Metallurgical investigation of cracked aluminium alloy valve

1-s2-0-s2213290213000096-gr1A case study published in « Case Studies in Engineering Failure Analysis« , July 2013.

The high strength aluminium alloy Al–5.5Zn–2.5Mg–1.5Cu (AA7075) is being widely used in realisation of aerospace components. A component ‘fill and vent valve’ used in liquid propulsion system was fabricated from AA 7075 forgings in T7352 temper condition, and subsequently undergone various functional tests, four years back. Recently, during dye penetrant test after proof pressure test at 525 bar, a valve indicated presence of a crack. Detailed metallurgical investigation indicated that failure was caused by stress corrosion cracking.

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Failure Analysis of Aircraft Aluminum Alloy Structures in Coastal Environments

Un cas de corrosion intergranulaire sur aluminium provoqué l’environnement marin aux îles Fidji


The failure of aluminum alloy stringer on the tour airplane servicing in the coastal environment of the Fiji Islands were analyzed. Through the analysis of surface topographies and failure characteristics and the consideration of service environment, the evolvement of failure process and the failure mechanisms were analyzed. Findings showed that ultraviolet radiation, temperature, high-humidity and salt spray caused the aging failure of structure coating and then pitting corrosion occurred in the oxide film on aluminum alloy. With the ongoing corrosion along the grain boundary, intergranular corrosion appeared. When the intergranular corrosion continued developing to the adjacent layers, denudation occurred. The volume expansion effect of corrosion products caused the stress concentration on the tip of corroded area and resulted in the initiation of cracks.

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