Handbook of Materials Failure Analysis with Case Studies from the Aerospace and Automotive Industries

Professor Abdel Salam Hamdy Makhlouf is the Vice President of Integrated Mechanical Material Corrosion Consulting (IM2C), Texas, USA, and a Full professor at Central Metallurgical Research and Development Institute. He has 26 years of experience working in R&D with a blend of both industrial and academic leadership as a Professor of Materials Science, and Advanced “nano-bio” Manufacturing Engineering, and Materials Engineering Consultant. He is the recipient of numerous national and international prizes and awards including the Humboldt Research Award for Experienced Scientists, at Max Planck Institute, Germany; Fulbright, NSF, and Dept. of Energy Fellowships, USA; Shoman Award in Engineering Science; and the State Prize of Egypt in Advanced Science and Technology. His research has focused on five critical areas: Energy, Health, Environment, Advanced manufacturing, Advanced materials. Dr. Makhlouf has published over 200 journal articles, as well as 17 books and handbooks for Springer and Elsevier on a broad range of cross‐disciplinary research fields including advanced multifunctional materials, nanotechnology, smart coatings, corrosion, biomaterials, waste/water treatment, and materials for energy applications. Dr. Makhlouf has served as both a Senior Editor and board member of many international journals, as well as reviewer for several international funding agencies in USA, Germany, UK, Qatar, Belgium, EU, Kazakhstan. He is a Consultant/Reviewer for several universities worldwide. Mahmood Aliofkhazraei is Senior Coating Engineer at National Oilwell Varco in Houston, Texas. He has also been a Fuel Cell Corrosion Engineer at General Motors, and an academic Researcher at the University of South Florida, after starting his career as Associate Professor in the department of materials science at the Tarbiat Modares University. With over 20 years of combined industrial and academic experience in coatings, corrosion protection, and surface engineering. His work has spanned the development, application, characterization, and failure analysis of metallic, ceramic, and polymeric coatings across diverse industrial sectors including automotive, oil and gas, aerospace, energy, and advanced manufacturing. Dr. Aliofkhazraei has published extensively in peer-reviewed journals and has authored and edited multiple books and book chapters in the fields of coatings, corrosion, and materials failure analysis, including previous publishing projects with Elsevier. In addition, he has served as a consultant and collaborator with leading companies, universities, and research institutions worldwide.

• Part 1. Failure Analysis in Aircraft and Aerospace Structures1. Strategies for Static Failure Analysis on Aerospace Structures2. Strategies for Dynamic Failure Analysis on Aerospace Structures3. The Evolution of Failure Analysis at NASA’s Kennedy Space Center and Lessons Learned4. Fleet Impact Resulting from a Space Shuttle Columbia Main Engine Controller Wire Failure during Mission STS-935. Fatigue Failures of Aeronautical Items: Trainer Aircraft Canopy Lever Reverse, Rescue Helicopter Main Rotor Blade and Fighter-Bomber Aircraft Ground-Attack Main Wheel6. Failure Investigations of Helicopter Tail Rotor Gearbox Casings at Agustawestland Limited7. Failures of Rotorcraft and Fixed-Wing Aircraft Aerospace Components8. Suspension and Landing Gear Failures9. Fatigue as a Cause of Failure of Aircraft Engine Cylinder Head10. Analysis of an Engine Bevel Pinion Failure11. Failure due to Synergistic Fracture and Pitting Corrosion of Ruptured Bolts in a LARZAC Engine of Alpha Jet12. A Failure-Processing Scheme based on Kalman Prediction and the Reliability Analysis for 25kVA Generators used on IDF13. Fatigue Failure in Aircraft Structural Components14. Chemical Analysis Techniques for Failure Analysis: Part 1, Common Instrumental Methods15. Chemical Analysis Techniques for Failure Analysis: Part 2, Examples from the LabPart 2. Failure Analysis in Automotive and Transportation Structures16. Characterization of Steel Cut-edge Properties for Improved Life Predictions for Preventing Automotive Structural Failure17. Failure Analysis Cases of Components of Automotive and Locomotive Engines18. Failure Mechanisms and Modes Analysis of Vehicle Exhaust Components and Systems19. Failure of Structural Parts for Large Road Vehicles 20. Failure of Steel Couplings used in Railway Transport21. Failure Analysis and Prevention in Powertrain Systems