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A small cross-section aluminium alloy rod was subjected to an unexplained phenomenon called the 'Hutchison Effect' which caused the rod end to 'burst' forming a bizarre, frayed failure consisting of peeled platelets 0·05 to 2 mm thick, many torn along striated surface features to form metal strands or filaments resembling a frayed rope. This unusual failure did not exhibit any unexplained metallurgical or materials phenomena when examined using a materials characterisation protocol including optical metallography, field emission scanning electron microscopy and transmission electron microscopy, leaving the mechanism for this bizarre failure unexplained. [ABSTRACT FROM AUTHOR]