Critical Failures in Aviation Components: The Role of Hydrogen Embrittlement

Hydrogen embrittlement (HE) poses a critical safety risk in the aviation industry, causing unexpected failures in high-strength metals and alloys used in essential components. This study focuses on detailed analyses of multiple aviation incidents and accidents where HE played a significant role, particularly concerning failures in helicopter drive systems and fixed-wing aircraft crankshaft bolts. Investigations revealed that these failures were primarily caused by hydrogen introduced during manufacturing processes, such as electroplating and surface treatments, which were insufficiently mitigated by post-processing techniques like dehydrogenation. These incidents led to Airworthiness Directives (ADs), which mandated corrective actions to prevent similar occurrences, such as improved manufacturing protocols and enhanced material testing. By presenting concrete evidence from metallurgical analyses and documented aviation failures, this paper highlights the critical need for robust manufacturing controls, stringent post-treatment procedures, and continuous monitoring to address hydrogen embrittlement risks effectively and enhance aviation safety.