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How can you identify common failures in aerospace materials?

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Aerospace materials are subjected to extreme conditions of temperature, pressure, stress, and fatigue, which can lead to various types of failures. These failures can compromise the safety, performance, and reliability of aerospace structures and components. Therefore, it is essential to identify and understand the common failure modes and mechanisms of aerospace materials and how to prevent or mitigate them. In this article, you will learn how to use different methods and tools to detect and analyze the signs and causes of common failures in aerospace materials.

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Sergio Antonio Mu?oz Pinzón

Welding Senior Expert en Alstom
Paul A. Burke, PhD

Space Physicist at The Johns Hopkins University Applied Physics Laboratory || Faculty at The Johns Hopkins…
Rashmi Gururajarao

Co-Founder Director @ Manleo Designs: Helping people adopt affordable Probing that ???? ???? their profitability &…

1 Visual inspection

Visual inspection is the simplest and most widely used method to identify failures in aerospace materials. It involves examining the surface and shape of the material for any cracks, deformations, discolorations, corrosion, or other defects. Visual inspection can be done by the naked eye or with the help of magnifying devices, cameras, or drones. Visual inspection can provide a quick and easy way to assess the condition of the material and identify any obvious or superficial failures. However, it cannot reveal the internal or hidden failures that may exist beneath the surface or inside the material.

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Sergio Antonio Mu?oz Pinzón

Welding Senior Expert en Alstom
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Visual testing can in some cases reveal internal defects, I have detected incomplete penetration in a weld with permanent backing that was previously VT inspected, inspector did not check the ends of the machined weld where the defects came out in a exposed surface, so with experience you can smell things that could be invisible at a first glance.

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2 Non-destructive testing

Non-destructive testing (NDT) is a method to identify failures in aerospace materials without damaging or altering the material. It uses various techniques to probe the material with different types of energy, such as sound, light, radiation, or electricity, and measure the response or changes in the material. Some common NDT techniques are ultrasonic testing, radiographic testing, eddy current testing, thermographic testing, and acoustic emission testing. NDT can detect and locate the internal or hidden failures that visual inspection cannot, such as cracks, voids, delamination, or inclusions. NDT can also measure the properties and characteristics of the material, such as thickness, density, elasticity, or conductivity.

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Sergio Antonio Mu?oz Pinzón

Welding Senior Expert en Alstom
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Shearography, interferometry, holography, DIC among others are techniques that uses light to assess strain and therefore damage in materials, including composites

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3 Destructive testing

Destructive testing (DT) is a method to identify failures in aerospace materials by intentionally breaking or damaging the material. It uses various techniques to apply controlled loads, stresses, or strains to the material and observe the resulting behavior or failure. Some common DT techniques are tensile testing, compression testing, bending testing, fatigue testing, and fracture toughness testing. DT can determine the strength, stiffness, ductility, toughness, and fatigue life of the material and how it fails under different conditions. DT can also reveal the microstructure and composition of the material and how they affect the failure mode and mechanism.

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4 Failure analysis

Failure analysis (FA) is a method to identify the causes and consequences of failures in aerospace materials. It involves collecting and examining the failed material and any relevant data, such as design specifications, operating conditions, maintenance records, or accident reports. It also involves performing various tests and experiments to reproduce or simulate the failure and analyze the results. FA can identify the root causes and contributing factors of the failure, such as material defects, design flaws, manufacturing errors, environmental effects, or human errors. FA can also evaluate the impact and severity of the failure and recommend corrective or preventive actions.

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5 Computational modeling

Computational modeling (CM) is a method to identify and predict failures in aerospace materials by using mathematical equations and algorithms to represent the material and its behavior. It involves creating and solving computational models that simulate the material's structure, properties, loading, and failure. It also involves validating and verifying the models with experimental data and observations. CM can provide insight and understanding of the failure mode and mechanism at different scales and levels, such as atomic, molecular, or macroscopic. CM can also explore and optimize the material's performance and reliability under various scenarios and conditions.

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Paul A. Burke, PhD

Space Physicist at The Johns Hopkins University Applied Physics Laboratory || Faculty at The Johns Hopkins University Whiting School of Engineering
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Computational modeling can only go as far as it's validation and verification will allow it to go. A reliable computational model must be backed up by empirical data.

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6 Data analytics

Data analytics (DA) is a method to identify and prevent failures in aerospace materials by using statistical and machine learning techniques to analyze large and complex data sets. It involves collecting and processing data from various sources, such as sensors, monitors, or databases, that capture the material's status, performance, or condition. It also involves applying data analytics techniques, such as descriptive, predictive, or prescriptive analytics, to extract useful information and insights from the data. DA can identify patterns, trends, anomalies, or correlations in the data that indicate or forecast the occurrence or risk of failure. DA can also suggest actions or solutions to improve or maintain the material's quality and durability.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Rashmi Gururajarao

Co-Founder Director @ Manleo Designs: Helping people adopt affordable Probing that ???? ???? their profitability & productivity through ???????????? Designs
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Another key step in the process to avoid failure is methods used begore, during and post inspection in the CNC Machining operations. Probes, Tool setters, CMM inspection are extremely critical to maintain high accuracy required in Aerospace engineering.

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How can you identify common failures in aerospace materials?

1

2

3

4

5

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1 Visual inspection

2 Non-destructive testing

3 Destructive testing

4 Failure analysis

5 Computational modeling

6 Data analytics

7 Here’s what else to consider

Aerospace Engineering

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How can you identify common failures in aerospace materials?

1

2

3

4

5

6

7

1 Visual inspection

2 Non-destructive testing

3 Destructive testing

4 Failure analysis

5 Computational modeling

6 Data analytics

7 Here’s what else to consider

Aerospace Engineering

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