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PROBLEMS WE SOLVE

PROBLEMS WE SOLVE

Component failure is usually due to a sequence or combination of events which can initiate from the design and choice of materials through to manufacturing, processing and assembly, including the application of heat, welding and grinding, as well as machining and distortion of the part due to bending, rolling or forging. In services, conditions can also contribute to the failure of a part such as variation in temperature and environmental conditions, uneven, high or low cyclic loads or stress profile, compression, torsion and bending as well as foreign object damage. Matching the maintenance needs of the component to its operating conditions and environment is also important to reduce the effects of aging and wear.

Curtiss-Wright Surface Technologies supports every stage of the manufacturing process from design and new manufacturing, to material testing and analysis through to in service maintenance, metal repair and overhaul of components – our metal repair and component protection services increase the strength and performance of parts, thereby reducing costs and downtime.

Contact Us

For materials characterization or failure analysis, contact IMR Test Labs

What Causes Component Failure?

The table below gives a brief overview of typical components that we process, what failures they are susceptible to and the component protection available to prevent failure.

Note: Failure Modes and Solutions may be relevant for some or all of the components.

  • Aero-Engine

  • Blade roots
  • Air foils
  • Tie wire holes
  • Propeller blades
  • Turbine discs and blisks and drums
  • Rotating rings
  • Engine mounting brackets
  • PTO Gears
  • Failure modes

  • Fretting
  • Galling
  • Fatigue
  • Contact fatigue
  • Corrosion
  • Stress corrosion cracking
  • Micro cracking
  • Foreign object damage
  • Erosion
  • Water droplet erosion
  • Solutions

  • Controlled shot peening
  • Laser shock peening
  • C.A.S.E. isotropic superfinishing
  • Thermal spray coatings
  • Liquid coatings
  • Aero Landing Gear

  • Failure modes

  • Foreign object damage
  • Temperature variation
  • Fatigue
  • Tensile stresses from hard chroming process
  • Stress corrosion cracking
  • Fretting
  • Galling
  • Solutions

  • Controlled shot peening
  • HVOF WC coating
  • Airframe

  • Wing skins
  • Fasteners
  • Fuselage
  • Stringers
  • Spars
  • Bulkheads
  • Bolts
  • Failure modes

  • Fatigue
  • Flexural bending fatigue
  • Stress corrosion cracking
  • Lighting strike
  • Solutions

  • Controlled shot peening
  • Shot peen forming
  • Laser peening
  • Laser peen forming
  • Connecting Rods

  • Bore fillets
  • Feed rollers
  • Bearing races
  • Screw and oil holes
  • Contact faces
  • Radii’s
  • Failure modes

  • Residual compressive stress
  • Fatigue
  • Solutions

  • Controlled shot peening
  • Crankshafts, Camshafts, Axles

  • Crank pin bearing fillet
  • Keyways
  • Splines
  • Shear sections
  • Torsion bars
  • CV joint windows
  • Gears
  • Drive shafts
  • Failure modes

  • Fatigue cracking
  • Contact fatigue
  • Pitting
  • Solutions

  • Controlled shot peening
  • Laser Peening
  • C.A.S.E. isotropic superfinishing
  • Exhaust Stacks and Manifold Adapters

  • Flanges
  • Holders
  • Weldings
  • Failure modes

  • Heat variation
  • Solutions

  • Controlled shot peening
  • Laser Peening
  • Gas and Steam Turbines

  • Blade roots
  • Air foils
  • Diaphragm couplings
  • Rotors
  • Fir tree grooves
  • Locking nuts
  • Failure modes

  • Fretting
  • Cavitation erosion
  • Water droplet erosion
  • Fatigue
  • Stress corrosion cracking
  • Solutions

  • Controlled shot peening
  • Laser shock peening
  • Thermal spray – HVOF, Plasma and Flame spray
  • Gears and Gear Systems

  • Fillet at root
  • Flanks
  • Failure modes

  • Macro and micro pitting
  • Fretting
  • Fatigue
  • Solutions

  • Controlled shot peening
  • C.A.S.E. isotropic superfinishing
  • Medical Implants

  • Hip joints
  • Medical screws
  • Bars
  • Failure modes

  • Fatigue
  • Stress corrosion cracking
  • Fretting
  • Environmental attack
  • Solutions

  • Parylene coating
  • Controlled shot peening
  • Laser peening
  • Pipes and Tubes

  • Internal bores and surfaces
  • Oil well drill pipes
  • Cooling tubes – water walls and heat exchangers
  • Transmission shaft oil holes
  • Steam generator roll transition zone
  • Plastic pallet transportation
  • Failure modes

  • Corrosion
  • Stress corrosion cracking
  • High temperature corrosion
  • Fatigue
  • Fretting
  • Galling
  • Angel hair effect
  • Solutions

  • Controlled shot peening
  • Liquid coatings
  • Thermal spray coatings
  • Thermal barrier coatings
  • Springs

  • Compression/tension coil springs
  • Valve springs
  • Torsion springs
  • Disc springs
  • Leaf springs
  • Failure modes

  • Fatigue
  • Fretting
  • Corrosion
  • Solutions

  • Controlled shot peening
  • Liquid coatings
  • Steam and Gas Turbines

  • Blade roots
  • Air foils
  • Diaphragm couplings
  • Rotors
  • Fir tree grooves
  • Locking nuts
  • Failure modes

  • Fretting
  • Cavitation erosion
  • Water droplet erosion
  • Fatigue
  • Stress corrosion cracking
  • Solutions

  • Controlled shot peening
  • Laser shock peening
  • Thermal spray – HVOF, Plasma and flame spray
  • Valves for Compressors and Pumps

  • Flapper valves
  • Seals
  • Failure modes

  • Fatigue
  • Solutions

  • Controlled shot peening
  • C.A.S.E. isotropic superfinishing
  • Welded Components and Fabrications

  • Fillet weld toe profile
  • HAZ (Heat affected zone)
  • Failure modes

  • Fatigue
  • Stress corrosion cracking
  • Solutions

  • Controlled shot peening
  • Laser peening
  • Subsea Components and Structures

  • Christmas tree structures
  • Welds – heat affected zones
  • Seals
  • Connectors
  • Valves
  • Fasteners, threads and shafts
  • Failure modes

  • Environmental corrosion
  • Stress corrosion cracking
  • Pressure and hydrogen cracking
  • Galling
  • Fretting
  • Solutions

  • Controlled shot peening
  • Liquid coatings
  • Thermal Spray coatings
  • Cathodic protection
  • Zinc phosphate coatings
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