Topic 4.5 - Discussion Case Analysis 2 Peer Review PDF

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7/7/2021

Topic: 4.5 - Discussion: Case Analysis 2 Peer Review

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This is a graded discussion: 100 points possible due Feb 8 at 10:29am 1

4.5 - Discussion: Case Analysis 2 Peer Review

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Complete your review of at least one peer's Case Analysis 2 document. To ensure that all students receive feedback, reply first to any students who have not yet received replies from other students. Post your review as a reply to the posting containing the document. In your reply, indicate whether or not you would be able to make a decision based solely upon what is presented in their analysis. Ensure that your feedback is constructive and positive.

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(https:/ Ryan Firdhaus Bin Alis Haizan (https://erau.instructure.com/courses/125588/users/234755) Jan 31, 2021

Attached is my case analysis on the aluminum fuselage used on the Boeing 777x Ryan Firdhaus 3.4 Case Analysis - Materials Selection-1.docx (https://erau.instructure.com/files/25398865/download? download_frd=1&verifier=jeJY1cgA9DDEoFpDoXRi7PG0s1OWpYFNsyhtz6Tw)

(http Corey Robinson (https://erau.instructure.com/courses/125588/users/166088) Feb 3, 2021

Ryan, After reading your case analysis and what happened to cause the problem. I agree with you final recommendation. The aircraft failed just under limitations while in the testing phase. That is just unlucky and could have possibly just been from a bad fuselage support in the area that had minor stress fractures from tempering or the rivets for the aircraft skin were put under to much load in this area. However, your analysis of just adding an extra fuselage support in this area would be a quick and easy solution to the problem. Many aircraft have fuselage supports closer together in high stressed areas of the aircraft. This https://erau.instructure.com/courses/125588/discussion_topics/2050304?module_item_id=7184343

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would however shift the center of gravity and affect the overall flight limitations and characteristics of the aircraft. -Corey

(http Dave DC Delcastillo (https://erau.instructure.com/courses/125588/users/425) Feb 3, 2021

In Ryan's case analysis, the 777x used an aluminum skin for the cabin design. According to articles I have read, many in the industry though Boeing should have gone with a composite material. However, this choice may have cost sales of the new aircraft due to the delayed entry into service time. (Hamilton & Valery, 2021 February). According to Creighton, the 777x failed it's pressurization test which if passed would show the fuselage could stand 1.5 times the force of pressurization of flight. This is 150 percent of the force of flight pressurization, but the 777x did not achieve this. Most aircraft use an aluminum alloy known as 2024 Alclad sheets (https://continentalsteel.com/blog/aluminum-in-the-aerospace-industry/) ; this is not the

material used in the 777x. The 777x uses Aluminum Lithium AlLI, and is very strong but light (Bjorn's Corner, 2015). This allowed a thinner skin for the 777x and may have been a point of failure. However, in Ryan's case study the two alternative actions were material change and reinforcement of problem areas. Given the information, which potential solution would you take class? References Bjorn’s Corner: Lighter fuselage materials and what they bring. (2015, April 02). Leham News and Analysis. https://leehamnews.com/2015/04/02/bjorns-corner-lighter-fuselagespractical-considerations/ Creighton, K. (2021, January 4). Another Boeing Blunder – 777x. https://flyersrights.org/boeing/another-boeing-blunder-777x/ Hamilton, S. and Valery V. (2021, Februrary 01). Exclusive: Boeing shifts 118 777 orders to “iffy” under accounting rule; 191 firm orders remain. Leham News and Analysis. https://leehamnews.com/2021/02/01/exclusive-boeing-shifts-118-777-orders-to-iffy-underaccounting-rule-191-firm-orders-remain/ Edited by Dave DC Delcastillo (https://erau.instructure.com/courses/125588/users/425) on Feb 3 at 10:01pm

(https:/ Joe Dapolito (https://erau.instructure.com/courses/125588/users/155994) https://erau.instructure.com/courses/125588/discussion_topics/2050304?module_item_id=7184343

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Jan 31, 2021

Case Analysis: Composite Material Failure on American Airlines Flight 587 Dapolito_Module 3.4-1.docx (https://erau.instructure.com/files/25399658/download? download_frd=1&verifier=SyNsX2O1NF3mNevoKfXjmoXnUb2ppMQloPsipxvW)

(http Dave DC Delcastillo (https://erau.instructure.com/courses/125588/users/425) Feb 3, 2021

