INVESTIGATION OF AERONAUTICAL AND ENGINEERING COMPONENT FAILURES
CONTENTS FAILURE ANALYSIS OR FORENSIC ENGINEERING? SYNOPSIS HISTORIC FAILURE ANALYSIS CONVENTIONAL FAILURE ANALYSIS PRODUCT DEFECTS CAUSAL ANALYSIS QUALITATIVE ANALYSIS SEMI-QUANTITATIVE ANALYSIS COMPUTER-AIDED CAUSAL ANALYSIS CASE STUDY: FAILURE OF A 45-INCH KITCHEN KNIFE DESIGN CALCULATIONS AND MODELLING MINER’S LAW FOR LIFE-TIME CUMULATIVE DAMAGE PREDICTION SUMMATION OF CONVENTIONAL FAILURE ANALYSIS FORENSIC ENGINEERING CASE STUDY: COLLAPSE OF THE RANA PLAZA FACTORY RANGE OF COMPETENCE A GENERIC FAILURE ANALYSIS OR A FORENSIC INVESTIGATION? INITIAL FORENSIC APPROACH TO FAILURE REVERSE ENGINEERING (TE ‘WEAKEST-LINK’ PRINCIPLE) ASSOCIATED COSTS OF FORENSIC INVESTIGATION 110 HISTORIC FAILURES 1101 COMPUTER-AIDED TECHNOLOGY LIMITATIONS 111 ANALYTICAL TECHNIQUES 112 DISSEMINATION OF KNOWLEDGE AND EXPERIENCE 1121 POPULAR BOOKS 1122 EVENT REPORTING 1123 TEXTBOOKS 1124 FORENSIC ENGINEERING TEACHING 113 CASE STUDY TEMES 1131 TE SAYANO-SHUSHENSKAYA POWER STATION ACCIDENT OF 114 RESEARCH-ENRICHED TEACHING 115 CONCLUDING REMARKS REFERENCES INITIAL ASPECTS OF FORENSIC FAILURE INVESTIGATION INTRODUCTION TREE ESSENTIAL ‘ABSTRACT’ ASSETS FOR THE INVESTIGATOR ASSESSING THE SITUATION INITIAL VISUAL OBSERVATION AS A FACT-FINDING EXERCISE TE FAILURE SCENARIO SUMMARY OF UNDERSTATED INVESTIGATIVE SKILLS VISUAL OBSERVATION CASE STUDY: VISUAL COMPARISON CASE STUDY: COMMON (ENGINEERING) SENSE FORENSIC PHOTOGRAPHY RECORD KEEPING WITNESS EVIDENCE DOCUMENTARY EVIDENCE CASE STUDY: FATAL AIRCRAF CRASH PRODUCT AND MATERIAL STANDARDS CASE STUDY: STEP LADDER FAILURE PATENTS SURVIVING REMAINS (DETRITUS) GATHERING OF EVIDENCE AND THE ‘CHAIN OF EVIDENCE’ 210 PRODUCT LIABILITY 2101 CASE STUDY: PREMATURE FAILURE OF A PRESENTATION CAKE KNIFE 211 TE ‘CORPORATE’ ENVIRONMENT 2111 CASE STUDY: BIRD-STRIKE TESTING OF AIRCRAF ENGINES 212 ABUSE OR MISUSE 2121 CASE STUDY: ABUSE 2122 CASE STUDY: MISUSE A FRAMEWORK OR METHODOLOGY FOR FORENSIC INVESTIGATION BACKGROUND TO FAILURE ANALYSIS METHODOLOGY AN INVESTIGATIVE PATH FOLLOWED BY THE WRITER INTUITION (REASONING) AND A ‘STRUCTURED’ INVESTIGATION FRAMEWORK INDIVIDUAL STAGES OF INVESTIGATION TE FIELD INVESTIGATION KIT INITIAL APPROACH TO FAILURE INVESTIGATION BACKGROUND DATA COLLECTION SIFING