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aircraft accident investigation
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Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006821
EISBN: 978-1-62708-329-4
... investigations and inspections and emphasizes cases where metallurgical or materials contributions were causal to an accident event. The article highlights how the failure of a component or system can affect the associated systems and the overall aircraft. The case studies in this article provide examples...
Abstract
This article focuses on failure analyses of aircraft components from a metallurgical and materials engineering standpoint, which considers the interdependence of processing, structure, properties, and performance of materials. It discusses methodologies for conducting aircraft investigations and inspections and emphasizes cases where metallurgical or materials contributions were causal to an accident event. The article highlights how the failure of a component or system can affect the associated systems and the overall aircraft. The case studies in this article provide examples of aircraft component and system-level failures that resulted from various factors, including operational stresses, environmental effects, improper maintenance/inspection/repair, construction and installation issues, manufacturing issues, and inadequate design.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006772
EISBN: 978-1-62708-295-2
... using the model may directly or indirectly give insight to the cause of an accident. Accident Reconstruction The term accident reconstruction has traditionally been used to describe the investigation and analysis of motor vehicle and aircraft accidents. However, the term is also being used more...
Abstract
Failure analysis is generally defined as the investigation and analysis of parts or structures that have failed or appeared to have failed to perform their intended duty. Methods of field inspection and initial examination are also critical factors for both reconstruction analysts and materials failure analysts. This article focuses on the general methods and approaches from the perspective of a reconstruction analyst. It describes the elements of accident reconstruction, which have conceptual similarity with the principles for failure analysis of material incidents that are less complex than a large-scale accident. The approach presented is that the analysis and reconstruction is based on the physical evidence. The article provides a brief review of some general concepts on the use and limitations of advanced data acquisition tools and computer modeling. Legal implications of destructive testing are discussed in detail.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003523
EISBN: 978-1-62708-180-1
... to describe the investigation and analysis of motor vehicle and aircraft accidents. However, the term is also being used more often to describe the investigation and analysis of any unexpected event that causes loss or injury. Accident reconstruction is rarely a simple endeavor, and accident...
Abstract
This article focuses on the general methods and approaches from the perspective of a reconstruction analyst and includes discussions relevant to materials failure analysts at the incident scene. The elements of accident reconstruction are described. These have conceptual similarity with the principles for failure analysis of material incidents that are less complex than a large-scale accident. The article provides a brief review of some general concepts on the use of modeling which can be a very powerful tool for information pertaining to the reconstruction of an accident where the model can be a physical, mathematical, or logical representation of a physical system or process.
Book: Fractography
Series: ASM Handbook
Volume: 12
Publisher: ASM International
Published: 01 June 2024
DOI: 10.31399/asm.hb.v12.a0006844
EISBN: 978-1-62708-387-4
... found itself employed in almost every possible job an aircraft can perform. One such task is aerial firefighting, which is a particularly hazardous mission that tragically sees the loss of several aircraft every fire season. Important to the investigation of any C-130 accident is the fact...
Abstract
With regard to documentation and photography of a catastrophic event, the field investigator's duties are fundamentally different from those of the laboratory-based analyst, even though both share the same goals. This article presents a case study on documentation considerations during the field investigation. It provides a detailed discussion on the general procedure to downselect from a multicomponent assemblage to a set of potential primary failed components. The article describes visual examination in macrofractography.
Book: Fractography
Series: ASM Handbook
Volume: 12
Publisher: ASM International
Published: 01 June 2024
DOI: 10.31399/asm.hb.v12.a0006848
EISBN: 978-1-62708-387-4
.... , A Survey of Serious Aircraft Accidents Involving Fatigue Fracture , Int. J. Fatigue , Vol 6 (No. 1 ), 1984 , p 25 – 30 10.1016/0142-1123(84)90005-7 4. Wanhill R.J.H. , Some Notable Aircraft Service Failures Investigated by the National Aerospace Laboratory (NLR) , Struct. Integ. Life...
Abstract
Quantitative fractography (QF) is the examination and characterization of fracture surfaces of failed or broken-open components and specimens. This article provides examples of the application of QF to evaluate real-life fatigue failures and also a comprehensive guideline chart for detecting and measuring fatigue striations and progression markings, with examples.
