Handbook of Materials Failure Analysis with Case Studies from the Aerospace and Automotive Industries

498 Pages·2015·108.045 MB·English

by  Abdel Salam Hamdy Makhlouf Ph.D., Mahmood Aliofkhazraei Ph.D

Handbook of Materials
Failure Analysis
With Case Studies
from the Aerospace
and Automotive
Industries
Handbook of Materials
Failure Analysis
With Case Studies
from the Aerospace
and Automotive
Industries
Edited by
Abdel Salam Hamdy Makhlouf
Mahmood Aliofkhazraei
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Contributors
Laura Allegrucci
Chemistry Department,Italian Air Force—FlightTest Centre,PraticadiMare
AFB, Pomezia, Rome, Italy
Mikael Amura
Chemistry Department,Italian Air Force—FlightTest Centre,PraticadiMare
AFB, Pomezia, Rome, Italy
In˜akiArmenda´riz
MaterialsandStructuresDepartment,InstitutoNacionaldeTe´cnicaAeroespacial
(INTA),Torrejo´n de Ardoz, Madrid Spain
Mohammad Azadi
Fatigueand Wear inMaterials (FWM) Workgroup, Irankhodro Powertrain
Company(IPCO),Tehran, Iran
FionaBelben
AWL MaterialsTechnologyLaboratory, AgustaWestlandLtd.,Yeovil,Somerset,
United Kingdom
ManueleBernabei
Chemistry Department,Italian Air Force—FlightTest Centre,PraticadiMare
AFB, Pomezia, Rome, Italy
Swati Biswas
Gas Turbine Research Establishment, Bengaluru,India
Victor K.Champagne
US Army Research Laboratory, Aberdeen Proving Ground,Adelphi,Maryland,
USA
Seyid F. Diltemiz
TurkishAirForce,1stAirSupplyandMaintenanceCenterCommand,Eskis¸ehir,
Turkey
Mirko Dinulovic
University ofBelgrade,Faculty ofMechanicalEngineering, Kraljice Marije 16,
Belgrade,Serbia
Kay Ellinghaus
Tenneco GmbH, Edenkoben,Germany
Jose´ M. Encinas
MaterialsandStructuresDepartment,NationalInstituteofAerospaceTechniques
(INTA),Torrejo´n de Ardoz, Madrid, Spain
Ahmed Z.Farahat
CentralMetallurgical Research and Development Institute, CMRDI, Helwan,
Cairo,Egypt
xix
xx Contributors
MudigereD. Ganeshachar
Gas TurbineResearchEstablishment,Bengaluru,India
Juan Garcı´a-Martı´nez
MaterialsandStructuresDepartment,InstitutoNacionaldeTe´cnicaAeroespacial
(INTA), Torrejo´n de Ardoz, MadridSpain
Thomas Goehring
Tenneco Inc.,GrassLake, Jackson, Michigan,USA
Roberto Gonza´lez
MaterialsandStructuresDepartment,InstitutoNacionaldeTe´cnicaAeroespacial
(INTA), Torrejo´n de Ardoz, MadridSpain
Selim Gu¨rgen
Department ofMechanicalEngineering, Eskis¸ehir OsmangaziUniversity,
Eskis¸ehir, Turkey
Vı´ctor H. Jacobo
Department ofMaterialsScience and Manufacturing, DIMEI Universidad
NacionalAuto´noma de Me´xico Avenida Universidad, Coyoaca´n,Me´xico D.F.