THE EVIDENCE 3261 CASE STUDY: FAILURE OF A NEW DESIGN OF HORSE BIT RECORDS SINGLE ITEMS OF EVIDENCE TE FAILURE DETECTIVE TRANSFORMATION STRESSES ESTABLISHING A LOAD TRANSFER PATH TO DETERMINE THE ‘WEAKEST LINK’ CASE STUDY: TE WEAKEST-LINK PRINCIPLE CASE STUDY: FAILURE OF A BACKHOE DIPPER ARM COMPUTER-AIDED TECHNOLOGIES CASE STUDY: FAILURE OF AN OPEN-ENDED SPANNER TE FORENSIC ENGINEERING REPORT CONCLUDING REMARKS ANALYTICAL METHODS INTRODUCTION TO A TYPICAL FORENSIC ENGINEERING ‘TOOLBOX’ NON-DESTRUCTIVE TESTING (NDT) CASE STUDY: FAILURE OF A POWER TRANSMISSION SHAF CRACK DETECTION AND THE HUMAN EYE SURFACE APPEARANCE OF COMMON CRACKS OTHER CRACK DETECTION TECHNIQUES HARDNESS TESTING CASE STUDY: PIN-PUNCH SPLINTERING RELATIONSHIP BETWEEN HARDNESS AND TENSILE STRENGTH INDIRECT STRESS/STRAIN ANALYSIS BRITTLE LACQUER TECHNIQUE CASE STUDY: CYCLING ACCIDENT PHOTOELASTIC STRESS MEASUREMENT CONVENTIONAL (CONTACT) RADIOGRAPHY CASE STUDY: FAILURE OF A VEHICLE MOTHERBOARD CASE STUDY: HEAVY GOODS VEHICLE FIRE SUMMARY OF NDT INSPECTION FORENSIC OPTICAL MICROSCOPY MACROSCOPIC EXAMINATION EXAMINATION UNDER MAGNIFCATION: OPTICAL MICROSCOPY 4721 UNIVERSAL SERIAL BUS (USB) MICROSCOPES 4722 WIFI-ENABLED MICROSCOPES REFECTED LIGHT MICROSCOPY STEREO MICROSCOPY METALLOGRAPHY SCANNING ELECTRON MICROSCOPY TE ENVIRONMENTAL SCANNING ELECTRON MICROSCOPE (ESEM) CASE STUDY: HIT-AND-RUN ACCIDENT 410 OPTICAL VERSUS SCANNING MICROSCOPY 4101 CASE STUDY: PRINTED CIRCUIT BOARD (PCB) FAILURE 4102 CASE STUDY: PROTOTYPE PCB FAILURE 411 ENERGY DISPERSIVE X-RAY ANALYSIS (EDAX) 412 DESTRUCTIVE TESTING METHODS 4121 TENSILE TESTING 4122 FLEXURE OR BENDING 4123 CASE STUDY: CRACKING OF ALUMINIUM PRESSINGS 4124 TORSION TESTING 4125 SHEAR TESTING 4126 IZOD OR CHARPY IMPACT TEST 4127 DIFERENTIAL SCANNING CALORIMETRY (DSC) 4128 CASE STUDY: ELECTRONIC COMPONENT REGISTRATION DIFCULTIES 413 NOVEL TOOLS AND TECHNIQUES 4131 TE CONTOUR METHOD 4132 NEUTRON DIFRACTION 4133 NANO TEST SYSTEMS 4134 FLASH TERMOGRAPHY 4135 TERMOGRAPHIC SIGNAL RECONSTRUCTION (TSR) 4136 ELECTROMAGNETICALLY INDUCED ACOUSTIC EMISSION (EMAE) 4137 PULSED EDDY CURRENT (PEC) 4138 MICROWAVE TECHNOLOGY 414 MICROGRAPH ACKNOWLEDGEMENTS SOURCES OF STRESS AND SERVICE FAILURE MECHANISMS FUNDAMENTAL MECHANICAL BACKGROUND STRESSES AND STRAINS DUCTILE AND