligned holes during testing
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Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c0047199
EISBN: 978-1-62708-234-1
... Abstract The lower receiver of the M16 rifle is an anodized forging of aluminum alloy 7075-T6. Degradation of the receivers was observed after three years of service in a hot, humid atmosphere. The affected areas were those in frequent contact with the user's hands. There was no question...
Abstract
The lower receiver of the M16 rifle is an anodized forging of aluminum alloy 7075-T6. Degradation of the receivers was observed after three years of service in a hot, humid atmosphere. The affected areas were those in frequent contact with the user's hands. There was no question that the material failed as a result of exfoliation corrosion, so an investigation was undertaken, centered around the study of thermal treatments that would increase the exfoliation resistance and still develop the required 448 MPa (65 ksi) yield strength. The results of the study concluded that rolled bar stock should be preferred to extruded bar stock. Differences in grain structure of the forgings, as induced by differences in thermal-mechanical history of the forged material, can have a significant effect on susceptibility to exfoliation corrosion. Regarding thermal treatment, the results show conclusively that large changes in strength and exfoliation characteristics of 7075 forgings can be induced by changes in temperature or time of thermal treatment. With regard to the effect of quenching rate on exfoliation characteristics, a cold-water quench below 25 deg C (75 deg F) would appear to be far superior to an elevated-temperature quench to minimize exfoliation for 7075 forgings in the T6 temper.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0006387
EISBN: 978-1-62708-217-4
... Abstract A routine examination on a seat ejection system found that the catapult attachment swivel fabricated from 7075-T651 aluminum alloy plate contained cracks on opposite sides of the part. This swivel, or bath tub, does not experience extreme loads prior to activation of the catapult...
Abstract
A routine examination on a seat ejection system found that the catapult attachment swivel fabricated from 7075-T651 aluminum alloy plate contained cracks on opposite sides of the part. This swivel, or bath tub, does not experience extreme loads prior to activation of the catapult system. Some loads could be absorbed however, when the aircraft is subjected to G loads. Visual examination of the part revealed that cracks through the wall thickness initiated on the inner walls of the fixture. Scanning electron microscopy (SEM) and electron optical examination revealed that the cracking pattern initiated and progressed by an intergranular failure mechanism. It was concluded that failure of the catapult attachment swivel fixture occurred by SCC. It was recommended that the 7075 aluminum ejection seat fixture be supplied in the T-73 temper to minimize susceptibility to SCC.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0091674
EISBN: 978-1-62708-217-4
... hinge brackets in service for cracks and for proper maintenance of paint. Also suggested was replacing the aluminum alloy 2015-T6 with alloy 7075-T6, and surface treatment for the 7075-T6 brackets was recommended using sulfuric acid anodizing and dichromate sealing. Finally, it was also recommended...
Abstract
Forged aluminum alloy 2014-T6 hinge brackets in naval aircraft rudder and aileron linkages were found cracked in service. The cracks were in the hinge lugs, adjacent to a bushing made of cadmium-plated 4130 steel. Investigation (visual inspection and 250X micrographs) supported the conclusion that the failure of the hinge brackets occurred by SCC. The corrosion was caused by exposure to a marine environment in the absence of paint in stressed areas due to chipping. The stress resulted from the interference fit of the bushing in the lug hole. Recommendations included inspecting all hinge brackets in service for cracks and for proper maintenance of paint. Also suggested was replacing the aluminum alloy 2015-T6 with alloy 7075-T6, and surface treatment for the 7075-T6 brackets was recommended using sulfuric acid anodizing and dichromate sealing. Finally, it was also recommended that the interference fit of the bushing in the lug hole be discontinued.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0091809
EISBN: 978-1-62708-217-4
... Abstract 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...
Abstract
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.