Failure analysis of an aircraft engine cylinder head |
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| Affiliation: | 1. The State Key Lab of High Performance Ceramics and Superfine Microstructure, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 200050, China;2. VTT Technical Research Centre of Finland, Espoo FI-02044, Finland;3. Key Laboratory of Inorganic Coating Materials, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 200050, China;1. Portuguese Air Force, Engineering and Programs Directorate, 2724-506 Amadora, Portugal;2. Portuguese Air Force, Institute of Higher Military Studies, Lisbon, Rua de Pedrouços, 1449-027 Lisbon, Portugal;3. Portuguese Air Force, General Staff — Resources Division, 2724-506 Amadora, Portugal;4. Portuguese Air Force Academy, Granja do Marquês, 2715-021 Pêro Pinheiro, Sintra, Portugal;5. ICEMS, Institute of Materials and Surfaces Science and Engineering, Instituto Superior Técnico, University of Lisbon, Av. Rovisco Pais, 1049-001 Lisbon, Portugal;6. LAETA, IDMEC, Instituto Superior Técnico, University of Lisbon, Av. Rovisco Pais, 1049-001 Lisbon, Portugal;7. Escola Superior Náutica Infante D. Henrique, Av. Engenheiro Bonneville Franco, 2770-058 Paço de Arcos, Portugal;8. ISEL - Instituto Superior De Engenharia de Lisboa, Rua Conselheiro Emídio Navarro, 1959-007 Lisbon, Portugal |
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| Abstract: | The piston engine of the training aircraft malfunctioned during the flight due to the cracking of its cylinder head (CH), which is manufactured from an aluminum casting alloy. Based on the fractographic examination of the mating fracture surfaces, the characteristic ratchet and beach marks were observed indicating the occurrence of fatigue failure. The crack was initiated from multiple origins located on the inner flange fillet on the exhaust side of the CH. The metallography examination has shown that the fatigue was promoted from pre-existing material defect due to an elevated presence of shrinkage pores at the crack initiation zone and was most likely associated with the manufacturing process of casting. The finite element (FE) method, utilized to determine the stress state of the CH subjected to gas pressure, also confirmed that the crack origin was located at the most stress area. |
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| Keywords: | Aircraft Cylinder head Failure analysis Fatigue failure Finite element analysis |
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