ENGINEERING MATERIALS

1669 FOXGROVE
UPLAND, CA 91784
909.260.5633
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Failure Analysis

Item 47 NAS6403U19D
Ti Bolt
RH Torsion Bar Anchor Bolt

Submitted To:

Bruce Glascock
Pacific Scientific
HTL/Kin-Tech Division
1800 Highland
Duarte, CA 91010

Submitted By:

Joseph King
Engineering Materials
1669 Foxgrove Court
Upland, CA 91784

June 17, 2007

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 SUMMARY

Subject bolt failed due to fatigue. Fatigue initiation was facilitated by

surface damage created by high bearing stresses. Witness marks clearly
indicate the bolt was rotated ~180 degrees when it was removed and reinserted.
Areas on the bolt with surface damage then became loaded in tension plus cyclic
bending when cycle testing resumed. This led to fatigue crack propagation from
the regions with surface damage and premature bolt failure.

INTRODUCTION

Item 4, NAS6403U19D, RH Torsion Bar Anchor Bolt failed after about

391,275 cycles. Failure occurred just after starting the full-stroke portion of the
14th set of 28,200 cycles or about 2.8xlife. The bottom portion, with the 1501677-
03 (MS14145 IVD AL coated) castellated nut and cotter pin fell off the RPA onto
the test stand. The rest of the bolt remained in place due to the torsion bar
preload, breakout load. The rudder pedal was removed, the preload was
released and the failed bolt was retrieved. The sections of the broken bolt were
forwarded with a request to determine the cause of failure. The bolt is reportedly
Ti-6AL-4V heat treated to 160-180 ksi strength level.

EXAMINATION AND RESULTS

Visual examination

An overall view of the broken bolt is presented in Figure 1. Witness marks

caused by high bearing stresses are present on the bolt’s outer surface. Closer
views of two of the witness marks are presented in Figures 2 and 3. The
approximate locations of 4 witness marks are presented in the schematic
drawing shown in Figure 4. Two additional witness marks (not shown) were
found on opposite sides of the bolt at the fillet radius transition between the bolt
head and shank. Scanning electron photomicrographs of one of the witness
marks are presented in Figures 5 and 6. Surface cracking is clearly evident in
Figure 6.

Fractographic examination

Overall views of the fracture surface are presented in Figures 7 and 8.

Relevant parts of the fracture are marked on Figure 8. Microvoid coalescence or
dimpled rupture (Figure 9) is present in the area marked as final fracture. Fatigue
striations (Figure 10) are present in the area marked fatigue. The fracture
surface in the region marked as the dark outer band (Figure 11) is contaminated
with a carbon rich material as demonstrated in the EDS data presented in
Figures 12 and 13. This contamination was removed by ultrasonic cleaning in
acetone.
Metallographic examination

Standard metallurgical procedures were used to prepare a longitudinal

view of the bolt’s microstructure. Low and higher magnification
photomicrographs are presented in Figures 14 and 15.

Hardness

The bolt hardness was evaluated on a face cut perpendicular to the

longitudinal axis of the bolt. Three hardness measurements were taken. The
average of the three measurements was 38 Rc.

DISCUSSION AND CONCLUSIONS

The EDS spectrum presented in Figure 12 indicate the bolt material is

predominately Titanium with additions of Aluminum and Vanadium. The
measured hardness and microstructure are consistent with 6-4 Titanium solution
treated and aged to 160-180 ksi.
Fractographic analysis clearly indicates that failure occurred by fatigue.
Markings on the fracture surface are consistent with fatigue crack propagation
under bending or bending plus tension loading. This is consistent with the
applied service loads. Cracking via fatigue occurred over approximately 30% of
the fracture surface.
Witness marks present on the bolt were caused by contact with the torsion
bar and feel assembly housing. This is due to the modest loads but relatively
small contact area leading to high bearing stresses. The torsion bar is preloaded
and then operated in one direction only. Therefore, normal operation would
dictate there be only two witness marks on the bolt associated with contact with
the torsion bar.
Two sets of witness marks are clear evidence the bolt was used twice. At
some point during testing the bolt was apparently (and reportedly) removed.
When it was reinstalled it was rotated by approximately 180 degrees. This
produced 2 sets of witness marks.
Normally, the surface damage caused by the high bearing stresses would
not be a problem as these areas remain in compression during the expected
service life. However, since the bolt was rotated ~180 degrees when it was
removed and reinserted, the damaged areas became loaded in tension and
cyclic bending. Crack initiation was undoubtedly facilitated by the pre-existing
surface damage. This allowed fatigue crack propagation from these regions and
ultimately, premature failure of the bolt.

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 LIST OF FIGURES

Figure 1. Overall view of broken bolt............................................................................5

Figure 2. Witness mark found near the origin.............................................................5
Figure 3. One of the two witness marks found about 0.25 inch from the bolt head
.....................................................................................................................................6
Figure 4. Location of four witness marks caused by high bearing stresses from
the torsion bar............................................................................................................7
Figure 5. Scanning electron micrograph of a witness mark caused by high
bearing stresses from the torsion bar....................................................................8
Figure 6. Higher magnification view of surface cracking associated with witness
mark in Figure 5........................................................................................................8
Figure 7. Optical photomicrograph of fracture surface..............................................9
Figure 8. Scanning electron micrograph of fracture surface.....................................9
Figure 9. Fracture surface in final fracture region. Crack propagation is via
dimpled rupture........................................................................................................10
Figure 10. Fracture surface of outer dark band observed on fracture surface.
Crack propagation method is difficult to read due to surface contamination
but is probably dimpled rupture............................................................................11
Figure 11. Fatigue striations found on the fracture surface in fatigue region.......12
Figure 12. EDS spectrum of central part of fracture—Spectrum is consistent with
chemical composition of 6-4 Ti.............................................................................12
Figure 13. EDS spectrum of outer dark region showing carbon contamination. .13
Figure 14. Photomicrograph of microstructure—dark regions of beta in an alpha
matrix........................................................................................................................13
Figure 15. Photomicrograph of bolt microstructure--beta phase (dark regions) in
an alpha matrix........................................................................................................14

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 Figure 1. Overall view of broken bolt

Figure 2. Witness mark found near the origin

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 Figure 3. One of the two witness marks found about 0.25 inch from the bolt head

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 Figure 4. Location of four witness marks caused by high bearing stresses from the
torsion bar

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 Figure 5. Scanning electron micrograph of a witness mark caused by high bearing
stresses from the torsion bar

Figure 6. Higher magnification view of surface cracking associated with witness mark in
Figure 5

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 Figure 7. Optical photomicrograph of fracture surface

Final
Fracture Dark outer band

Fatigue

Origin

Figure 8. Scanning electron micrograph of fracture surface

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 Figure 9. Fracture surface in final fracture region. Crack propagation is via dimpled
rupture

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 Figure 10. Fracture surface of outer dark band observed on fracture surface. Crack
propagation method is difficult to read due to surface contamination but is probably
dimpled rupture.

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 Figure 11. Fatigue striations found on the fracture surface in fatigue region

Figure 12. EDS spectrum of central part of fracture—Spectrum is consistent with chemical
composition of 6-4 Ti

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 Figure 13. EDS spectrum of outer dark band showing carbon contamination

Figure 14. Photomicrograph of microstructure—dark regions of beta in an alpha matrix

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Figure 15. Photomicrograph of bolt microstructure--beta phase (dark regions) in an alpha
matrix

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