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Investigating FOD Damage Part 2

Investigating FOD Damage Part 2. Example 1: DC-10 #2. Vibrations in #2 engine during take-off Take-off aborted Engine then pulled for fan blade damage. Example 1: DC-10 #2. Good place to sample. Circular symmetry. Apparent thread marks. Example 1: DC-10 #2. LE fan blade damage.

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Investigating FOD Damage Part 2

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  1. Investigating FOD DamagePart 2 George A. Morse, FAST, Inc.

  2. Example 1: DC-10 #2 • Vibrations in #2 engine during take-off • Take-off aborted • Engine then pulled for fan blade damage George A. Morse, FAST, Inc.

  3. Example 1: DC-10 #2 Good place to sample Circular symmetry Apparent thread marks George A. Morse, FAST, Inc.

  4. Example 1: DC-10 #2 LE fan blade damage George A. Morse, FAST, Inc.

  5. Example 1: DC-10 #2: Analysis • Most of the impacts occurred to the LE concave surface, indicating that the impacting object entered through the intake • There is circular damage symmetry • There is rectangular damage symmetry • There are apparent thread marks • Blades are made of titanium George A. Morse, FAST, Inc.

  6. Example 1: DC-10 #2 FAST samples reveal nickel - chrome plated steel tool material George A. Morse, FAST, Inc.

  7. Example 1: DC-10 #2: Analysis Source of thread marks A nickel - chrome plated crescent wrench accounts for the damage George A. Morse, FAST, Inc.

  8. Example 2: Blade fracture in HPC • 6 HPC blades were submitted for analysis • The 3 blades on the right are HPC-7 blades • The 3 blades on the left are HPC-9 blades • An HPC-9 blade is broken George A. Morse, FAST, Inc.

  9. Example 2: Blade fracture in HPC Two HPC-7 blades with TE cracks George A. Morse, FAST, Inc.

  10. Example 2: Blade fracture in HPC • HPC-9 blade shows LE impact • Fatigue crack growth emanates from LE impact • Knife edge fast fracture shear lip at TE TE shear lip Fatigue LE impact George A. Morse, FAST, Inc.

  11. Example 2: Blade fracture in HPC 1000X Scanning electron microscope (SEM) photo showing fatigue striations in fatigue crack growth zone of HPC-9 blade George A. Morse, FAST, Inc.

  12. Example 2: Blade fracture in HPC 500X SEM photo showing ductile dimples in TE fast fracture zone of HPC-9 blade George A. Morse, FAST, Inc.

  13. Example 2: Blade fracture in HPC Aluminum fastener material found as foreign debris George A. Morse, FAST, Inc.

  14. Example 3: B-727 #2 Engine • B-727 had been airborne approximately 1 hour. • The plane was cleared for a climb from FL 300 to Fl 340. • During the level off, the #2 engine disintegrated. • What happened? George A. Morse, FAST, Inc.

  15. Example 3: B-727 #2 Engine Blade remnants George A. Morse, FAST, Inc.

  16. Example 3: B-727 #2 Engine These circular shaped impacts are not the result of liberated airfoil and are good places to take FAST samples George A. Morse, FAST, Inc.

  17. Example 3: B-727 #2 Engine Nickel-chrome plated socket material found as foreign debris George A. Morse, FAST, Inc.

  18. Example 4: Fan Blade Damage Found on Arrival Two fan blades found with LE tip curls. Blade tips are curled in the direction opposite to engine rotation. George A. Morse, FAST, Inc.

  19. Example 4: Fan Blade Damage Found on Arrival • Only two fan blades damaged • The blade tip curls are smooth with no obvious impact deformation • The energy of the impact did not result in blade tearing • FAST samples revealed no foreign debris • This is consistent with ice damage • The ice ingestion occurred during a low power setting, probably during the approach phase • The scratch on one of the fan blades below the tip curl was due to the two blades being shipped together for analysis and not protected from contact with one another George A. Morse, FAST, Inc.

  20. Example 5: Fan Blade Damage FOA • Damage found on arrival (FOA) • Only three blades were damaged • Impacts resulted in blade tearing and loss of material • The impacts are smooth without obvious secondary impact deformation Concave surfaces shown, LE at top George A. Morse, FAST, Inc.

  21. Example 5: Fan Blade Damage FOA Large smooth blade curl This blade is torn George A. Morse, FAST, Inc.

  22. Example 5: Fan Blade Damage FOA • There was sufficient impact energy to result in blade tearing, which indicates the impacts occurred at a high power setting, probably during the takeoff roll • Black light test was negative for a bird strike • FAST samples revealed no foreign debris, which is consistent with ice damage • This example differs from example 4 in power settings at time of impact George A. Morse, FAST, Inc.

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