United States Department of Transportation
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Guidelines to Minimize Manufacturing Induced Anomalies in Critical Rotating Parts - 2019 Revision
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2019-05-01
[PDF-2.09 MB]
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Abstract:This report was developed by a partnership of the Aerospace Industries Association (AIA) Rotor Integrity Steering Committee (RISC) member company manufacturing experts and the Federal Aviation Administration (FAA) in response to accidents and incidents caused by Manufacturing Induced Anomalies in critical rotating parts. According to a 2017 summary from the AIA Rotor Integrity Steering Committee, slightly fewer than 30% of rotor cracks/events are caused by post-forging Manufacturing Induced Anomalies. The data do indicate a significant reduction in circular hole and axial blade slot cracks and events over the last decade. The guidelines contained herein represent an industry consensus on the currently available best practices to minimize Manufacturing Induced Anomalies in critical rotating parts consistent with the AIA RoMan team charter and vision. Recommendations for nominal rotor Manufacturing Process development and control, including process validation, quality assurance, disposition of suspect parts, process monitoring, human factors and training, and non-destructive evaluation, are included to provide an overall framework for a highly reliable Manufacturing Process. Because critical rotating part reliability has demonstrated particular sensitivity to hole and axial blade attachment slot Manufacturing Methods, specific recommendations for hole-making and axial blade attachment slots are included. In addition, a section containing industry lessons learned is included to provide guidance on issues common in the industry. The term “lessons learned” generally refers to useful pieces of practical wisdom acquired by experience or study. Appendices are attached which include the team charter and vision, detailed information concerning process monitoring of holes, non-destructive evaluation techniques, Manufacturing Methods for axial blade attachment slots, manufacturing credits for damage tolerance assessments promoting introduction of improved Manufacturing Methods, guidance for preventing damage from titanium spark impingement, and guidance for titanium polishing and blending.
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