Joe's analysis of Flight 587 is very good, although one bit of key information about flight 587 is not mentioned: The aircraft is an A320 Airbus. Something I found interesting about the A320 is recently, the first ever American built A320 was delivered from Airbus's Mobile Alabama site (Milberg, 2017). Much is made of offshoring, but it is not often mentioned that offshoring can occur from European companies to the Continental US. Per Joes' case, the A320 is a composite aircraft and one of the first to be rely on composite materials (Milberg, 2017). Ever since the A320 was first introduced, other designs rely heavily on composite material. Does anyone want to mention some of the other primarily composite aircraft designs? Dave DC

References Milberg, E. (2017, August 28). First Ever US-Built Airbus A320 Takes Off. http://compositesmanufacturingmagazine.com/2017/08/first-ever-us-built-airbus-a320takesoff/#:~:text=The%20primary%20structures%20of%20the,to%20incorporate%20composite% 20primary%20structures.

(https:/ Tharini Warakaulle (https://erau.instructure.com/courses/125588/users/244288) Feb 2, 2021

Hi class, Attached below is my case analysis.

https://erau.instructure.com/courses/125588/discussion_topics/2050304?module_item_id=7184343

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Tharini Warakaulle_ 3.4 Case Analysis 2_ Materials Selection.docx (https://erau.instructure.com/users/244288/files/25424722? wrap=1&verifier=1hwHqPCa73ZUMPYwGQsHsfNF58rROiNQNP226cPx) (https://erau.instructure.com/users/244288/files/25424722/download? verifier=1hwHqPCa73ZUMPYwGQsHsfNF58rROiNQNP226cPx&download_frd=1)

(http Corey Robinson (https://erau.instructure.com/courses/125588/users/166088) Feb 3, 2021

Tharini, I believe you had a well laid out case analysis and that you explained the topic and gave good examples of your recommendation along with the alternative actions. The article stated that the factory was not adhering to FAA approved quality control and that they also made 83 other parts in this factor so who know how many other parts could go bad (“Breaking Travel News”, 2011). Thankfully they grounded the fleet of aircraft and came to a conclusion of poor manufactured parts. This just goes to show you the complexities of a composite material and how humidity can affect curing drastically. I would believe that a quality control program as required by the FAA could have prevented this easily. Due to the fact that testing is normally done on composites to recommend best practice when forging or curing. The same thing goes to something like tempering steel. The different temperatures that it is tempered at can affect the brittleness drastically. References Breaking Travel News. (2011, September 25). FAA proposes $2.4 million Civil Penalty against Cessna Aircraft. https://www.breakingtravelnews.com/news/article/faa-proposes2.4-million-civil-penalty-against-cessna-aircraft/.

(http Dave DC Delcastillo (https://erau.instructure.com/courses/125588/users/425) Feb 3, 2021

Tharini, put together a fascinating case study on the Cessna TT which has become known as the TTx. According to an article in Aircraft Owner and Pilot Association (AOPA) web page, the "TT" stands for Twin Turbocharged. Another interesting fact is that Cessna did not actually design the aircraft in-house, they acquired the design when the bought Columbia Aviation out of bankruptcy and thus acquired it's assets. Finally, and this is to the point in Tharini's case, the aircraft has two composite (carbon-fiber) wing spars (Horne, 2017 February). The aircraft has since moved past it's early issues and is a favored aircraft

https://erau.instructure.com/courses/125588/discussion_topics/2050304?module_item_id=7184343

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for owners who like a luxury, fast, aircraft. Why do you think, it is common for aircraft failures to occur even after extensive testing? References Horne, T. (2017, February 1). Cessna TTX: Prime Performer Power And Panel To The Max. https://www.aopa.org/news-and-media/all-news/2017/february/pilot/ttx-prime-performer

(https:/ Corey Robinson (https://erau.instructure.com/courses/125588/users/166088) Feb 3, 2021

Hello class attached is my case analysis of the O-ring that failed on the space shuttle Challenger.

Corey_Robinson_AMNT429_MOD3.4-1.docx (https://erau.instructure.com/files/25437710/download? download_frd=1&verifier=BpfttkhKSUIs8HdvBOr3bWRCaplexcjAPJHPnFdX)

(http Dave DC Delcastillo (https://erau.instructure.com/courses/125588/users/425) Feb 3, 2021

Corey, fascinating topic selection! Multiple movies have been made on this topic. While the point of the case study is materials selection, this story is also one of the failure of the material when subjected to climates for which it was not intended. What else could we draw from this case analysis class?

