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Pitostatic system connectors were being found cracked on several aircraft. Two of the cracked connectors made of 2024-T351 aluminum alloy were submitted for failure analysis. The connectors had cut pipelike threads that were sealed with Teflon-type tape when installed. Longitudinal cracks were located near the opening of the female ends of each connector. A cross section showed intergranular cracking with multiple branching in one connector. Scanning electron microscopy (SEM) showed intergranular cracking and separation of elongated grains. A cross section of connector threads showed an incomplete thread form resulting from improper tapping. It was concluded that the pitostatic system...

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