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006802
EISBN: 978-1-62708-329-4
... takeoffs. The Columbia Accident Investigations Board concluded that organizational issues contributed to the fatal incident. The panel made specific recommendations (such as better preflight inspection routines) to improve the safety of future shuttle flights. Overview of the Design Process...
Abstract
Life assessment of structural components is used to avoid catastrophic failures and to maintain safe and reliable functioning of equipment. The failure investigator's input is essential for the meaningful life assessment of structural components. This article provides an overview of the structural design process, the failure analysis process, the failure investigator's role, and how failure analysis of structural components integrates into the determination of remaining life, fitness-for-service, and other life assessment concerns. The topics discussed include industry perspectives on failure and life assessment of components, structural design philosophies, the role of the failure analyst in life assessment, and the role of nondestructive inspection. They also cover fatigue life assessment, elevated-temperature life assessment, fitness-for-service life assessment, brittle fracture assessments, corrosion assessments, and blast, fire, and heat damage assessments.
Book: Fractography
Series: ASM Handbook
Volume: 12
Publisher: ASM International
Published: 01 June 2024
DOI: 10.31399/asm.hb.v12.a0006843
EISBN: 978-1-62708-387-4
..., such as aircraft safety-of-flight investigations, a replica of the fracture is often acquired from the component, so that microfractography on the replica can be conducted in parallel with other work, such as three-dimensional analysis of the component. The reader is referred to the literature for such methods...
Abstract
This article presents the concept of fracture mechanisms in general terms in order to impart a practical understanding as well as enable readers to develop the ability to identify the basic fracture mechanisms correctly based on microscope observations. The key microscopic features of fracture surfaces are described and illustrated for the important types of fracture mechanisms. It provides a detailed discussion on environmentally assisted crack initiation and growth.
Book: Fatigue and Fracture
Series: ASM Handbook
Volume: 19
Publisher: ASM International
Published: 01 January 1996
DOI: 10.31399/asm.hb.v19.a0002392
EISBN: 978-1-62708-193-1
... design was not always readily understood. During the 1950s, the loss of several Comet aircraft within a short period of time prompted an investigation into the structural integrity of the Comet's fuselage. A pressurization test on a sample aircraft revealed that the combination of fatigue and stress...
Abstract
This article describes two analysis methods that are used to determine the life of aircrafts: fatigue life and fracture mechanics methods. The life limiting factors that control the durability of the aircraft are also discussed. The article provides an overview of the various approaches to corrosion identification and prevention. These include safe-life, fail-safe, and damage tolerance approaches. The article discusses their application to the process of extending the life of aircraft structural components.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003512
EISBN: 978-1-62708-180-1
... and inspection of tanks, aircraft, and pressure vessels are mandatory. Extreme care during maintenance and the inspection following maintenance must be taken to ensure that proper procedures and techniques are rigorously followed. Role of the Failure Investigator The typical role of the failure...
Abstract
This article provides an overview of the structural design process and discusses the life-limiting factors, including material defects, fabrication practices, and stress. It details the role of a failure investigator in performing nondestructive inspection. The article provides information on fatigue life assessment, elevated-temperature life assessment, and fitness-for-service life assessment.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003502
EISBN: 978-1-62708-180-1
... maintenance leading to premature wear of components was claimed. A detailed investigation revealed that the door closer was not working properly at the time of the accident, allowing the door to swing freely in either direction. In addition, the door had a specially designed hinge system to facilitate...
Abstract
This article provides assistance to a failure analyst in broadening the initial scope of the investigation of a physical engineering failure in order to identify the root cause of a problem. The engineering design process, including task clarification, conceptual design, embodiment design, and detail design, is reviewed. The article discusses the design process at the personal and project levels but takes into consideration the effects of some higher level influences and interfaces often found to contribute to engineering failures.
Book: Fatigue and Fracture
Series: ASM Handbook
Volume: 19
Publisher: ASM International
Published: 01 January 1996
DOI: 10.31399/asm.hb.v19.a0002393
EISBN: 978-1-62708-193-1
... undertaken and precipitated investigations into the history of USAF accidents related to fatigue. These investigations culminated in a complete change in design criteria for USAF aircraft. Many of the design specifications were changed and others were introduced. The most important document to come out...