(http Ryan Firdhaus Bin Alis Haizan (https://erau.instructure.com/courses/125588/users/234755) Feb 6, 2021

Hey Corey, Changing the material of the O-ring to something more robust would have definitely prevented such an accident. However, I believe that the material used at the time of the accident would have been the most suitable based on the capability of materials science and engineering in the 80s'. Kim (2020) also mentions that the director of the Space Shuttle Solid Rocket Motor Project for the engineering contractor had refused to sign a recommendation for the launch due to the safety concerns the night before. NASA and high level manages should have heeded this warning as the capability of the craft is best https://erau.instructure.com/courses/125588/discussion_topics/2050304?module_item_id=7184343

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assessed by the very people who designed and manufactured it. Simply postponing the launch could have saved the lives of the seven astronauts. It serves as a lesson for current and future management personnel in the industry that safety concerns brought forward by engineers and/or technicians should not fall on deaf ears no matter how minute its severity. References Kim, A. (2020, January 28). 34 years ago today, the space shuttle Challenger broke apart and killed everyone on board. CNN. https://edition.cnn.com/2020/01/28/us/spaceshuttle-challenger-34-years-scn-trnd/index.html (https://edition.cnn.com/2020/01/28/us/space-shuttle-challenger-34-years-scn-trnd/index.html) .

(https:/ Samuel Sargent (https://erau.instructure.com/courses/125588/users/39171) Feb 3, 2021

Sargent, Sam 3.4 Case Analysis-1.docx (https://erau.instructure.com/files/25437792/download? download_frd=1&verifier=f0L93R9kyfZdozZicfzQALbyocGkGexELyzHdqAG)

(http Joe Dapolito (https://erau.instructure.com/courses/125588/users/155994) Feb 4, 2021

Sam, Your analysis of structural issues related to composite materials is detailed and thorough. You provided all of the relevant information regarding failure of the composite control surfaces on the Concorde. Your rationale for both of your alternatives, as well as your final recommendation, are well-presented and supported with pros and cons. Your analysis of the problem of composite failure due to moisture intrusion is easy to follow and I can see how you arrived at your recommendation of exploring new coating methods to provide extra strength to these structures. An interesting category of coatings that may be useful in the prevention of moisture intrusion is that of self-healing coatings. Lutz et al (2016) explain that such materials are able to return to their original properties after sustaining damage and have already found use in concrete, asphalt, and thermal barrier applications (p. 157). Development of such a coating that could be applied to an aircraft skin would be a huge benefit to aircraft manufacturers and maintenance personnel. These coatings would be able to recover from https://erau.instructure.com/courses/125588/discussion_topics/2050304?module_item_id=7184343

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minor damages automatically and not allow openings for moisture to infiltrate and weaken the material underneath. I think something like this would be an exciting area to explore, especially as it could apply to providing safety for aircraft and prolonging service life.

References: Lutz, A., Mol, J.M.C., De Graeve, I., & Terryn, H. (2016). In Montemor, M. F. (Ed.), Smart composite coatings and membranes: Transport, structural, environmental and energy applications (pp. 157-181). Amsterdam: Elsevier.

(https:/ Vit Nedoma (https://erau.instructure.com/courses/125588/users/169212) Feb 4, 2021

Hello class, My case analysis 2 is attached. Vit Vit Nedoma 3.4 Case Analysis-1.docx (https://erau.instructure.com/files/25449258/download? download_frd=1&verifier=3WDToWTxpR1ZgSao8eFircIlky4WEsEps3YLVq9H)

(http Dave DC Delcastillo (https://erau.instructure.com/courses/125588/users/425) Feb 5, 2021

Vit, I checked out the AD source you used and found it interesting. The International Aero Engines 1133 and 1122 series engines replacement of LPC 3rd-stage blades would have a total cost to operators of $48,750,000 (FAA, 2020 April 14). No small cost, in fact, the dollar cost is very high for this Airworthiness directive. But the cost in lives worth it, along with ensuring the aircraft, its crew and passengers a safe flight without incident. In short the 3rd stage blades must be replaced in Pre-2019 manufactured engines and those manufactured after that date will roll out in compliance with the new blades installed. References Federal Aviation Administration. (2020 April 14). RIN 2120-AA64 Airworthiness Directives; International Aero Engines LLC, Turbofan Engines AD Supplement. https://rgl.faa.gov/Regulatory_and_Guidance_Library/rgad.nsf/0/158e69f4e5c9f1b2862585 4c00425195/$FILE/2020-08-04.pdf https://erau.instructure.com/courses/125588/discussion_topics/2050304?module_item_id=7184343