BRITTLE TRANSITION FRACTURE TOUGHNESS AND LINEAR ELASTIC FRACTURE MECHANICS (LEFM) LIMITATIONS OF A FRACTURE MECHANICS APPROACH STRESS CONCENTRATION (KT) CASE STUDY: STRESS CONCENTRATION – CEMENT MILL POWER INPUT SHAF RESIDUAL STRESSES SUMMARY OF FUNDAMENTAL MECHANICAL BACKGROUND SERVICE FAILURE MECHANISM CASE STUDY: HUBBLE SPACE TELESCOPE MIRROR AND THE TEAM PHILIPS CATAMARAN MECHANICAL FAILURE HYDROGEN EMBRITTLEMENT SOURCES OF HYDROGEN HYDROGEN-INDUCED BRITTLE FAILURE REDUCING THE PROBABILITY OF HYDROGEN EMBRITTLEMENT IMPACT BENDING TORSION CREEP FATIGUE MINIMISING FATIGUE CASE STUDY: FAILURE OF A POWER TRANSMISSION GEAR WHEEL FATIGUE-RELATED FAILURE MODES APPROXIMATING THE HISTORY OF A FATIGUE FAILURE SUMMATION OF FATIGUE AS A SERVICE FAILURE MECHANISM 510 WEAR 511 CORROSION 5111 CASE STUDY: TE STATUE OF LIBERTY 5112 STRESS CORROSION CRACKING (SCC) 5113 CASE STUDY: SCC OF BRASS IMPELLER BLADES 512 MANUFACTURING FABRICATION AS A SOURCE OF STRESS 5121 CASTING 5122 CASTING FAILURE ANALYSIS 5123 CASE STUDY: EXTRUSION PRESS 5124 WELDING 5125 QUENCH CRACKING 5126 TEMPERING AND TOUGHENING FRACTURE MORPHOLOGY AND TOPOGRAPHY WHAT IS MEANT BY THE TERM ‘FAILURE’? FRACTURE PATH AND FRACTURE MORPHOLOGY DUCTILE OR BRITTLE FAILURE BRITTLE OVERLOAD (FAST) FRACTURE FEATURES DUCTILE/BRITTLE TRANSITION FRACTURE SURFACE FEATURES FATIGUE FRACTURE LOW- AND HIGH-CYCLE FATIGUE CHEVRON AND STRIATION COMBINATION CASE STUDY: INTERNAL COMBUSTION ENGINE CRANK-SHAF FAILURE SPLINED SHAFING RATCHET MARKS TERMAL FATIGUE ADDITIONAL MODES OF PROGRESSIVE FAILURE CORROSION STRESS CORROSION CRACKING (SCC) CREVICE CORROSION ENVIRONMENTALLY ASSISTED CRACKING (EAC) WEAR WEAR OF ROLLING CONTACT ELEMENTS CASE STUDY: AN AGRICULTURAL BEARING FAILURE SUMMARY THE ENGINEER IN THE COURTROOM TE ROLE OF THE ‘EXPERT’ TE EXPERT REPORT PRE-TRIAL MEETING OF EXPERTS ALTERNATIVE DISPUTE RESOLUTION TE SINGLE JOINT EXPERT (SJE) TE ROLE OF CASE LAW TE ENGINEER IN THE COURTROOM IN SUMMARY ENGINEERING FAILURE CASE STUDY ANALYSIS AS A TEACHING TOOL HISTORIC USE OF CASE STUDY ANALYSIS ANCIENT ROME LATE GEORGIAN–EARLY VICTORIAN ERA TO DATE AIR ACCIDENTS, MORTALITY STATISTICS AND FAILURE CASE STUDIES WHAT CONSTITUTES A ‘CASE STUDY’? CASE STUDY: NORTH-SEA FERRY ENGINE BOLTS CASE STUDY: HOT-SPOT BOILING EROSION WRITING A RELEVANT