Experience & Selected Projects

Black Laboratories, L.L.C. has extensive experience in forensic engineering, materials characterization, root cause analysis, and advanced materials research. Our work spans complex engineering investigations across automotive, marine, construction, and aerospace applications, alongside federally funded research and development in collaboration with industry and national laboratories.

Forensic Engineering Cases

    • Impact Failure of Truck Power Steering Pitman Arm in a Multiple Fatality Collision

    • SEM/EDS Study of Braze Failures in a Series of CNG Truck Fires

    • Tread Separation of a Steel-belted Radial Tire

    • Fracture of D-bolt Allowing Detachment of a Trailered Heavy Truck and Injuries

    • Through-Hull Fixture Crevice Corrosion Failure and Sinking of a 35’ Viking Yacht

    • Fracture of Rod Rigging Leading to 40’ Racing Yacht Dismasting

    • Fatigue at Weld Hot Spots Leading to 157’ Sailing Yacht Dismasting

    • Marine Diesel Engine Failure of 63’ Burger Pilothouse Boat Due to Bearing Run-out Due to Sand Ingestion 

    • Marine Diesel Engine Failure on a 45’ Grand Banks Due to Water Pump Failure Because of Galvanic, Crevice Corrosion and Fatigue Fracture of a Water Pump Shaft

    • 304 Stainless Steel Hose Clamp Failure Due to Overtightening

    • Connecting Rod Buckling and Failure of a Mercury Outboard Motor 

    • Investigated for the City of Norfolk on a Collapse of an 800 lb. Steel Gate Onto a Pedestrian Resulting in TBI Claim

    • Fatigue of Recreational Swing Causing TBI

    • Fracture Study of large BLEVE Boiler Failure Which Caused a Factory Collapse

    • FTIR Identification of Food Substance Related to Slip and Fall

    • FTIR Identification of Multi-ply Grit and Alkyd Coatings Related to Slip and Fall

    • FTIR Investigation of Polymer Biodegradation Fracture of a Commercial Plumbing Product

    • Identification of Source of Damage in Architectural Plate Glass Scratching

    • Failure of Polypropylene Water Filter Canisters Due to Porosity During Injection Molding

    • Failure of Fire Suppression Sprinkler System and Flooding Due to Cracking of CPVC Pipe

    • Fracture of Cast Iron Butterfly Valve in Municipal Water Supply Line

    • Fractographic Study of Heat Exchanger System Failure and Flooding Due to Cavitation Corrosion of 4” Black Steel Pipe In a Public Elementary School

    • Discovery of an Improper Seal Which Allowed Separation of a 12” Pipe Junction and the Environmental Release of 160 BBL of Process Water at a Fracking Facility

    • Trenchless, Water Supply Pipe Liner Failure

    • Comparison of Hardness and Stiletto Heel Damage to Hardwood and Laminate Flooring 

    • Corrosion of Steel by Microbiologically Influenced Corrosion 

    • Electroplating Failure and Pitting in Small Caliber Military Rifles

    • Multiple Cases: Stress Corrosion Cracking of Brass Components and Water Loss

    • Perforation of Copper Tubing

    • Fatigue Failure of Helicopter Tail Rotor Control Pedal Return Spring

    • Hydrogen Embrittlement Failure of Helicopter Mounting Bolt

    • Turbine Engine Component Failure in USCG Aircraft 

    • FTIR and SEM Identification of Contaminants in USCG Aircraft Fuel Tank

    • Fatigue Failures of USCG Stainless Steel Cables 

    • Fatigue Failure of Army Helicopter Rotor Lag Straps

    • Weld Process Development in NASA Space Shuttle Superlightweight (SLWT)l Tank

    • External Tank Straps Cracking on NASA Shuttle SLWT

    • SEM/EDS Study of Faulty Tether on NASA $443MM Tethered Satellite Loss on STS-75

    • Space Shuttle Columbia Crash Investigation Documenting Damage During Descent

    • Fracture of NASA Titanium Satellite Mounting Bolts 

    • Failure Analyses of Wind Tunnel Hardware

    • Environmental Effects on 440C Steel Ball Bearings Used in Liquid Oxygen Pumps for Space Shuttle Main Engines

Recent Forensic Engineering Presentations

Blayton Piping +

Helicopter Spring Failure +

Areas of Technical Expertise

Root Cause Failure Analysis

Structure and Deformation Studies by EBSD Crystallographic Methods

All Optical and Electron Microscopy Methods

Electrochemical & Corrosion Studies

Chemical Analysis by Infra-red spectroscopy, FTIR, and EDS, EELS, and GC/MS

ASTM Standard Testing

Funded Research Proposals

Accelerator Cavities Research

under small business SBIR/STTR funding

2004 DOE Phase I SBIR Grant No. DE-FG02-04ER83909

2005 DOE Phase II SBIR Grant No. DE-FG, 2009 DOE Phase III SBIR

2006 DOE Phase I Grant No. DE-FG02-06ER84453

2008 DOE Phase I SBIR Grant No. DE-FG02-07ER84746

2008 DOE Phase I SBIR Grant No. DE-FG02-08ER85165

2009 DOE Phase I STTR Grant No. DE-SC0000965

2011 CRCF (Commonwealth of Virginia) Award No. CP-008

Aerospace Materials

under small business SBIR

2009 ONR/OSD Phase I SBIR Award No.: N00014-09-M-0401

2011 NASA Phase I SBIR Contract No. NNX11CH14P

R&D SUCCESS STORY

Superconducting Accelerator Cavity Development

The Research

DOE SBIR funding in excess of $1M for Phase I, Phase II and (National Laboratory funded) Phase III was won for a Metallurgical Product development with an industrial partner for application in large particle accelerator projects.

The Technology

A proprietary process developed by Black Laboratories in collaboration with an Industrial Partner was used to manufacture superconducting structures at DESY in Hamburg, Germany.

Testing & Collaboration

Testing was performed in part at Jefferson Lab in Newport News, Virginia. The resulting cavity is currently in storage with plans for final testing.