Mexico
AdamKotrba
Tenneco Inc.,GrassLake, Jackson, Michigan,USA
BranimirKrstic
University ofDefence inBelgrade, Military Academy,Generala Pavla Jurisica
Sturma 33,Belgrade,Serbia
MelihC.Kus¸han
Department ofMechanicalEngineering, Eskis¸ehir OsmangaziUniversity,
Eskis¸ehir, Turkey
JivanKumar
Gas TurbineResearchEstablishment,Bengaluru,India
Victoria L. Long
NationalAeronauticsandSpaceAdministration(NASA),KennedySpaceCenter,
Florida, USA
Limin Luo
Tenneco Inc.,GrassLake, Jackson, Michigan,USA
AbdelS.H. Makhlouf
Manufacturing and Industrial Engineering Department,Collegeof Engineering
and ComputerScience,University ofTexas RioGrandeValley
Steven J. McDanels
NationalAeronauticsandSpaceAdministration(NASA),KennedySpaceCenter,
Florida, USA
Contributors xxi
Javier S.Milla´n
MaterialsandStructuresDepartment,InstitutoNacionaldeTe´cnicaAeroespacial
(INTA),Torrejo´n de Ardoz, Madrid Spain
Melany Mioduszewski
Tenneco Inc.,Grass Lake, Jackson,Michigan, USA
Teresa L.M. Morgado
EngineeringDepartmentalUnitofTomarPolytechnicInstitute,EscolaSuperiorde
Tecnologiade Abrantes do Instituto Polite´cnicode Tomar,Abrantes, Portugal,
and ICEMS-IST-UL—Institute ofMaterials and SurfacesScience and
Engineering, Lisbon University, Lisboa, Portugal
Sangli N. Narendra Babu
Gas Turbine Research Establishment, Bengaluru,India
Jose´ Olarrea
E.T.S.I.Aerona´uticos,UniversidadPolite´cnicadeMadrid(UPM),Madrid,Spain
ArmandoOrtiz
Department ofMaterials Science and Manufacturing, DIMEI Universidad
NacionalAuto´nomade Me´xico AvenidaUniversidad, Coyoaca´n, Me´xico D.F.
Mexico
Edgar A.Ossa
MaterialEngineeringResearchGroup,SchoolofEngineering,UniversidadEafit,
Medell´ın,Colombia
Marco Paniagua
MaterialEngineeringResearchGroup,SchoolofEngineering,UniversidadEafit,
Medell´ın,Colombia
Marc S. Pepi
US Army Research Laboratory, Aberdeen Proving Ground,Adelphi,
Maryland, USA
Markus Pieszkalla
Tenneco GmbH, Edenkoben,Germany
Igor Radisavljevic
MilitaryTechnical Institute,Ratka Resanovica1, Belgrade,Serbia
Zoran Rajic
MilitaryTechnical Institute,Ratka Resanovica1, Belgrade,Serbia
Edgar I.Ramı´rez
Department ofMaterials Science and Manufacturing, DIMEI Universidad
NacionalAuto´nomade Me´xico AvenidaUniversidad, Coyoaca´n, Me´xico D.F.
Mexico
Bosko Rasuo
University ofBelgrade,Faculty ofMechanicalEngineering, Kraljice Marije 16,
Belgrade,Serbia
xxii Contributors
MarekRybarz
Tenneco Automotive Polska sp. z o.o.Rybnik, Poland
VaradaN. Satish Kumar
Gas TurbineResearchEstablishment,Bengaluru,India
RafaelSchouwenaars
Department ofMaterialsScience and Manufacturing, DIMEI Universidad
NacionalAuto´noma de Me´xico Avenida Universidad, Coyoaca´n,Me´xico D.F.
Mexico
DanielJ. Thomas
College ofEngineering, Swansea University, Swansea,UK
Dragan Trifkovic
University ofDefence inBelgrade, Military Academy,Generala Pavla Jurisica
Sturma 33,Belgrade,Serbia
Zhigang Wei
Tenneco Inc.,GrassLake, Jackson, Michigan,USA
William J.Wolfgong
RaytheonSpace and Airborne Systems,Component Engineering Department,
McKinney, Texas
MariaC.Wright
NationalAeronauticsandSpaceAdministration(NASA),KennedySpaceCenter,
Florida, USA
XiaoleiXu
KeyLaboratory ofShip-MachineryMaintenance & Manufacture Ministry of
Communication,PRC,andDepartmentofMaterialsScience,EngineeringDalian
Maritime University, Dalian, PR China
Shang-Kuo Yang
Department ofMechanicalEngineering, NationalChin YiUniversity of
Technology, Taichung, Taiwan
Zhiwei Yu
KeyLaboratory ofShip-MachineryMaintenance & Manufacture Ministry of
Communication,PRC,andDepartmentofMaterialsScience,EngineeringDalian
Maritime University, Dalian, PR China
Preface
OneofthemostcommonapplicationsoffailureanalysisisintheAerospaceindustry.
