Failure Analysis of Bolt of Rear Mounting Trunion of an Aero-Engine: A Case of Bending Induced Chevron Pattern as well as Fatigue Failure on the Same Fracture Surface

Abstract

Present work describes the failure investigation of failed bolt of starboard rear mounting trunion of an aero-engine. Multiple fracture initiation points are noticed. This is a classic case of a single bending type of load initiating reversed bending fatigue as well as chevron pattern on the same fracture surface. Visually observed bending phenomenon supports the each type of failure mode. More interestingly, point of initiation of fast as well as the reversed bending fatigue failure is the same, although those two events have been found to be separate phenomena. It has been established that two different fatigue crack fronts, typical of reversed bending fatigue phenomenon propagated towards each other to make half of the cross-section fractured, while the another half failed by chevron patterned fast fracture. In this, the fast fracture of one half has preceded the reversed bending fatigue fracture of the other half, although the former is not responsible for happening of the later. Modes of fracture and factors influencing have been established in this article with emphasis on circumstantial evidence involving background information and visual examination, supported often by the open literature. Presence of cadmium (Cd) and its possible source, residence time and relative presence on differently fractured surfaces have offered important clues on establishing the sequence and relative inter-dependence of the said two fracture types. Presence of cadmium on the fracture surfaces, multiple crack initiation sites and numerous well-revealed secondary cracks on Branson cleaned fracture surface indicate that the cracks pre-existed on the material even before the cadmium plating and manifestation of chevron pattern is its extreme revelation. This pre-existing chevron pattern primarily aggravated the present failure through bending fatigue phenomenon in the later stages. Low alloy steel (ASTM grade 16) with presently used hardness (340 HV) level does not seem to suit the present application, as it is clear from its extreme brittleness as manifested by pre-existing cracks.