This paper presents a supporting case study that examines fatigue cracks that were detected in an F/A-18 Hornet bulkhead during post-service testing and teardown. The in-service phase of the cracking had significant evidence of oxidation on their surfaces which indicated an exposure to a mildly corrosive environment. Both the service and laboratory phases of the cracking were the subject of quantitative fractography and estimates of the crack growth rates were made. A comparison of the in-service and the in-test phases of crack growth indicated that no notable effect on the service part of the fatigue crack could be attributed to its exposure to the service environment.
Valve had failed as a result of particles of material becoming trapped between the valve seat recess and the valve seat ball, leading to erosion of the valve seat recess, valve seat ball and the valve operating pin; this allowed hydraulic fluid to flow when the valve was nominally in the de-energised position.The material of construction of the valve seats was not compliant with engineering drawings.The investigation demonstrated the importance of maintaining the cleanliness of hydraulic systems and of the need to control the materials of manufacture in safety critical applications.
