Engineering Failure Analysis of Aerospace Applications and suggest design improvements

Components perform their function and eventually fail for a variety of reasons, components ranging from small daily life use products to components or sections in major structures and enterprises. It is critical to find out the reason of a given malfunction in order to resist similar fai

Project Title

Engineering Failure Analysis of Aerospace Applications and suggest design improvements

Project Area of Specialization

Mechanical Engineering

Project Summary

Components perform their function and eventually fail for a variety of reasons,
components ranging from small daily life use products to components
or sections in major structures and enterprises. It is critical to find
out the reason of a given malfunction in order to resist similar failures in
the future. Overlooking this source of failure could lead to disaster in the
future. Any failure requires a certain amount of skill to analyse and determine
the cause. Failure of a structural component of an aircraft can have
disastrous repercussions, resulting in the loss of life and the aircraft it self.
Defects and failures in aircraft construction must thus be investigated in
order to prevent such incidents. Any breakdown of the structural elements
used on-board platforms must be investigated in order to prevent further
accidents on another aircraft. Economic and safety concerns, however,
are driving forces in the development of a more efficient failure analysis.

Project Objectives

Engineering failure analysis aims to identify the root causes of components
failure, devise strategies to prevent further failures, adjust design and production
methods to manufacture a product or system that is resistant to
failure.Aerospace components fail during flight or on the ground. The scope of
the project is understanding the failure causes of material in the components.
It also covers the failure mechanism analysis of the aerospace
components.

Project Implementation Method

Failure analysis is a step by step process. Following are the main analysis
steps:
• Background History
• Initial inspection
• Fractography
• Analysis of material composition
• Analysis of material properties
• Structural analysis of the component
• Final Step
Steps are explained in detail as:
1. Background History
When we secure the sample, first of all we collect all the data and history
related to that component. The data includes the information about the specific function of that component, its mechanism, and all the data provided
by the manufacturer. We will also procure the statistical data about
the component i.e. the frequency of its failure etc.
2. Initial Inspection
In this step the component is inspected with the naked eye. For better
results, images can be taken through a camera with high magnification
lens. In this step one can find out the nature of fracture or failure(if visible).
3. Fractography
The study of fractured surface is fractography. Main steps involved in fractography
are given as following:
• Visual Examination (Non Destructive inspection)
• Stereoscopic Viewing
• Microscopic Examination (Scanning and transmission Electron Microscopy)
• Micro Analysis of surface (Energy dispersive/Wave length X-ray Analysis)
4. Analysis of material composition
In this step different techniques like XRF (X-Ray Fluorescence Spectrometry),
ICP-OES (Inductively Coupled Plasma Optical Emission Spectroscopy)
etc. are used to find out the material composition of the component. If the
composition relates to the composition provided by the manufacturer then
we move onto the next steps.

5. Analysis of material properties
In this step we find out the yield strength, hardness etc. of the component
under testing. We compare our analysis results with the properties
provided by the manufacturer and draw conclusions.
6. Structural analysis of the component
In this step we simulate the service of the component in software like ANSYS
etc. to understand the structural behavior of the component. We
can also perform structural analysis using FEM techniques. From this step
we can find out the boundary conditions, stress concentrations or we can
comment on the design of the component.
7. Final step
Finally, we analyze all the reults obtained from the above performed steps.
Based on these results we compile the conclusions about the failure of the
component. In the end, we formulate a report about the failure analysis of
the component.

Benefits of the Project

By identifying the failure in the aerospace applications and suggesting design improvements can avoid catatrophes in the future and also saves alot of money that may be spent on the repititive changing and maintainance of the damaged or failed parts.

Technical Details of Final Deliverable

final deliverable is actaully the suggestions and conceptual design improvements in the design of the failed part.

Final Deliverable of the Project

Software System

Core Industry

Others

Other Industries

Manufacturing

Core Technology

Others

Other Technologies

Sustainable Development Goals

Industry, Innovation and Infrastructure

Required Resources

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