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The Gravity of Error: Forensic Engineering in Flight


Key Insights
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  • Forensic engineering reveals how microscopic flaws lead to catastrophic failures in aerospace systems.
  • Material interactions under extreme conditions require specialized lubrication and maintenance strategies.
  • Electrical systems in aging vehicles are vulnerable to mechanical damage and insulation degradation.
  • Propeller failures demonstrate the importance of non-destructive testing and design for dynamic tolerance.
  • Failure analysis combines microscopy, spectroscopy, and mechanical testing to prevent future incidents.

References
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  1. Allegrucci, L., Amura, M., Bagnoli, F., & Bernabei, M. (2009). Fatigue fracture of a aircraft canopy lever reverse. Engineering Failure Analysis, 16, 391–401.
  2. Amura, M., Allegrrucci, L., De Paolis, F., & Bernabei, M. (2013). Fatigue fracture of an AMX aircraft main wheel. Engineering Failure Analysis, 27, 194–202.
  3. Ashby, M. F. (2009). Materials and the environment: Eco-informed materials choice. Butterworth-Heinemann.
  4. Ashby, M. F. (2011). Materials selection in mechanical design (4th ed.). Butterworth-Heinemann.
  5. Kushan, M. C., Diltemiz, S. F., & Sackesen, I. (2007). Failure analysis of an aircraft propeller. Engineering Failure Analysis, 14, 1693–1700.
  6. Makhlouf, A. S. H., & Aliofkhazraei, M. (Eds.). (2016). Handbook of materials failure analysis with case studies from the aerospace and automotive industries. Butterworth-Heinemann.
  7. McDanels, S. J. (1999). Failure analysis of a 115 VAC 400 Hz main engine controller wire from the midbody port side lower wire tray 11/12 frame from OV-102 that shorted during the launch of STS-93. NASA Report KSC-MSL-0729-1999.
  8. Newman, J. C., Jr., James, M. A., & Zerbst, U. (2003). A review of the CTOA/CTOD fracture criterion. Engineering Fracture Mechanics, 70(3–4), 371–385.
  9. Wright, M. C. (2008). International Space Station (ISS) Expedition 16 Starboard Solar Alpha Rotary Joint (s-SARJ) debris analysis. Internal report KSC-MSL-2008–0099.
  10. Yu, Z., & Xu, X. (2006). Failure analysis and metallurgical investigation of diesel engine exhaust valves. Engineering Failure Analysis, 13, 673–682.