H. N. Chou, Boeing Phantom Works, St. Louis, MO
The USAF has reported that several end washers on cam follower assemblies have cracked. One of these steel end washers has been submitted to the Boeing-STL Failure Analysis Lab to determine if hydrogen embitterment was a contributing cause of the failure. The cam follower is an assembly that consists of a bolt, roller bearing and end washer and the cam follower is a part of the F-15 NLG Shimmy Damper Retrofit Kit. The steel end washer was cadmium plated and plating process inadequacies was reported. The end washer was received in two (2) segments and one side of the washer had been ground flat. Microscopic examination and magnetic particle inspection revealed no evidence of any secondary cracking. Metallographic analysis verified the existence of plating and abusive grinding damage was observed. The microstructure consisted of tempered martensite with a dispersion of carbides. Chemical analysis indicated a hydrogen content of 2.1 ppm in the failed washer sample. Fractographic analysis identified an initiation site on the fracture surface that contained a stringer like inclusion cavity surrounded by a small zone exhibiting an intergranular topography. The intergranular topography could be indicative of several failure modes including hydrogen embitterment. With no evidence of corrosion products was detected and the part was being subjected to a sustained load condition at the time of failure, it was concluded that the failure of the end washer was attributed to hydrogen embitterment. A contributing factor was the location and size of the stringer. Having been open to the surface of the washer, the stringer would have created a path into the washer interior, allowing for greater permeation and localized absorption of hydrogen during the plating operation. Inadequacies in the cadmium plating and subsequent embitterment relief all contributed to the failure.