Abstract
Damage tolerance is a philosophy used for maintaining the structural safety of commercial transport aircrafts. This article describes the structural evaluations necessary to comply with the regulations contained in the Federal Air worthiness Requirements 25.571 whose guidance is given in Advisory Circular 25.571-1A from the Federal Aviation Administration. It provides an overview of the historical evolution of damage tolerance philosophy and presents a discussion of the design philosophies and a summary of the evaluation tasks for damage tolerance certification.
Book: Fatigue and Fracture
Series: ASM Handbook
Volume: 19
Publisher: ASM International
Published: 01 January 1996
DOI: 10.31399/asm.hb.v19.a0002394
EISBN: 978-1-62708-193-1
... of pressure vessels) and the F-111 aircraft accident. Fracture Mechanics as a Design Tool in the Space Program In 1965, Tiffany and Masters wrote an article ( Ref 33 ) that was instrumental in promoting the use of fracture mechanics as a technique that would be useful in aircraft design. This article...
Abstract
The inclusion of damage tolerance design and a systematic review of design procedures allow the U.S. Air Force to design, manufacture, and maintain systems that are structurally safe and economically prudent. After a brief introduction of fracture mechanics, this article describes the particular aspects that relate to damage tolerance in aircraft design. It discusses the use of fracture mechanics as a method of predicting failure, understanding failure mechanisms, and suggesting inspection methods to protect against failure in pressure vessels. Various programs of U.S. Air Force to design aircraft structure, namely, airframe structural integrity programs, engine structural integrity program, and mechanical subsystems structural integrity program are also discussed.
Series: ASM Handbook
Volume: 13C
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v13c.a0004128
EISBN: 978-1-62708-184-9
... true for tension-dominated loading spectra. In a different study, an evaluation of the effects of exfoliation of the 7075-T6 upper wing skin of the C141 aircraft showed that the fatigue lives decreased with increase of exfoliation depth ( Ref 36 ). In investigating the effects of corrosion of lap...
Abstract
Corrosion, fatigue, and their synergistic interactions are among the principal causes of damage to aircraft structures. This article describes aircraft corrosion fatigue assessment in the context of different approaches used to manage aircraft structural integrity, schedule aircraft inspection intervals, and perform repair and maintenance of aircraft in service. It illustrates the types of corrosive attack observed in aircraft structures, including uniform, galvanic, pitting, filiform, fretting, intergranular, exfoliation corrosion, and stress-corrosion cracking. The article discusses geometric parameters such as pit dimensions, surface roughness, loss of metal thickness, and volume increase due to pillowing to quantitatively characterize the types of corrosion. It also explains the two most common fatigue life assessment methods used in the military aerospace industry: fatigue crack initiation and crack growth analysis.
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006815
EISBN: 978-1-62708-329-4
..., organizational factors, and (perhaps) additional physical factors. The engineering design process is significant in root-cause failure analysis because it contains the original contributing factors that led to the design that was produced and failed. By investigating not only the failed component or system...
Abstract
The intent of this article is to assist the failure analyst in understanding the underlying engineering design process embodied in a failed component or system. It begins with a description of the mode of failure. This is followed by a section providing information on the root cause of failure. Next, the article discusses the steps involved in the engineering design process and explains the importance of considering the engineering design process. Information on failure modes and effects analysis is also provided. The article ends with a discussion on the consequence of management actions on failures.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003573
EISBN: 978-1-62708-180-1
... in design computations. The reason for using such low fractions of yield (or ultimate) strength is to allow for such factors as possible errors in computational assumptions, accidental overload, introduction of residual stress during processing, temperature effects, variations in material quality (including...
Abstract
Distortion failure occurs when a structure or component is deformed so that it can no longer support the load it was intended to carry. Every structure has a load limit beyond which it is considered unsafe or unreliable. Estimation of load limits is an important aspect of design and is commonly computed by classical design or limit analysis. This article discusses the common aspects of failure by distortion with suitable examples. Analysis of a distortion failure often must be thorough and rigorous to determine the root cause of failure and to specify proper corrective action. The article summarizes the general process of distortion failure analysis. It also discusses three types of distortion failures that provide useful insights into the problems of analyzing unusual mechanisms of distortion. These include elastic distortion, ratcheting, and inelastic cyclic buckling.
