How to Detect Common Defects Found in Aerospace Applications

In the intricate realm of aerospace engineering, where precision and safety are non-negotiable, detecting defects is a critical endeavor. Aerospace components operate under extreme conditions and forces that can push materials to their limits, so understanding how to identify and mitigate defects is essential to ensure the reliability and longevity of aerospace systems. In this guide, we will delve into some of the most prevalent defects encountered in aerospace applications and explore effective detection strategies.

One of the primary concerns in aerospace engineering is the occurrence of fatigue cracks. These cracks develop over time due to cyclic stress, which is caused by repetitive loading and unloading of components during flight cycles. Fatigue cracks are particularly insidious because they often start small and gradually spread, eventually leading to catastrophic failure if left undetected. To detect fatigue cracks, aerospace engineers employ various non-destructive testing (NDT) techniques such as ultrasonic testing, eddy current testing, and radiographic inspection.

Another common defect encountered in aerospace applications is corrosion. Aerospace components are exposed to a variety of corrosive environments, including saltwater, humidity, and chemical contaminants. Corrosion can weaken metal structures, leading to reduced performance and increased susceptibility to fatigue cracking. Detecting corrosion early is crucial for preventing structural failures in aerospace systems, and engineers employ visual inspections, corrosion monitoring systems, and electrochemical techniques to identify corrosion damage and assess its severity. Regular maintenance and corrosion prevention measures are also essential to preserving the integrity of aerospace components and extending their service life.

Composite materials, which are increasingly used in aerospace applications for their lightweight and high-strength properties, present unique challenges in defect detection. Unlike traditional metallic materials, composites can exhibit defects such as delamination, fiber breakage, and voids. Delamination, which is where layers of composite material separate from each other, can significantly compromise the structural integrity of an aerospace component. To precisely detect delamination and other similar defects in composite materials, engineers utilize advanced NDT methods such as thermography, shearography, and acoustic emission testing.

In addition to fatigue cracks, corrosion, and issues faced by composite materials, aerospace engineers must also be vigilant for defects like manufacturing flaws, material degradation, and foreign object damage (FOD). Manufacturing flaws, such as porosity and voids, can compromise the structural integrity of aerospace components and increase the risk of failure. Additionally, material degradation due to exposure to extreme temperatures, radiation, and chemical agents can lead to defects such as embrittlement and degradation of mechanical properties. Finally, foreign object damage, caused by debris or foreign particles impacting aerospace components, can result in surface scratches, dents, and cracks that weaken the structure.

By staying vigilant and proactive in defect detection and mitigation, aerospace professionals can ensure the continued safety, reliability, and performance of aerospace systems. If you are in search of replacement parts for aerospace applications, we invite you to explore our offerings here on NSN Matrix. We carry over 2 billion high-caliber products that are sourced from reputable manufacturers and guaranteed for fit, form, and function. If you find anything of interest using our curated catalogs or robust search engine, do not hesitate to utilize our online RFQ service to receive custom quotes for your comparisons in 15 minutes or less. Kick off procurement for the items you need today and see for yourself why NSN Matrix is countless customers’ preferred source for aerospace components.