Failure Analysis Virtual Lab

1. David W. Dickinson Failure Analysis Virtual Lab A failure occurred on the tail section of a commercial aircraft (the failure was video recorded). The transportation safety board has called you in to look at the video and the failed weld in the structural beam weld. Click on the video to see the failure occurring. Click on the beam to analyze the failure. Click For Student Data Sheet

2. Would you like to find some properties of Aluminum Alloys and Other Data? What Type of Testing Do You Want To Do On This Part? What Type of Testing On a Similar Weldment? Cost Record Keep Track of Your Costs To Bill the Customer (Print out for Reference) All Done Write Report

3. Hardness Conversion Tables Al Alloy Chem & Type Al Alloys Properties Etching Al Alloys Return to Home Page

4. Metallographic Sectioning Slice Fracture Surface Slice Fracture Surface Return to Home Page

5. Examine Higher Magnification Microstructure Do Microhardness Traverse Across Weld

6. Macro-Section Select Location Return to Section Selection

7. 1000x 100x Keller’s Etch Return to Macrostructure

8. 1000x 100x Keller’s Etch Return to Macrostructure

9. 1000x 100x Keller’s Etch Return to Macrostructure

10. 1000x 100x Keller’s Etch Return to Macrostructure

11. 1000x 100x Keller’s Etch Return to Macrostructure

12. Hardness (Hv 0.2) 82 80 75 70 66 63 60 Millimeters Start Here by Placing Hardness Indentation Return To Section 61 63 65 68 71 76 75 80 85 90 99 107 110 112 111

13. Examine Higher Magnification Microstructure Do Microhardness Traverse Across Fracture Return to Section Selection

14. Macro Section Make Selection Return to Section Selection

15. 1000x 100x Keller’s Etch Return to Macrostructure

16. 1000x 100x Keller’s Etch Return to Macrostructure

17. 1000x 100x Keller’s Etch Return to Macrostructure

18. 1000x 100x Keller’s Etch Return to Macrostructure

19. Hardness (Hv 0.2) 110 111 110 109 111 115 122 Start Here by Placing Hardness Indentation Return To Section 120 107 108 111 108 113 109 111 107 111 110 109 110 114 112

20. Fracture Surface Bottom Select Analysis Option Scanning Electron Microscopy Optical Microscopy Return To Section

21. Fracture Surface Bottom Return to Fracture Return To Microscopy Choices

22. Fracture Surface Bottom Return to Fracture Al Al2O3 Return To Microscopy Choices

23. Fracture Surface Top Select Analysis Option Scanning Electron Microscopy Optical Microscopy Return To Section

24. Fracture Surface Top Return to Fracture Return To Microscopy Choice

25. Fracture Surface Top Return to Fracture Return To Microscopy Choice

26. Make a Weld: Select Material Return to Home Page 6061 T0 As Welded 5356 Wire 6061 T6 As Welded 4043 Wire 2219 T87 As Welded 2319 Wire 5456-H116 As Welded 5356 Wire

27. 6061 T6 As Welded 4043 Wire Tensile Sample Prep Microhardness Prep Return to Weld Selection

28. 6061 T6 As Welded 4043 Wire (ksi) Return

29. 6061 T6 As Welded 4043 Wire Your technician says that welds can be made with varying heat input on this material. Do you want him to make 3 welds each with different heat input and do microhardness traverses? YES DPH (500g) 120 90 60 Return

30. 6061 T6 As Welded 4043 Wire 120 DPH (500g) 100 80 Return

31. 6061 T0 As Welded 5356 Wire Tensile Sample Prep Microhardness Prep Return to Weld Selection

32. 6061 T0 As Welded 5356 Wire Return

33. 6061 T0 As Welded 5356 Wire DPH (500g) 60 50 40 30 Return

34. 2219 T87 As Welded 2319 Wire Tensile Sample Prep Microhardness Prep Return to Weld Selection

35. 2219 T87 As Welded 2319 Wire Return

36. 2219 T87 As Welded 2319 Wire Return

37. 5456-H116 As Welded 5356 Wire Tensile Sample Prep Microhardness Prep Return to Weld Selection

38. 5456-H116 As Welded 5356 Wire Return

39. 5456-H116 As Welded 5356 Wire Return

40. Write Report Please decide on who your audience will be for this report and prepare a report for that audience with all the appropriate appendices.