CASE STUDY CASE STUDY: CRANKPIN AXLE FROM A BICYCLE EXAMPLES OF CASE STUDY TEMES CASE STUDY: COLLAPSE OF TERMINAL 2E CHARLES DE GAULLE INTERNATIONAL AIRPORT MARINE DISASTER CASE STUDY EXAMPLES CASE STUDY: LOSS OF THE FIRST BRITISH OF-SHORE OIL DRILLING PLATFORM CASE STUDY: LOSS OF THE ALEXANDER KIELLAND SEMI-SUBMERSIBLE OIL DRILLING PLATFORM COLLIERY DISASTER CASE STUDY EXAMPLES ENGINEERING IN MEDICINE CASE STUDY: TE DEPUY ULTAMET METAL-ON-METAL (MOM) ARTICULATION HIP REPLACEMENT FAILURE DUE TO MANUFACTURING FAULTS TRAUMATIC FAILURE FEMORAL STEM FAILURE OF A TOTAL HIP PROSTHESIS FAILURE OF FREIGHT CONTAINERS SPLINTERING FAILURE OF A PIN PUNCH FAILURE OF A VEHICLE FUEL DELIVERY RAIL FAILURE OF A PRESENTATION CAKE KNIFE FAILURE OF AN AEROBIC MINI-STEPPER FAILURE OF OIL PUMP GEARING REPLACEMENT GEARS FOR HGV (HEAVY TRUCK) GEARBOX 910 VEHICLE ENGINE RADIATOR COOLING FAN COMPONENT FAILURE IN ROAD TRAFFIC INCIDENTS AND ACCIDENTS 100 INTRODUCTION 101 MOTOR VEHICLE ACCIDENTS AS A RESULT OF STEERING SHAF FAILURE 1011 FATAL CRASH OF A SMALL FAMILY SALOON CAR 1012 HEAVY GOODS VEHICLE (HGV) ACCIDENT 1013 STEERING SHAF FAILURE ON A VINTAGE CAR 1014 TE ‘BOY RACER’ 102 WHEEL DETACHMENTS 1021 WHEEL NUT LOOSENING AND STUD FATIGUE 1022 WHEEL DISH CRACKING 1023 STUB AXLE FAILURE 103 BRAKE PIPE FAILURES 1031 BRAKE FAILURE BY FATIGUE 1032 FAILURE OF A POLYMERIC AIR-BRAKE HOSE 104 GEARBOX SYNCHRONISER RING 105 FATAL TOW HITCH ACCIDENT FRAUDULENT INSURANCE CLAIMS 110 INTRODUCTION 111 PERFORATED CENTRAL HEATING RADIATOR 112 PERFORATED OIL FILTER 113 MAJOR ENGINE DAMAGE, ALLEGEDLY DUE TO LOSS OF OIL 1131 A PROBABLE MOTIVE FOR INFICTING THE DAMAGE OBSERVED 114 ENGINE HAIRLINE CRACKING AS A RESULT OF AN ALLEGED IMPACT 115 AGRICULTURAL TRACTOR ENGINE DAMAGE 116 CON-ROD FAILURE 117 PISTON FAILURE ON A RACING CAR CRIMINAL CASES 120 INTRODUCTION 121 COUNTERFEIT COINS 1211 TE USE OF CURRENCY AS A FEEDSTOCK MATERIAL FOR COUNTERFEITING 1212 TE BASE METAL £1 COIN 1213 TE ‘STRUCK’ £1 COIN 1214 FOOTNOTE TO COUNTERFEITING 122 STAGED OR FRAUDULENT ROAD TRAFC ACCIDENTS WITHIN THE UK 1221 DELIBERATE ‘DAMAGE’ 1222 CAR HIRE INSURANCE FRAUD 1223 STAGED ‘ACCIDENTS’ 123 SHOTGUN PELLETS 124 METAL TEF 1241 AN ADDITIONAL METAL TEF CASE 125 CHAIN FROM MURDER 126 COIN BOX BUSTERS 127 RE-MELTING BEER BARRELS