Failures in Inspection Procedures Case Studies
Engineering Failure Analysis 11 (2004) 167-176 www.elsevier.com/locate/engfailanal
Failures in inspection procedures: case studies
A.J. McEvily* Department of Metallurgy and Materials Engineering, Institute of Materials Science, University of Connecticut, Storrs, CT, USA Received 1 July 2002; accepted 21 May 2003
Abstract
The most frequently used inspection methods, i.e., visual examination, dye penetrant examination, magnetic particle examination, eddy current examination, and ultrasonic examination, are, for the most part, effective and reliable. There have been instances, however, particularly in the aviation field, where the designated methods of inspection were not able to detect cracks, and as a result catastrophic failures occurred. In the aviation field, when major-accidents occur there is usually a thorough investigation to determine the cause. We are fortunate the accident reports concerning such events are made public, so that engineers can learn from the mistakes which led to an accident and take corrective action to prevent a recurrence of such accidents. The present paper discusses a number of cases wherein faulty inspection procedures resulted in accidents. These cases are based upon published reports as well as personal experiences, and will deal with the crashes which involved: a 707 freighter (visual examination), a DC-10 (dye penetrant), a small passenger plane (magnetic particle), a 737 (eddy currents), and a 747 freighter (ultrasonics). # 2003 Elsevier Ltd. All rights reserved.
Keywords: Inspection procedures; Visual inspection; Dye penetrant inspection; Magnetic particle inspection; Fatigue
1.Introduction
An important purpose of a failure analysis is to discover shortcomings in design, material selection and inspection procedures in order to prevent a
Failures in inspection procedures: case studies
A.J. McEvily* Department of Metallurgy and Materials Engineering, Institute of Materials Science, University of Connecticut, Storrs, CT, USA Received 1 July 2002; accepted 21 May 2003
Abstract
The most frequently used inspection methods, i.e., visual examination, dye penetrant examination, magnetic particle examination, eddy current examination, and ultrasonic examination, are, for the most part, effective and reliable. There have been instances, however, particularly in the aviation field, where the designated methods of inspection were not able to detect cracks, and as a result catastrophic failures occurred. In the aviation field, when major-accidents occur there is usually a thorough investigation to determine the cause. We are fortunate the accident reports concerning such events are made public, so that engineers can learn from the mistakes which led to an accident and take corrective action to prevent a recurrence of such accidents. The present paper discusses a number of cases wherein faulty inspection procedures resulted in accidents. These cases are based upon published reports as well as personal experiences, and will deal with the crashes which involved: a 707 freighter (visual examination), a DC-10 (dye penetrant), a small passenger plane (magnetic particle), a 737 (eddy currents), and a 747 freighter (ultrasonics). # 2003 Elsevier Ltd. All rights reserved.
Keywords: Inspection procedures; Visual inspection; Dye penetrant inspection; Magnetic particle inspection; Fatigue
1.Introduction
An important purpose of a failure analysis is to discover shortcomings in design, material selection and inspection procedures in order to prevent a
References: [1] Boeing 707 321G-BEBP, Report of an accident near Lusaka International Airport, Zambia, on 14 May 1977, Dept. of Trade Accidents Investigation Branch, Aircraft Accident Report 9/78, London: Her Majesty’s Stationery Office. [2] Aircraft Accident Report, Uncontained Engine Failure, Delta Airlines Flight 1288, MD-88, Pensacola, Florida, 6 July 1996. NTSB/AAR-98-01. [3] Aircraft Accident Report, UAL Flight 232, McDonald Douglas DC-10-10, Sioux Gateway Airport, Sioux City, Iowa, 19 July 1989,NTSB/AAR 90/06. [4] Aircraft Accident Report, Aloha Airlines Flight 243, NTSB/AAR-89/03. 1989. [5] Aviation Accident Report, Uncontained Engine Failure,/Fire, ValueJet Airlines Flight 597,Douglas DC-9-332, Atlanta, Georgia, 8 June 1995. NTSB/AAR-96-03. [6] McEvily AJ. Metal failures: mechanisms, analysis, prevention. NY: John Wiley and Sons; 2002.