- Page 1: ATSB TRANSPORT SAFETY INVESTIGATION
- Page 4 and 5: Published by: Australian Transport
- Page 6 and 7: 4.4 Powertrain component failure co
- Page 8 and 9: 8.3 Factors associated with bearing
- Page 10 and 11: THE AUSTRALIAN TRANSPORT SAFETY BUR
- Page 12 and 13: stresses in the component during en
- Page 14 and 15: • a combined reduction in compone
- Page 16 and 17: Figure 1.1: High-power reciprocatin
- Page 18 and 19: - 4 -
- Page 20 and 21: from human behaviour and the behavi
- Page 22 and 23: Risk in the context of public trans
- Page 24 and 25: and certificated against a simpler
- Page 26 and 27: 3.3 Reciprocating-engine reliabilit
- Page 30 and 31: Between 1972 and 1976, the NTSB inv
- Page 32 and 33: feather position. He set maximum po
- Page 34 and 35: 79 (8% of the accidents, 15% of the
- Page 36 and 37: 4.2 Powertrain component design An
- Page 38 and 39: 2 2 T. n P. D. K. N P. D. n. S. N b
- Page 40 and 41: powertrain components affected by c
- Page 42 and 43: Figure 4.3: Schematic illustration
- Page 44 and 45: that variations from a norm do occu
- Page 46 and 47: 4.5 References Repco 1980, Repco En
- Page 48 and 49: 5.3 Information gathering Informati
- Page 50 and 51: 5.3.4 Evaluating Evidence associate
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- Page 54 and 55: Figure 6.1: Timeline of powertrain
- Page 56 and 57: 6.2.1 Occurrence 2000/2157 VH-MZK (
- Page 58 and 59: Examination of the remaining five p
- Page 60 and 61: Figure 6.6: Ground tracks, radar da
- Page 62 and 63: • the separation of the destructi
- Page 64 and 65: Figure 6.10: Cracking in the fillet
- Page 66 and 67: 6.2.4 Occurrence 2001/3357 VH-RNG R
- Page 68 and 69: 6.2.5 Occurrence 2001/3251 VH-FIA R
- Page 70 and 71: Figure 6.17: The No.3 piston and cy
- Page 72 and 73: 6.2.8 Occurrence 2003/3532 VH-HJS R
- Page 74 and 75: 6.3.2 Occurrence 2000/90 VH-MZK (le
- Page 76 and 77: Figure 6.23: Galling (adhesive wear
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earing alloy layer from the steel b
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It is evident that the initial frac
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Figure 6.27: Detailed views of the
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6.3.6 Occurrence 200303701 VH-OCF R
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Figure 6.31: The condition of littl
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6.4.2 Occurrence 2000/2157 VH-MZK (
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Figure 6.35: The No.6 connecting ro
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Figure 6.39: No.6 connecting rod, b
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Figure 6.42: The initiation site of
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6.4.3 Occurrence 2000/2276 VH-ODE R
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6.4.4 Occurrence 2001/2544 VH-TTX R
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Figure 6.48: Crankshaft secondary f
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Figure 6.50: Detailed views of the
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Figure 6.52: Pneumatic pump couplin
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Figure 6.55: The No.6 connecting ro
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It is evident that with continued e
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Figure 6.61: Views of the fatigue f
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The engine had been operated under
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6.4.8 Occurrence 2005/02231 VH-IGW
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Figure 6.70: Crankshaft web fractur
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6.5 Crankshaft bearing, reported se
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Figure 6.74: Back surface of the bi
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7 EVALUATION OF POWERTRAIN COMPONEN
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7.2 Cylinder head fatigue fracture
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Figure 7.4: Cause-and-effect diagra
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7.4 Cylinder attachment fastener fa
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7.5.2 Connecting rod little-end fat
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Figure 7.9: Cause-and-effect diagra
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Inherent points of stress concentra
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friction is relatively small, so be
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speeds that exceed the design allow
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8 ANALYSIS OF POWERTRAIN STRUCTURAL
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shockwaves through the gas in the c
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The relationship between engine pow
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Figure 8.5: Cylinder head surface c
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Figure 8.7: Piston surface conditio
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Figure 8.9: Cylinder head surface c
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Figure 8.11: Cylinder head surface
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Figure 8.13: Piston surface conditi
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Figure 8.15: Piston surface conditi
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Figure 8.17: Cylinder head surface
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Figure 8.19: Cylinder head surface
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Figure 8.21: Piston surface conditi
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Lead oxybromide deposits may also f
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The extent of detonation; light, me
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Combustion chamber component temper
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8.3 Factors associated with bearing
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Any increase in oil-film temperatur
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Figure 8.37: Examples of trimetal b
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phase, in bearings manufactured wit
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emains attached to the aluminium al
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Bearing clearance Bearing clearance
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Figure 8.48: Detailed view of the n
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The available connecting-rod bearin
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Figure 8.52: Detailed view showing
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8.4 Factors associated with the ret
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Figure 8.57 Example of insert-locat
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8.4.3 Crankshaft main-bearing reten
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Figure 8.62: Detailed view of the m
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8.5 Factors associated with fatigue
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• a change in the component has o
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Figure 8.68: Detailed view of the p
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8.5.4 Crankshaft fatigue failure Cr
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Figure 8.74: Schematic showing the
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8.5.5 Crankshaft fatigue failure -
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Figure 8.80: Metallographic section
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Example 2: Teledyne Continental TSI
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Figure 8.86: Metallographic section
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Example 4: The Federal Aviation Adm
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Example 6: Lycoming TIO-540-J2B, oc
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Figure 8.94: Detailed view of the f
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Examination of the connecting rod e
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Planar defects created by journal g
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Example 10: Lycoming TIO-540-J2BD,
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Example 11: Lycoming TIO-540-J2BD,
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Example 13: Lycoming IO-360-A1B6, m
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Figure 8.114: Detailed views of the
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Fatigue crack initiation, occurrenc
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evident, from these sections, that
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Figure 8.121: Detailed view, sectio
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Figure 8.124: Fatigue crack initiat
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8.6 Multiple event sequences It is
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GAMI, General Aviation Modification
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9 ANALYSIS OF AIRWORTHINESS ASSURAN
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Engine reliability (issued December
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In your letter of 5 August 2002, yo
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Since August 2001, CASA has receive
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Lycoming has received several field
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1. Engines that have complied with
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ACTION: Final rule. Date: October 2
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Aggressive leaning: Aggressive lean
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Feedback is an important component
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feedback, in response to system mal
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10 CONCLUSIONS The reliability of r
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adial-engine combustion chamber (du
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complete certainty, the consequence