Failure Investigation Laboratory Manual

FAILURE INVESTIGATION LABORATORY

AIRCRAFT ENGINEERING DIRECTORATE

PROCEDURE MANUAL

Revision 3.0
September, 2023

DGCA Headquarters
New Delhi

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 Failure Investigation Laboratory Manual

REVISIONS

The revisions are carried out to accommodate the amendments made in

Aircraft Rules, Civil Aviation Requirements and to accommodate any
changes in the tests carried out.

The below table provides the record of revisions:

RECORD OF REVISIONS

Date of
Rev. No. Remarks Initials
Revision

November
1 Initial Print
2012
October Amendment in Reporting Structure
2
2021
Removal of Regional Office and -SD-
September Directorate details Shri.Amit Gupta,
3
2023
Amendment in Investigation Tests Director, AED

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 Failure Investigation Laboratory Manual

TABLE OF CONTENT

CHAPTER CONTENT PAGE NO

1 GENERAL 4

2 STRUCTURE OF FAILURE INVESTIGATION LABORATORY 5

3 SCOPE OF FAILURE INVESTIGATION LABORATORY 6

4 MACHINES/EQUIPMENTS USED IN LABORATORY 7

5 PROCEDURE 12

6 WORK FLOW OF FAILURE INVESTIGATION LABORATORY 13

7 FORMAT OF THE REPORT 14

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 Failure Investigation Laboratory Manual

CHAPTER – 1

GENERAL
The Directorate General of Civil Aviation (DGCA) is the
regulatory body in the field of Civil Aviation, primarily dealing with the
safety issues. It is responsible for the regulation of air transport services
to/from/within India and for enforcement of civil air regulations, air safety
and airworthiness standards. It is also co-ordinates all the regulatory
functions with the International Civil Aviation Organization (ICAO).

The DGCA headquarters is located in New Delhi with the

regional offices in various location of India. The Directorate General of
Civil Aviation is an attached office to the Ministry of Civil Aviation.

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 Failure Investigation Laboratory Manual

CHAPTER – 2

STRUCTURE OF FAILURE INVESTIGATION LABORATORY

Director General of Civil Aviation

Joint Director General

Deputy Director General

Director, Aircraft Engineering

Deputy Director, Aircraft Engineering

Assistant Director, Aircraft Engineering

Aeronautical Officer, Aircraft Engineering

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 Failure Investigation Laboratory Manual

CHAPTER – 3

SCOPE OF FAILURE INVESTIGATION LABORATORY

The objective of the failure investigation laboratory is to determine the

primary cause of the failed aircraft/helicopter components involved in
accident/incident, under Rule 13(1) of the The Aircraft (Investigation of
Accident and Incidents) Rules, 2017. The primary objective of ‘Failure
Analysis Laboratory’ is twofold, firstly to know the most probable cause
of failure and secondly, to provide the remedial action to avoid its
recurrence. The main objectives of the laboratory investigations are in
the following areas:

o Design deficiency

o Errors in the selection of materials

o Processing and fabrication faults

o Improper inspection & maintenance

o In-service abnormalities and environmental effects, etc.

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 Failure Investigation Laboratory Manual

CHAPTER – 4

MACHINES /EQUIPMENTS USED IN LABORATORY

1. SCANNING ELECTRON MICROSCOPE (SEM)

MODEL EVO 18 (5X - 1 MILLION MAGNIFICATION)

2. ULTRASOUND CLEANING MACHINE

3. STEREO MICROSCOPE MODEL WILD M8 (UP TO 50X

MAGNIFICATION)

4. OPTICAL MAGNASCOPE MODEL VAISESHIKA 7009 (UP TO 10X

MAGNIFICATION)

5. MEASURING INSTRUMENTS

6. SAMPLE CUTTING MACHINES

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 Failure Investigation Laboratory Manual

DESCRIPTION OF MACHINES /EQUIPMENTS

SCANNING ELECTRON MICROSCOPE (SEM) (MODEL EVO 18)

The SEM is used to study the fracture surfaces of failed components. It
allows the direct study of fracture surfaces without any need for replica
formation as used in Transmission Electron Microscope (TEM). There
are unique features in the fracture surfaces which characterize the type
of failure and these generally require a very high magnification which
can only be attainable in an instrument like SEM. The laboratory has a
state-of-art Digital Scanning Electron Microscope (SEM).

