Ugur Dikbas Module 7 Composite Failure - Short Essay

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Embry-Riddle Aeronautical University *

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Mechanical Engineering

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Dec 6, 2023

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1 Composite Failure Incidents in Aerospace Engineering Ugur Dikbas College of Aeronautics, Embry-Riddle Aeronautical University BSAS 335 Mechanical and Structural Factors in Aviation Safety Mike Millard December 2, 2023

2 Composite Failure Incidents in Aerospace Engineering Introduction Composite materials have revolutionized the aerospace industry with their remarkable strength-to-weight ratio, making them integral in constructing aircraft and spacecraft structures. However, despite their numerous advantages, composite materials are susceptible to failure, which can lead to catastrophic incidents. Composite failure occurs when these materials are unable to endure the stresses or damages they encounter, resulting in structural breakdowns that compromise safety (Ransom et al., 2009). The article "Lessons Learned from Recent Failure and Incident Investigations of Composite Structures" delves into several aviation incidents that highlight the mechanical factors involved in composite failures. For example, the American Airlines Flight 587 crash was caused by excessive rudder pedal inputs, leading to the separation of the composite vertical tail and subsequent structural overload, resulting in the loss of aircraft control (Ransom et al., 2009). Similarly, the failure of the X-33 liquid hydrogen tank was initiated by a debond caused by Teflon tape, leading to increased internal pressure and eventual structural failure. Additionally, the Space Shuttle Columbia disaster resulted from foam liberation during ascent, striking the wing and causing a crack in the carbon/carbon panel, leading to structural damage during reentry. These incidents illustrate how mechanical stresses, design flaws, and unexpected damage propagation contribute to composite failure.

3 Composite failure incidents often unfold due to a combination of factors. Operational errors, manufacturing defects, and unexpected damages are among the primary causes. In these incidents, the failures occurred as a result of loads exceeding design limits, flaws in the materials or manufacturing processes, and external factors such as impacts or debris strikes. The incidents unfolded gradually, with initial issues escalating into catastrophic failures, compromising the structural integrity of the aircraft or spacecraft (Ransom et al., 2009). Understanding composite failure is crucial in preventing such incidents. Thorough analysis and testing play a pivotal role in ensuring the structural integrity and safety of composite structures. It involves evaluating material properties, design limitations, and conducting comprehensive testing to verify the materials' capabilities and resilience under various conditions. Additionally, multidisciplinary collaboration among engineers, scientists, and manufacturers is essential for developing advanced methodologies and continually improving composite structures' reliability and safety in aerospace applications. Conclusion Composite failure remains a significant challenge in aerospace engineering. To mitigate the risks associated with composite materials, a deeper understanding of their mechanical behavior, stringent analysis, and continuous advancements in testing methodologies are essential. By acknowledging the lessons learned from past incidents, fostering collaboration across disciplines, and implementing rigorous testing and

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4 validation processes, the aerospace industry can proactively address composite failure challenges and ensure the safety and reliability of future aircraft and spacecraft structures.

5 References Ransom, J., Glaessgen, E., Raju, I., Knight, N., & Reeder, J. (2009, December). Lessons learned from recent failure and incident investigations of composite structures. In 49th AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference, 16th AIAA/ASME/AHS Adaptive Structures Conference, 10th AIAA Non- Deterministic Approaches Conference, 9th AIAA Gossamer Spacecraft Forum, 4th AIAA Multidisciplinary Design Optimization Specialists Conference (p. 2317).