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006817
EISBN: 978-1-62708-329-4
... and the Douglas DC-8, into passenger service. Industry-wide safety statistics began to be published in 1959, and they were troubling. If the jet airliners were flying at today’s operating tempos, they would have an accident roughly every day. (In commercial aviation statistics, accident is defined...
Abstract
Reliability-centered maintenance (RCM) is a systematic methodology for preventing failures. This article begins by discussing the history of RCM and uses Society of Automotive Engineers (SAE) all-industry standard JA1011 as its model to describe the key characteristics of an RCM process. It then expands on questions involved in RCM process, offering definitions when necessary. Next, the article describes the approach of RCM to failure modes and effects analysis (FMEA), the failure management policies available under RCM, and the criteria of RCM for deciding when a specific failure management policy is technically feasible. Then, after discussing the ways that RCM classifies failure effects in terms of consequences, it describes how RCM uses failure consequences to identify the best failure management policy for each failure mode. Next, the building blocks of RCM are put together to create a failure management program. The article ends with a discussion on some practical issues pertaining to RCM that lie outside the scope of SAE JA1011.
Series: ASM Handbook
Volume: 13A
Publisher: ASM International
Published: 01 January 2003
DOI: 10.31399/asm.hb.v13a.a0003706
EISBN: 978-1-62708-182-5
... of a countersunk fastener relative to a rivet or hole edge. Centerline is the center between two fasteners that aligned perpendicular to the applied in-plane hoop stress direction. Multisite Damage Since the Aloha Airlines B-737 accident in 1988, a paradigm shift in the aircraft structural integrity...
Abstract
This article discusses corrosion fatigue, its effects on the damage tolerance of aircraft, and its predictive modeling. A conceptual framework is presented that incorporates two distinctive cyclic-based life-prediction philosophies and expands them both to include the time domain in order to consider the effects of corrosion. These philosophies include crack initiation used for safe-life design and crack growth used for damage tolerance. The article presents the methodology for computing the effects of real-time age degradation on an aircraft structure for two different corrosion types: crevice and pitting corrosion. It describes the rationale and techniques needed to apply the age-based structural integrity processes to in-service structures in order to realize the benefits throughout the full structural life cycle.
Book Chapter
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006797
EISBN: 978-1-62708-295-2
... for such factors as possible errors in computational assumptions, accidental overload, introduction of residual stress during processing, temperature effects, variations in material quality (including imperfections), degradation (for example, from corrosion), and inadvertent local increases in applied stress...
Abstract
Distortion often is observed in the analysis of other types of failures, and consideration of the distortion can be an important part of the analysis. This article first considers that true distortion occurs when it was unexpected and in which the distortion is associated with a functional failure. Then, a more general consideration of distortion in failure analysis is introduced. Several common aspects of failure by distortion are discussed and suitable examples of distortion failures are presented for illustration. The article provides information on methods to compute load limits, errors in the specification of the material, and faulty process and their corrective measures to meet specifications. It discusses the general process of material failure analysis and special types of distortion and deformation failure.
Book Chapter
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003524
EISBN: 978-1-62708-180-1
.... For example, an investigation of an aircraft accident involves the development of a considerable inventory, including listing the number of engines, flaps, landing gear, and the various parts of the fuselage and wings. It is essential to establish whether all the primary parts of the aircraft were aboard...
Abstract
This article describes the preliminary stages and general procedures, techniques, and precautions employed in the investigation and analysis of metallurgical failures that occur in service. The most common causes of failure characteristics are described for fracture, corrosion, and wear failures. The article provides information on the synthesis and interpretation of results from the investigation. Finally, it presents key guidelines for conducting a failure analysis.
Book: Fatigue and Fracture
Series: ASM Handbook
Volume: 19
Publisher: ASM International
Published: 01 January 1996
DOI: 10.31399/asm.hb.v19.a0002356
EISBN: 978-1-62708-193-1
... for safety regulations to protect society against fatal accidents. The economic and social impact of fatigue failures will not be discussed here, but designing against fatigue obviously is a matter of concern. It encompasses various design options, and needless to say, experience and engineering judgment...
Abstract
This article summarizes fatigue phenomena in metallic materials. It discusses fatigue under variable-amplitude (VA) loading, with emphasis on crack growth. The article presents the prediction models of crack initiation and crack growth under VA loading. It concludes with a discussion on the conditions associated with engineering applications of VA loading.
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