Aerospace Services

MATCO has collaborated with the FAA and Designated Engineering Representatives (DER’s) to provide top-of-the-line failure analysis and materials testing to the airline industry for many years. Our experienced engineers and specialists have determined the root cause of failures and responded expeditiously and efficiently in an impressively broad area of aircraft applications.

We have been called in, for example, by a major airline when they were faced with the need for emergency inspections of aircraft componenets.  Among our many investigations we have examined:

• engine chip analysis,
• fuel contamination studies,
• turbine / compressor blades,
• engine bearing failures,
• stress corrosion of landing gear,
• avionic components,
• short-circuiting by dendritic corrosion,
• ground equipment failures,
• APU components,
• flight control cables,
• fuselage and structure components,

and many more. Quality control of components of active aircraft has been the centerpiece of many of our investigations.

A failure analysis should provide the answers to the following questions:

a. Which component failed first?

b. What was the mode of failure, How did it fail?

c. What were the trajectories of failed parts and the consequential damage?

d. The root cause of the failure?

e. What are possible orrective actions ?

On-site investigation and reviewing operating conditions and maintenance records may be essential to determine the most likely sequence of events in a failure.

Routine Laboratory Testing and Failure Analysis Procedures

Used in Examination of Turbine Blades:

1. Visual examination of failed turbine/compressor blades, including comprehensive photographic documentation of all fracture surfaces.

2. Light microscopy to used to examine morphology of blade failure/fracture surface and to determine mode of fracture. A macroscopic examination of the surface of the selected specimen begins this stage of analysis, followed by a microscopic examination. A close examination using a stereo microscope at magnification of 50x or less may reveal details of the fracture surface, or perhaps that the blade is exhibiting corrosion. An examination of failed and non-failed samples may reveal that all of the failed samples exhibit similar or varying fracture morphology. Magnifications ranging from 50x to 1000x can be used to examine the cross section of failed blade samples for microstructural defects, as well as for observation of corrosion products if present. Metallographic techniques are used to determine if an over-temperature condition has existed and SEM and EDS are used to develop engine profiles.

3. Scanning electron microscopy (SEM) is also used to examine morphology of blade failure/fracture surface and to determine fracture mode. SEMs have a large depth of field allowing a large amount of the sample to be in focus at one time, helpful feature on rough fracture surfaces. The SEM produces images of fine features at high resolution.

4. Energy dispersive x-ray spectroscopic (EDS) analysis to determine elemental composition in the area of the blade failure/fracture and to identify possible elemental contaminants contributing to the failure. EDS systems excite characteristic x-rays to identify the elemental composition of the sample.

5. Auger electron spectroscopic (AES) analysis of fracture surfaces is used to look for elemental segregation at fracture surfaces and to identify corrosion products. AES is used to determine the elemental composition of a fracture surface and can provide elemental depth profiles through sputtering. This information can then be used to solve problems associated with surface appearance, cleanliness and chemical bonding.

6. Analysis of all data collected in items 1-5, above, allows determination of the mechanism and mode of failure/fracture, and identification of root cause of failure/fracture of the turbine/compressor blades.

7. FEA and fracture mechanics analysis of engine components, turbine/compressor blade material.

8. Thermo-mechanical fatigue testing and practical life analysis.

9. An illustrated formal report documents the results of the investigation including analysis of data, identification of cause(s) of failure, conclusions, and recommendations.

If necessary, MATCO personnel can usually be on site almost immediately when requested during emergency situations.

Many major corporations have used MATCO’s services repeatedly over the years. These have included US Airways, Rolls Royce, GE, Siemens/Westinghouse, Cutler Hammer/Eaton Elec trical, 3Mand many others.We value the relationships that we have established with these large corporations and we are delighted that we can meet their technical needs. We also place great value though on the work we do to help our smaller clients grow and establish footholds in their respective markets. Whether your company is large, medium or small, MATCO will do its best to meet your requirements.

Failure Analysis Team

Our team includes certified and experienced personnel from a variety of technical disciplines including: mechanical engineering, cathodic protection, paint inspection, chemistry, metallurgy, and materials science. We have a vast array of laboratory and field testing equipment. MATCO's testing equipment is calibrated on a routine basis in accordance with both national and international standards, and is ready to be put to use at a moment's notice.

Our team includes professional engineers, mechanical engineers, chemists, coating specialists and NACE Certified Materials Selection/ Design / Corrosion/Coating Specialists (*) . Members include:

Dr Zee (*)                       Mr. Geoff Rhodes (*) 

Dr. George Bayer            Mr. Ed Larkin

Mr. Marty Latona            Dr. Behazad Bavarian

Dr. Ben Kasraie, PE       Dr. Huiping Xu