aerospace/metallurgical/ 1 weeks

Titanium alpha-case discovered pre-shipment saves an aerospace program

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Problem

An aerospace subcontractor was about to ship a batch of Ti-6Al-4V forgings when their in-house lab flagged surface hardness variability. Program deadline was 72 hours.

Approach

Rush turnaround: microhardness surveys per AMS 2801; metallographic cross-sections through affected zones; comparison to alpha-case control specimens.

Finding

10–30 μm continuous alpha-case layer on all inspected sections — direct evidence of atmospheric contamination during solution heat-treat.

Outcome

Lot rejected before shipment. Root cause traced to furnace argon leak. Program deadline preserved by using a hold-back inventory; supplier corrected the furnace within a week.

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