Planescrashesarememorabletothepublic,duetotheresultinglossoflivesofmany
people and the spiritual injuries suffered by survivors. In 2005, a hydroplane
explodedduringtakeofffromMiamiBeach,Florida.Theplanewascarryingfifteen
passengers.Duringthistragedy,duetoanexplosion,theplanewasengulfedinflame
and the right wing was damaged prior to collision with the surface of the water.
Experiments on the wreck of the plane indicated that the cracks resulting from
fatigueintherightwingoftheplanewerethecauseoftheaccident.Anotherexample
wasanincidentinRailwayTransportin1998.AnexpresstraininGermanywentoff
therails.ThetrainwastravellingontherailwaybetweenMunichandHamburg.At
11AM,aroundEschede(situated35milestothenorthofHanover),thetrainwent
off the rails. According to reports, some of the passengers had heard a knocking
sound.Investigationsclarifiedthattheknockingsoundwascreatedduetothefrac-
ture of one of the wheels, prior to the reversal of the train. Failure analysis is not
limitedtoplanecrashesandtrainsreversals.Failureanalysisisthekeytofailurepre-
vention.Materialengineersplaythemostimportantroleintheinvestigationoffail-
ure analysis and methods of prevention. Therefore, studying materials science and
engineering isthe doortoeffective failure analysisand materialsprotection.
Thishandbookprovidesathoroughunderstandingofthereasonsmaterialsfailin
certainsituations,coveringimportantscenarios,includingmaterialdefects,mechan-
icalfailureasaresultofimproperdesign,corrosion,surfacefracture,andotherenvi-
ronmentalcauses.Thehandbookbeginswithageneraloverviewofmaterialsfailure
analysisanditsimportance,andthenlogicallyproceedsfromadiscussionofthefail-
ureanalysisprocess,typesoffailureanalysis,andspecifictoolsandtechniques,to
chapters onanalysis ofmaterials failure from various causes.
Thishandbookcontainsmanyreal-worldfailurecasesandcasestudiescoveringa
widespectrumofmaterialsfailureinNASA,aerospace,army,marine,andautomo-
tive applications. The editors thank all the contributors for their excellent chapter
contributionstothishandbook,andfortheirhardworkandpatienceduringtheprep-
aration and production of the book. We sincerely hope that the publication of this
handbookwillhelppeoplefromIndustryandAcademiatogetthemaximumbenefits
from the experience contained inthe published chapters.
Summer 2015
Abdel Salam Hamdy Makhlouf
Mahmood Aliofkhazraei
xxiii
CHAPTER
1
Strategies for static failure
analysis on aerospace
structures
JavierS.Milla´n,In˜aki Armenda´riz, JuanGarcı´a-Martı´nez, Roberto Gonza´lez
MaterialsandStructuresDepartment,InstitutoNacionaldeTe´cnicaAeroespacial(INTA),
Torrejo´ndeArdoz,MadridSpain
CHAPTER OUTLINE
1 Introduction .........................................................................................................4
2 DelaminationGrowthinComposites .......................................................................4
2.1 VCCTFundamentals .............................................................................5
2.2 ExperimentalBenchmarkandFEMSimulation .......................................7
2.3 FEMsComparison ................................................................................8
2.4 DelaminationGrowthTool .....................................................................9
2.5 CorrelationBetweenFEMSimulationsandTests.....................................9
2.6 MeshSizeEffects ..............................................................................10
2.7 ComparisonofMixed-ModeFailureCriteria ..........................................10
2.8 ConclusionandFurtherWorkinDelaminationGrowthAnalysis...............10
3 DebondingOnsetandGrowth ...............................................................................12
3.1 DCBCoupon:ModeIInterlaminarFractureToughnessTest ...................13
3.2 FEModeling ......................................................................................13
3.3 CZFundamentals ...............................................................................14
3.4 MeshDependency ..............................................................................14
3.5 ExperimentalResults .........................................................................16
3.6 CorrelationFEMSimulation—Tests .....................................................17
3.7 ConclusionandFutureWorkinDebondingAnalysis...............................20
4 CrackGrowthinMetallicStructures ....................................................................20
4.1 CTOACriterion—ExperimentalObtainingofCTOA ...............................21
C
4.2 CrackGrowthTool ..............................................................................23
4.3 BenchmarksDescription .....................................................................23
4.4 FEMModeling ...................................................................................24
4.5 CorrelationSimulations—Tests ...........................................................24
4.6 CrackGrowthinMetallicStructures—ConclusionandFutureWork .........26
References ..............................................................................................................26
HandbookofMaterialsFailureAnalysisWithCaseStudiesfromtheAerospaceandAutomotiveIndustries.