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(https:/ Colin Cheng En Yao (https://erau.instructure.com/courses/125588/users/233747) Feb 5, 2021

Hi Class! Attach is my Case Analysis 2. Thank you. Regards, Colin Case_Analysis2_ColinCheng-1.docx (https://erau.instructure.com/files/25459256/download? download_frd=1&verifier=g5vBp8dsdzChvY3aqHnYpsfYdi0Mf5hBushJ6UkV)

(http Samuel Sargent (https://erau.instructure.com/courses/125588/users/39171) Feb 7, 2021

Colin, You had a good overall review of the inferior design of the 777x. Aluminum is one of the more malleable materials and really needs to be reinforced properly. That is why a good underlying structure is very important. Your section about properly reinforcing the aluminum skin speaks on this. From our few weeks in this course and our collective review on their aircraft, they really continue to show that they fail to produce 100% flight-worthy aircraft at the end of their manufacturing process. This could largely be due to trying to shave a few dollars off the total costs. Substituting a different material as you suggested could have been a very effective method as well. Suppose the underlying structure was more than enough to handle a stronger skin. Something such as a fiber reinforced metal laminate (FRML) could provide the strength to meet the 1.5 safety factor. These RML materials are layers of fiber composites and aluminum sheets to gain some benefits and strengths from both materials (Davies, 2012). While the materials would cost more than just aluminum sheets, Boeing could do a cost analysis to see if just changing the skin material or going deeper to do reinforcements is the most effective measure at a price range they desire. V/R, Sam

https://erau.instructure.com/courses/125588/discussion_topics/2050304?module_item_id=7184343

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Reference Davies, G. (2012). Aluminum Skin. Science Direct. https://www.sciencedirect.com/topics/engineering/aluminium-skin

(https:/ Lithira Abeysinghe (https://erau.instructure.com/courses/125588/users/232625) Feb 5, 2021

Hello class, Attached below is my Case Analysis 2.

LithiraAbeysinghe3.4-1.docx (https://erau.instructure.com/files/25461172/download? download_frd=1&verifier=NQzCDNzcIVKJGkirBUNi4CDnRWVsiiJTCneWVcWS)

(http Dave DC Delcastillo (https://erau.instructure.com/courses/125588/users/425) Feb 5, 2021

Great analysis Lith. Composites are the way of the future in aircraft design and manufacturing. They are generally lightweight and strong, but as discussed in your case they are still prone to issues. According to an article from Gardiner, the 787 composite wing box was ground breaking at the time of development (2007 March). The wing box is the center section of the wing that is just below the fuselage and connects the left and right wing structures to together. Apparently, Boeing partnered with Japanese firm Taricco Corp to build the wing box for the 787 (Gardiner, 2007 March). Anytime a design such as this is a new concept there will always be growing pains, as outlined in Lith's case. References Gardiner, G. (2007, March 1). Inside Manufacturing: An autoclave for the 787 center wing box. https://www.compositesworld.com/articles/inside-manufacturing-an-autoclave-for-the787-center-wing-box

(http Tharini Warakaulle (https://erau.instructure.com/courses/125588/users/244288) Feb 8, 2021

https://erau.instructure.com/courses/125588/discussion_topics/2050304?module_item_id=7184343

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Hi Lithira, You have put together a fascinating case study on the Boeing 787 composite issue. As you have mentioned, the ultimate goal of the Boeing company was to boost the fuel efficiency slashing component weights by 20% making it the first commercial aircraft in which major structural elements are made of composite materials rather than aluminum alloys. But this strategy was not in the favor of them. In addition, since the wings are designed to transfer the loads into the fuselage box, the damage that occurred in the test was mirrored on either side of the joints. The delamination of the composite-plastic material is not likely to lead to catastrophic failure of the airplane, but it would require constant monitoring and potentially costly repairs by the airlines. Any tear would have to be promptly fixed to prevent it from spreading. The Boeing company experienced a large accounting loss in response to cover the extra expense of the repeated delays losing large sums of money on the first 400 to 600 aircraft. Moreover, your alternative actions as well as your final recommendation, are well-...