This paper presents two incidences of failures of collective control rods which resulted in accidents to a particular type of helicopter. The control rods were made of 2024 Al-alloy tubes fitted with fork at one end and a spherical bearing at the other end (eye-end). In terms of physical appearance, the two failures in the control rods were identical to each other wherein there was fracture in the Al-alloy tube at the eye-end. Fractography study confirmed that in both the cases, multiple fatigue cracks had initiated over a sector at the internal thread roots on the Al-alloy tubes corresponding to 1st/2nd thread on the eye-end stud. After initiation, the cracks had propagated progressively into the tube-wall and then along the circumferential direction. As the crack propagation progressed, the load bearing capacity of the tubes diminished resulting in final overload fracture under the operational load at the time of accidents. Although failures in both the control rods looked alike in terms of failure location, fracture pattern and fracture mechanism, the primary reasons of failures were found to be different. Investigation revealed that premature fatigue crack initiation was due to non-uniform stress distribution on the internal threads of the control tube with increased level of stress over a sector. In one case, the non-uniform stress distribution resulted from thread manufacturing deficiency, and in the other case, it was due to incorrect assembly at the eye-end.
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