Research

Omega Research

Research

OMEGA RESEARCH is a Testing Laboratory however we are much more with a focus on research and when testing failures occur, helping our customers understand causes more quickly to enable them make changes and avoid further test failures. Omega Research was founded by Craig Willan who has a life-long passion for problem solving and understanding the science and physics around metallurgy. Here we are providing access to some of the most important research work completed by Craig.

Failures in the Real World

At Omega Research these past 25+ years, we have found that Hydrogen Embrittlement failures in the "Real World' rarely have a single source or cause. Many investigators, not trained in the art of failure analysis, will take a failed part, throw it into an SEM, look for intergranular cracking, shout Eureka! and pronounce the failure "Hydrogen Embrittlement."

In the real world, hydrogen embrittlement is many times the effect, not the cause. By this we mean, hydrogen simply can be the catalyst for a lurking failure. 

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Materials

Understanding materials is fundamental to solving complex engineering problems. This section gathers research, commentary, and perspective on the role of materials in advancing performance, reliability, and innovation across high-stakes industries.

AerMet 100

This white paper explores the unique properties and processing challenges of AerMet 100, a high-carbon, high-strength steel developed as an advanced alternative to 300M-type alloys for aerospace applications requiring strengths of 280 ksi and above. Known for its exceptional fracture toughness, AerMet 100 demands strict control over heat treatment, cryogenic stabilization, and aging processes to avoid serious risks such as hydrogen embrittlement and stress corrosion cracking. The paper traces the alloy’s development history, highlights its sensitivity to retained austenite and austenite reversion, and outlines how even minor deviations—like insufficient cold stabilization or prolonged aging—can compromise structural integrity. It also reviews real-world failures linked to improper processing, reinforcing the need for metallurgical discipline and process precision. Ultimately, the paper makes clear that while AerMet 100 offers outstanding performance potential, that potential can only be realized through rigorous quality control.

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Materials and Processes - Landmark Aircraft of the USAF

This paper offers a reflective overview of the critical role Materials and Processes (M&P) have played in the evolution of United States Air Force aircraft, from the Wright Brothers' first military contract in 1908 to landmark innovations of the modern era. Driven by the relentless pursuit to go “higher, faster, farther,” aviation has continually depended on M&P advancements, particularly in reducing weight and improving performance. Through a metallurgist’s lens, this commentary highlights the significant milestones and benchmark aircraft that illustrate how innovations in materials, from wood and fabric to advanced composites and metals, have shaped aerospace progress.

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Testing

Behind every component that flies is a history of testing, failure, and refinement. This section brings together papers that explore the rigorous world of materials testing, especially in relation to hydrogen embrittlement. These documents tell the story of how subtle design factors can have dramatic consequences, and why careful, evidence-based testing is at the heart of engineering.

All About Hydrogen Embrittlement

This white paper provides a comprehensive examination of hydrogen embrittlement in high-strength steels, particularly in the context of metal finishing processes. It explores the metallurgical mechanisms behind embrittlement, sources of hydrogen, and various testing methodologies to detect damage. The paper outlines key strategies for controlling hydrogen, both by preventing its introduction and removing it post-process through proper baking procedures. Detailed guidance is offered for specific plating processes, including cadmium, chrome, nickel, silver, zinc, electroless nickel, phosphate coating, and copper, highlighting best practices and potential pitfalls. The document serves as a technical guide to help metal finishers avoid costly and potentially catastrophic failures associated with hydrogen embrittlement.

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The History of Hydrogen Embrittlement

Hydrogen Embrittlement in our aerospace industry is a metallurgical phenomenon in high strength structural alloys. Very simply, the ductility-strength properties of the alloy are lowered to a level below what the design engineer anticipated in his component design. The resultant reduction in ductility inherently lowers the load carrying capability of the metallic component, hence failure by sudden brittle fracture can occur. Dozens if not hundreds of aircraft accidents, many fatal, have resulted through the years from hydrogen embrittlement. The focus of this paper is centered on aircraft-aerospace steel alloys and the history of their embrittlement problems. This is not a research paper. The solid state physics of embrittlement mechanisms are not intended to be discussed here. Rather, a general overview of the fundamental metallurgical interactions are given, and discussions on inspection methodology are presented. A historical overview of the events, organizations, people, and sadly some serious accidents that have furthered the understanding of hydrogen embrittlement over these past 50 years are set forth.

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