Failure analysis on a safety clip

 Today's Knowledge Share:

I completed a failure analysis on a safety clip, which had failed an impact test at -30 °C. The parts are specified to be able to withstand the cold temperature impact test, and the failures were of serious concern due to potential safety issues. The parts were injection molded from an unfilled, impact modified nylon 6/6 resin.

The fractographic examination indicated that the cracking was initiated through a brittle fracture mechanism, characterized by a relatively high crack propagation rate, and a significant amount of driving energy. In particular, this was characterized by the presence of stepwise-cracking associated with crack bifurcation, as well as secondary cracking. Additionally, the fracture surface within the origin zone showed a very smooth morphology, without micro ductility. The observed features were indicative of a high level of energy within the fracture as it propagated from the origin. The fracture surface characteristics were consistent with the application of a high strain rate impact load, in agreement with the described testing that precipitated the cracking. Specifically, the observed features were indicative of brittle fracture associated with stresses that exceeded the short-term strength of the material through a high strain rate impact mechanism. 

Remote to the crack initiation zone, the fracture surface morphology was significantly different. Outside the crack origin, hackle marks and river markings were evident, indicative of rapid crack extension. With increasing distance from the crack origin, a relative increase in the level of micro ductility was apparent in the form of an overlapping morphology and stretching and deformation. This was important, as it indicated that the material was not inherently brittle.

This fracture surface presented classic features, illustrating how the crack features can change as the crack propagates.

Source:Jeffrey A Jansen

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#failureanalysis #fracture #nylon #cracking #morphology #deformation #testing #stress #impactmeasurement #ductility #injectionmolding #safety

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The usage of composite materials on the Boeing 787 Dreamliner project:

 Today's knowledge share:

The usage of composite materials on the Boeing 787 Dreamliner project

The Boeing 787 makes greater use of composite materials in its airframe and primary structure than any previous Boeing commercial airplane. Undertaking the design process without preconceived ideas enabled Boeing engineers to specify the optimum material for specific applications throughout the airframe. 

The result is an airframe comprising nearly half carbon fiber reinforced plastic and other composites. This approach offers weight savings on average of 20 percent compared to more conventional aluminum designs. Without preconceived ideas, Boeing engineers were able to specify the optimum material for specific applications throughout the airframe. The result couldn't be different: the 787 is 50% composites by weight and by 80% volume with each aircraft containing approximately 32,000 kg of CFRP composites. 

Selecting the optimum material for a specific application meant analyzing every area of the airframe to determine the best material, given the operating environment and loads that a component experiences over the life of the airframe. For example, aluminum is sensitive to tension loads but handles compression very well. On the other hand, composites are not as efficient in dealing with compression loads but are excellent at handling tension. The expanded use of composites, especially in the highly tension-loaded environment of the fuselage, greatly reduces maintenance due to fatigue when compared with an aluminum structure. This type of analysis has resulted in an increased use of titanium as well. 

In addition to lowering the overall airplane weight, moving to a composite primary structure promises to reduce both the scheduled and nonroutine maintenance burden on the airlines. In total, the reduced risk of corrosion and fatigue associated with composites combined with the composite repair techniques described will lower overall maintenance costs and maximize airline revenue by keeping airplanes flying as much as possible! 

Source:Managing Composites

Innovative Robotic sheet molding process

 Innovative method for rapidly producing hard tooling (and other metal parts) is being commercialized by Machina Labs Inc. (Los Angeles, Calif., U.S.). Described as dieless robotic sheet forming... Machina’s contributions are in the application of computational modeling and simulations, machine learning/artificial intelligence (ML/AI), sensor technologies and kinematic solutions (industrial robot arms). The entire process runs off a software stack and interfaces developed by Machina. It transforms CAD files into robot tool paths and uses sensors to interpret force and torque being applied as well as optical scans measuring deformation to incrementally manipulate sheet metal to form parts. The process creates a digital twin as the part takes shape, and a digital thread captures all relevant process characterization and part qualification information..."

For more information,pls have a look at

https://lnkd.in/gqqGQpPn

Source:Compositesworld/machinalabs

Decarbonization action taken by Germany

 #hydrogen #fuelcell #trucks come with a sgnificant #decarbonization potential, once #blue #hydrogen and #green #hydrogen are available

With #green_hydrogen entering the market in Germany in 2023/24 #hydrogen #trucks can help decarbonizing #transportation timely. The impact will be larger once #blue and #green #hydrogen will be imported.

#battery trucks (#bev) for long-haul application need huge batteries, but still could contribute to decarbonization, once the grid mix in Germany gets cleaner. For the last two years though, carbon intensity of the German grid has increased and it may continue to do so in 2023 and 2024.

Liquid hydrogen (#LH2) and cryo-compressed hydrogen (#CcH2 #CRYOGAS) will play a significant role in decarbonzing transport, once #green and #blue #hydrogen are available.

Source:CRYOMOTIVE GmbH

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The first environmentally-friendly cabin interior concept made with natural fibers!

 The first environmentally-friendly cabin interior concept made with natural fibers! 

Meet AEROFLAX! 

Aircraft operators are constantly looking for ways to make flying more sustainable. With AeroFLAX Lufthansa Technik has developed the first airworthy composite solution based on renewable, eco-efficient, and airworthy pre-impregnated fiber meeting the flammability requirements for aircraft cabins! 

With its unique combination of ampliTex™ and powerRibs™ flax fiber reinforcements and a bio-based resin system, a cabin component's weight can be reduced by up to 20 percent, and additional CO2 savings can be leveraged over its entire lifecycle. 

As new eco-efficient aircraft types will only come into market in a decade and as every part that is made of glass fiber or carbon fiber can also be made of flax fiber, the entire interior cabin lining can soon be made of AeroFLAX during line-fit on-site at the aircraft manufacturer or during retrofit. 

With AeroFLAX, Lufthansa Technik is paving the way to a more environmentally-friendly aircraft interior. By offering eco-efficient materials for cabin interior, additional weight and CO2 savings can be achieved and sustainability becomes perceivable on board. 

Source:Managing composites