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Failure Analysis of Engineering Structures: Methodology and Case Histories (#05127G)
Failure Analysis
of Engineering Structures
Methodology and
Case Histories
ASM International姞
Materials Park, Ohio 44073-0002
www.asminternational.org
Failure Analysis of Engineering Structures: Methodology and Case Histories Copyright © 2005 ASM International®
V. Ramachandran, A.C. Raghuram, R.V. Krishnan, S.K. Bhaumik, p102-106 All rights reserved.
DOI:10.1361/faes2005p102 www.asminternational.org
CASE 17
Failure of Dowel
Bolts in an Aircraft Engine
Summary
The spur and bevel gears of an aircraft engine were fastened by
Testing Procedure and Results
a set of six dowel bolts. Following a few incidents of dowel bolt
failure, the diameter of the bolts at the shank was increased. Still, Macroexamination
there were a series of accidents caused by the failure of dowel
bolts. Detailed investigations revealed that the bolts failed due to The bevel and spur gears along with the failed dowel bolts in
fatigue. Fatigue was initiated by fretting in some bolts. position are shown in Fig. CH17.1. All six bolts failed inside the
bevel gear. The fracture surfaces of the halves held in the spur gear
were damaged. Those in the bevel gear are shown in Fig. CH17.2.
After removing the bolts, the distance from the bolt collar to the
fracture origin was measured and found to range from 5.8 to 8.4
Background mm in one engine. The fracture surfaces of the six bolts are shown
in Fig. CH17.3. All of them contained beach marks covering a
The spur and bevel gears of an aircraft engine were fastened major portion of the fracture surface. The fracture had originated
together with a set of six dowel bolts of 8.5 mm diameter. Because at the outer periphery and progressed inward (Fig. CH17.4). In a
there were a few incidents of dowel bolt failure, the bolt diameter few cases, two diametrically opposite origins were found (Fig.
at the shank was increased from 8.5 to 9.2 mm based on a seven- CH17.5).
bolt configuration used in another engine. Since then, there were The shanks of most of the bolts and bolt holes contained cir-
a series of accidents caused by the failure of the modified dowel cumferential grooves (Fig. CH17.6, CH17.7). Severe fretting
bolts. marks with associated debris were noticed in some bolts at the
fracture origin (Fig. CH17.8). The web portion of the spur gears The bolts with double fracture origins showed dimple rupture at
showed lapping marks around the shaft over a large area, while the central region (Fig. CH17.12). In each assembly, one or two
wear marks were observed on either side of the bolt holes (Fig. bolts showed mixed intercrystalline and transcrystalline fracture
CH17.9). Near the bolt hole, marks resembling erosion tracks with features ahead of the beach marks (Fig. CH17.13).
their origin at the hole and progressing radially outward were ob-
served (Fig. CH17.10).
Metallography
Scanning Electron Fractography Metallographic examination was carried out on the barrel sur-
face of a few failed bolts. A number of cracks were observed close
The failed bolts were examined in a SEM. In each assembly, to the fracture surface, propagating in inter and transgranular mode
there were a few bolts with two fracture origins. At the origin, (Fig. CH17.14). The bolt heads, shanks, and longitudinal sections
fatigue striations were observed with an average spacing of 2.5 near the threaded region were also examined. Deep intergranular
lm (Fig. CH17.11). At other places on the same fracture surface, oxidation was observed on the bolts chosen at random, at all lo-
striations were also observed with an average spacing of 0.4 lm. cations excluding the shank (Fig. CH17.15).
The steel was relatively clean and contained a few sulfide, oxide,
and carbonitride inclusions. The steel was fine grained and the
1 mm 3 mm
Fig. CH17.2 Failed bolts in the bevel gear Fig. CH17.3 Fracture surfaces of the six failed bolts in the bevel gear
1 mm 10 m
Fig. CH17.4 SEM fractograph showing crack initiation at the outer pe- Fig. CH17.5 Two diametrically opposite fracture origins found in some
riphery and propagation inward bolts
104 / Failure Analysis of Engineering Structures: Case Histories
microstructure was tempered martensite. The raw material also had Chemical composition
a tempered martensitic structure. Element Raw material Failed bolt
Carbon 0.19 0.16
Silicon 0.30 0.31
Manganese 0.39 0.31
Nickel 4.20 4.40
Chemical Analysis Chromium 1.5 1.4
Molybdenum 0.11 0.11
Tungsten 0.70 0.57
The chemical composition of the raw material and a failed bolt Sulfur 0.004 0.009
is given in wt%: Phosphorus 0.007 ...
1 mm
20 m 20 m
Fig. CH17.8 Fretting marks and debris at the fracture origin in some bolts Fig. CH17.9 Wear marks in the bolt holes
Case 17: Failure of Dowel Bolts in an Aircraft Engine / 105
Hardness marked. On the fracture surfaces, the ratio of fatigue crack area to
the overload failure area was approximately 60:40.
The average hardness at 10 kg load was 370 HV on the failed
bolt and 430 HV on the raw material.
Discussion
Low-Cycle Fatigue Tests The chemical composition of the failed bolts conformed to the
specifications. The cleanliness and microstructure of the steel were
Low-cycle fatigue tests were carried out on heat treated and satisfactory. The hardness and microstructure suggested that cor-
phosphated samples at stress amplitude of 904 MPa and plastic rect heat treatment was given to the bolts. The intergranular oxi-
strain amplitude of 5.65 ⳯ 10ⳮ3. The unphosphated samples with- dation in the bolts is an abnormality even though the failure is not
stood 680 cycles, while the phosphated samples, 590 cycles. Con- directly related to this defect.
sidering the usual scatter in fatigue tests, the difference is not The presence of beach marks and striations on the fracture sur-
face indicates clearly that the failure was due to fatigue. The dif-
1 mm
10 m
Fig. CH17.10 Marks resembling erosion tracks with the origin at the bolt
hole
Fig. CH17.11 Fatigue striations in a failed bolt, at the fracture origin
10 m 5 m
Fig. CH17.12 Dimple rupture at the central region of the fracture with Fig. CH17.13 Mixed intercrystalline and transcrystalline fracture ahead of
double origins the beach marks in a bolt
106 / Failure Analysis of Engineering Structures: Case Histories
100 m
Fig. CH17.14 Cracks on the barrel surface of a failed bolt, close to the
fracture surface, propagating in intercrystalline and trans- Fig. CH17.15 Intergranular oxidation on bolts chosen at random
crystalline modes