Here is my note about catastrophic failure of composites:
As mentioned earlier, we had a substantial Altitude Test Chamber … This was used both for testing our own products, and for hire to others. We had an enquiry from someone wanting an ‘Explosive Decompression Test’ on some fairly small equipment: this is to simulate the loss of a window or door on an aircraft.
Meanwhile, I was having some considerable success using Ciba-Geigy ‘F-Board’ for lightweight vibration test fixtures. This material has an aluminium honeycomb core with two thin skins of Glass Reinforced Epoxy [a high-tech equivalent of the construction used for internal domestic doors, etc.]
So … we hatched a plan:
- Build a box from F-Board, with a pipe and valve connecting to the big chamber.
- Seal the test item inside the box
- Pull the big chamber to 30,000 feet
- Open the valve
Sounds easy … but we felt obliged to first do a test on the F-Board.
The 3’ diameter hatch on the chamber had a nice wide flange, so it was a simple matter to attach a sheet of 2” board with a gasket of Plasticine.
Three of us were working late on another trial, so we had time to do this little test as a freebie.
I will mention here that there was a ‘closed porch’ built onto the chamber, to allow access through the hatch without losing too much heat or cold … This was timber framed, insulated with cork, about 3” thick, and double-skinned with hardboard.
We pulled the chamber to 10,000’ and held it for a while … everything was stable with no sign of leakage. So we proceeded.
As we approached 30,000’ there was an almighty bang and a rush of wind past our heads [the control panel was several feet away from the chamber, in an alcove]
Turning the corner … we realised that most of the ‘porch’ was missing, including its full-sized door !!
The F-Board had suffered ‘catastrophic failure’ and the inrush of air was sufficient to drag it all into the chamber.
My meeting next day, with the head of Test-House, was interesting … he was surprisingly supportive, despite the fact that the clean-up would involve overhaul of both vacuum pumps [it ended-up taking months].
There is a PostScript about Health&Safety Inspectorate, but I will save that for another day.
MichaelG.
Edited By Michael Gilligan on 23/06/2023 11:52:34