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 Failure Investigation Laboratory Manual

ULTRASOUND CLEANING MACHINE:

The ultrasound cleaning machine is used to clean the sample for further
investigation under macro and microscopic examination. The cleaning
procedure is performed to remove any surface deposits in order to
examine the sample effectively/clearly.

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 Failure Investigation Laboratory Manual

STEREO MICROSCOPE (MODEL WILD M8)

A stereo microscope is a low-powered microscope used for macro
examination of the fracture surfaces. The instrument provides a better
depth of field and the three-dimensional image, which helps in macro
examination of the entire fracture surface to obtain a better
understanding of the component failure. The failure of the component
can be classified from a microscopic point of view, locating the origin of
the fracture by tracing the fractured path. It provides higher
magnification up to 50X with the photographic facilities.

The fracture surface is macroscopically examined in position locally to

have a preliminary view of the failure and to collect the extensive
amount of information from the fracture surface at low magnification.
Configuration of the fracture surface may give an indication of the stress
system leading to failure. The area of interest to be examined under
SEM is also decided at low magnification under the stereomicroscope.

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 Failure Investigation Laboratory Manual

OPTICAL MAGNASCOPE (MODEL VAISESHIKA 7009)

The optical magnascope (up to 10X magnification) available in the
laboratory is used for the visual and macro examination purposes.

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 Failure Investigation Laboratory Manual

CHAPTER – 5
PROCEDURE

The following steps are adopted by the laboratory for investigation after
receiving the accident/incident failed parts (Aircraft/Helicopter) from the
Air Safety Directorate / Aircraft Accident Investigation Bureau (AAIB).

Step-1
Collection of background data and selection of investigation sample.

Step-2
Visual examination of failed parts and photographic evidence in-as-is
condition.

Step-3
Mechanical Testing (If Required)
Dimensional Check (If Required)

Step -4
Selection and cutting of sample

Step-5
Cleaning of sample

Step-6
Macroscopic examination (Optical & Stereo Microscopes)
(fracture surface, secondary cracks, surface condition, etc).

Step-7
Microscopic examination (SEM)
(failure mechanism and fracture patterns).

Step-8
Finalization of the report indicating the probable cause of failure.

Step-9
Issuance of report after the approval.
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 Failure Investigation Laboratory Manual

CHAPTER – 6

WORKFLOW FOR FAILURE INVESTIGATION LABORATORY

Technical Information from

Failed parts received Operators/OEM through Air Safety
From Air Safety / AAIB Directorate / AAIB

Collection of background data and selection of Investigation sample

Laboratory Examination at
Macro & Micro Level with
the help of Optical, Stereo
and Scanning Electron
Microscope

Release of Report
Fig.1

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 Failure Investigation Laboratory Manual

CHAPTER – 7

FORMAT OF THE REPORT

INTRODUCTION
Contains observations made on the part in-as-is received condition and
a brief history of the failed part.

LABORATORY EXAMINATION
a) Visual and Macro Examination
Contains preliminary information gathered macroscopically about the
type of failure and type of loading.

b) Dimensional Check / Mechanical Testing (if required)

Contains decision on the basis of part/assembely dimension checks.

c) Scanning Electron Microscope (SEM) Examination

Contains information about characteristics of the type of failure.

DISCUSSION
Contains a summary of the laboratory examination.

CONCLUSION
Contains the exact cause of failure.

RECOMMENDATIONS
Contains steps to be taken to avoid recurrence.

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