3
http://dx.doi.org/10.1016/B978-0-12-800950-5.00001-6
Copyright©2016ElsevierLtd.Allrightsreserved.
4 CHAPTER1 Strategiesforstaticfailureanalysisonaerospacestructures
1 INTRODUCTION
Failure analysis comprises the prediction of damage onset on a structure when
subjectedtoloadsandenvironmentalconditions.Damagesmayconsistinpermanent
structural deformations (plastic strains for instance); local damages as cracks
forinstance,oringeneralanydeteriorationofthestructure,orlackoffunctionality.
Itshouldbenotedthatdamageonsetdoesnotmeanthefinalorcatastrophicfailureof
thestructure.Failureanalysisalsocomprisesthesubsequentprogressivefailureanal-
ysis(PFA)thatoccurswhenthestructureisloadedinstaticorfatigueenvironments.
In PFA, two features are commonly studied. The first is damage progression
before it may reach a critical size producing the final failure. The second is the
so-called residual strength, the remaining capability of the damaged structure to
withstandloads.Intheaircraftsector,itiscommontorefertheconceptofdamage
tolerance, which means that a structure in presence of undetected damages, either
producedbymanufacturingdefects,fatigue,ambientconditions,oraccidental,isstill
abletowithstandtheloadsproducedduringitsservicelife.Thefail-safeconceptis
employedandisdefinedasdamagethatmustnotleadtofailurebeforeitisdetectable
bymeansofinspections.ProperlyunderstandingoffailurecausesandPFA,allows
theengineerimprovingandoptimizingthestructuraldesign,additionallyimproving
structural reliability.
Instituto Nacional de Te´cnica Aeroespacial (INTA) is currently involved in
developing reliable simulation techniques for damaged structures including PFA.
Themethodologiesarebasedinthefiniteelementmodel(FEM)techniqueandhave
beenappliedtotypicalaerospacestructuresmadeinmetallicorcompositematerials,
monolithic orsandwich, etc. Some examplesare shown below:
(cid:129) Composite structures with interlaminardelaminations:prediction of
delamination growth under staticloads.
(cid:129) Debondinganalysis:predictionofdebondingonsetandgrowthunderstaticloads.
(cid:129) Crack growth inthin metallic structures(structures with high plasticity).
Besidesaccuracy,INTAfocusesondevelopingefficienttechniquesfromacompu-
tationalpointofview(reasonablecomputationandpostprocessingtime)aswellas
understanding and correcting the mesh size effects (FE results dependency on
meshsize).
2 DELAMINATION GROWTH IN COMPOSITES
The general trend in modern aircraft structures is the progressive replacement of
metallicmaterialswithcomposites.Compositesexhibitsuperiorstructuralproperties
suchashigherstressallowable,betterbehaviorinfatigueanddamagetolerance,less
sensitivitytocorrosionphenomena,etc.BoththenewAirbusA350andBoeingB787
eachwithover50%oftheirstructuremadeupofcompositesareillustrationsofthis
tendency. Thefuel consumptionof these aircrafts isreduced around 20%.