failure analysis virtual lab a failure occurred on the tail section of a commercial aircraft (the...
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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.
David W. Dickinson
ClickFor
StudentData
Sheet
What Type of Testing Do You Want To Do On
This Part?What Type of Testing On a Similar Weldment?
Keep Track of Your Costs To Bill the Customer
(Print out for Reference)
Would you like to find some properties of Aluminum Alloys and Other Data?
All DoneWrite Report
Cost Record
Return to Home Page
Hardness Conversion Tables
Al Alloy Chem & Type
Al AlloysProperties
Etching Al Alloys
Slice
Slice
Fracture Surface
Fracture Surface
Return to Home Page
Metallographic Sectioning
Examine Higher Magnification Microstructure
Do Microhardness Traverse Across Weld
Return toSection Selection
Select Location
Macro-Section
Return to Macrostructure
100x1000x
Keller’s Etch
Return to Macrostructure
100x
1000x
Keller’s Etch
Return to Macrostructure
100x
1000x
Keller’s Etch
Return to Macrostructure
100x
1000x
Keller’s Etch
Return to Macrostructure
100x
1000x
Keller’s Etch
1111121101079990858075767168656361
60636670758082
Start Here byPlacing HardnessIndentation
Return To Section
Hardness (Hv 0.2)
Millimeters
Examine Higher Magnification Microstructure
Do Microhardness Traverse Across Fracture
Return toSection Selection
Return toSection Selection
Macro Section
Make Selection
Return to Macrostructure
100x1000x
Keller’s Etch
Return to Macrostructure
100x1000x
Keller’s Etch
Return to Macrostructure
100x
1000x
Keller’s Etch
Return to Macrostructure
100x1000x
Keller’s Etch
112114110109110111107111109113108111108107120
122115111109110111110
Start Here byPlacing HardnessIndentation
Return To Section
Millimeters
Hardness (Hv 0.2)
Fracture Surface Bottom
Return To Section
Fracture Surface
Select AnalysisOption
Optical Microscopy
Scanning Electron Microscopy
Fracture Surface Bottom
Return To Microscopy
Choices
Fracture Surface
Return toFracture
Return To Microscopy
Choices
Fracture Surface Bottom
Fracture Surface
Return toFracture
Al
Al2O3
Fracture Surface Top
Return To Section
Fracture Surface
Optical Microscopy
Scanning ElectronMicroscopy
Select AnalysisOption
Fracture Surface Top
Return To Microscopy
Choice
Fracture Surface
Return toFracture
Fracture Surface Top
Fracture Surface
Return toFracture
Return To Microscopy
Choice
Make a Weld: Select Material
6061 T6 As Welded 4043 Wire
6061 T0 As Welded 5356 Wire
5456-H116 As Welded 5356 Wire
Return to Home Page
2219 T87 As Welded 2319 Wire
Tensile Sample Prep
Microhardness Prep
6061 T6 As Welded 4043 Wire
Return to Weld Selection
6061 T6 As Welded 4043 Wire (ksi)
Return
UTS YS EL
50.1 32.2 16
48.7 30.3 15.4
6061-T6/4043 UTS
0
10
20
30
40
50
60
-3 -2 -1 0 1 2 3
Distance From Centerline (cm)
Ult
imate
Ten
sil
e
Str
en
gth
(ksi)
6061 T6 As Welded 4043 Wire
Return
60
90
120
DPH (500g)
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
6061 T6 As Welded 4043 Wire
Return
120
100
80
DP
H (
500g
)
Tensile Sample Prep
Microhardness Prep
6061 T0 As Welded 5356 Wire
Return to Weld Selection
Return
6061 T0 As Welded 5356 Wire
UTS YS EL
28.4 16.0 12
26.5 15.4 11.5
6061 T0 As Welded 5356 Wire
Return
60
50
40
30
DPH (500g)
Tensile Sample Prep
Microhardness Prep
2219 T87 As Welded 2319 Wire
Return to Weld Selection
2219 T87 As Welded 2319 Wire
UTS YS EL
58.3 35.0 3
56.2 33.0 4.2
2219-T87/2319 UTS
0
20
40
60
80
-3 -2 -1 0 1 2 3
Distance from Centerline (cm)
Ult
imat
e T
ensi
le
Str
eng
th (
ksi)
Return
2219 T87 As Welded 2319 Wire
Return
2219-T87 Microhardness
405060708090
100110
0 0.5 1 1.5 2 2.5 3
Distance From Weld (cm)
Ha
rdn
es
s (
Re
)
Tensile Sample Prep
Microhardness Prep
5456-H116 As Welded 5356 Wire
Return to Weld Selection
5456-H116 As Welded 5356 Wire
Return
UTS YS EL
48.1 30.1 8.3
46.2 29.2 9.1
5456-H116/5356 UTS
0
10
2030
40
50
60
-3 -2 -1 0 1 2 3
Distance from Centerline (cm)
Ult
imat
e T
ensi
le
Str
eng
th (
ksi)
5456-H116 As Welded 5356 Wire
Return
5456-H116 Microhardness
60
6570
7580
8590
95
0 0.5 1 1.5 2 2.5 3
Distance From Weld (cm)
Ha
rdn
es
s (
Re
)
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.
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