Aircraft Structural Integrity Insights
Aircraft Structural Integrity Insights
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National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia)
Overview
DE HAVILLAND COMETS
BOEING 737
BOEING B-47’S
AERMACCHI MB-326H
CONTINUING DEVELOPMENTS
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 2
Evolution of civil aircraft fatigue
requirements
Fatigue (Safe-Life)
Yes
Either Inspection Impractical?
No
Fail-Safe
Damage Tolerance
Full-Scale Fatigue Test
LOV
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 3
Evolution of military aircraft fatigue
requirements and techniques
Fatigue (Safe-Life)
Static Strength USAF ASIP*
Both
Requirements
only Damage Tolerance
USAF
Quantitative Fractography (QF)
and ASIP*: DSTO/RAAF
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 5
Comet Case Histories
G-ALYP wreckage showed fatigue failure from R.H. aft corner of rear automatic
direction finding (ADF) window, see slides 8 −10.
Early fatigue failures attributed to high local stresses, see slides 7,8,10.
Cutouts in frames, slide 10, facilitated crack extension and fuselage rupture:
crack-stopper straps (tear straps) would have been needed.
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 6
Failure origin of test aircraft G-ALYU
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 7
Failure origin of service aircraft G-ALYP: I
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 8
Failure origin of service aircraft G-ALYP: II
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 10
Lessons Learned
Owing to analysis limitations, cracks can occur much earlier than anticipated
from Safe-Life fatigue design.
However:
some components, e.g. landing gear, are not amenable to Fail-Safe design
no requirement as yet (see slide 12) to do Full-Scale Fatigue Testing.
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 11
Evolution of civil aircraft fatigue
requirements: I
COMETS
1954
Fatigue (Safe-Life)
Either
Fail-Safe
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 12
DAN - AIR Boeing 707-321C 1977
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 13
Boeing 707 Case History: I
Dan - Air Boeing 707-321C G-BEBP air freighter lost the right-hand horizontal
stabilizer just before landing at Lusaka airport on May 14, 1977.
The aircraft had accumulated 47,621 airframe flight hours and was past its
prime: the term ‘Geriatric Jet’ was introduced.
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 14
Boeing 707 Case History: II
Failure origin of 707-321C G-BEBP
Fatigue from a fastener hole in the upper chord of the rear spar.
Fastener − linked
chord elements
intended to be
:
damage should
have been easily
detectable before
final failure.
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 15
Causes of failure
Fatigue:
unanticipated high local stresses and oscillating loads owing to speed brake
deployment during normal landings.
Lack of Fail-Safety:
periodic inspection time less than 30 minutes, i.e. visual inspection
visual inspection unable to detect partial failure of upper chord (see slide 15)
once upper chord failed completely (visually detectable), the structure was
unable to sustain service loads long enough to enable detection.
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 16
Lessons Learned
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 17
Civil Aviation actions
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 18
Evolution of aircraft fatigue
requirements: II
Fatigue (Safe-Life)
Yes
Either Inspection Impractical?
No
Fail-Safe
Damage Tolerance
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 19
Aloha Airlines Boeing 737-297 1988
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 20
Boeing 737 Case History: I
The aircraft had accumulated 35,496 airframe flight hours and 89,680 (!) landings.
It was 19 years old and had operated with long-term exposure to warm sea air.
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 21
Boeing 737 Case History: II
Failure location of 737-297 N73711
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 22
Causes of failure: I
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 23
Causes of failure: II
defective bonding allowed moisture into skin splice, causing corrosion and
disbonding of skin splice and Fail-Safe tear straps
loss of skin splice integrity led to all load transfer via the rivets
knife edges in upper skin caused MSD fatigue cracking in critical upper rivet row
disbonded tear straps could not provide Fail-Safety via controlled decompression
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 24
Lessons Learned
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 25
Evolution of aircraft fatigue
requirements: III
Fatigue (Safe-Life)
Yes
Either Inspection Impractical?
No
Fail-Safe
Damage Tolerance
Full-Scale Fatigue Test
LOV*
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 27
B-47 Case Histories
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 28
Fatigue-critical areas (only R.H. side shown)
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 29
Strategic Air Command (SAC) and USAF
fleet actions
Most of fleet modified by October 1958. By June 1959 only a few interim-fixed
aircraft still needed work.
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 30
Lessons Learned
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 31
Evolution of aircraft fatigue
requirements and techniques: I
B-47’S
1958
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 32
USAF General Dynamics F-111 1969
RAAF General Dynamics F-111C with wings extended and swept back.
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 33
F-111 Case History: I
USAF F-111A lost the left wing during low-level flight on December 22,
1969.
Failure occurred after only 107 airframe flight hours and at about 3.5g, less
than 0.5 DLL (Design Limit Load).
Crash-site investigation revealed a large flaw in the lower plate of the L.H.
wing pivot fitting, see slide 35. The plate and pivot fitting was made from a
high-strength steel.
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 34
F-111 Case History: II
Failure origin of F-111A 67-0049
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 35
USAF actions and Lessons Learned
Accident and airframe test problems led to a fracture control programme for
critical steel parts:
aircraft periodically removed from service and proof tested at −40ºC*
inspectable areas checked by standard non-destructive inspection (NDI).
*Steel fracture toughness and hence critical flaw/crack size less at low temperatures.
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 36
Evolution of aircraft fatigue
requirements and techniques: II
B-47’S F-111
1958 1969
Fatigue (Safe-Life)
Static Strength USAF ASIP
Both
Requirements
only Damage Tolerance
USAF
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 37
RAAF Aermacchi MB-326H 1990
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 38
Aermacchi Case History: I
A7-076 left wing separated during a 6.5g manoeuvre on November 22, 1990.
Failure after 2188 airframe flight hours, only 70% of the Safe-Life derived
from Full-Scale Fatigue Testing in 1975.
Wing loss due to fatigue and fracture of lower spar cap close to the centre
section attachment fitting. Fatigue began at a badly drilled bolt hole, see
slide 40.
Fleet-wide NDI found fatigue cracks growing from bolt hole manufacturing
flaws in four other wings, including the A7-076 right wing.
However: detailed examination of the A7-076 right wing found many cracks
growing from normal quality structural details.
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 39
Aermacchi Case History: II
Failure origin of MB-326H A7-076
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 40
DSTO and RAAF actions: I
Safe-Life reassessment:
Teardown of nine high-life wings, NDI and (QF)
QF data used to estimate ‘worst case’ fatigue crack growth lives
conversion of fatigue crack growth lives into Safe-Life damage units used
for the Full-Scale Fatigue Test in 1975
pooling the damage estimates and applying an appropriate scatter factor.
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 41
DSTO and RAAF actions: II
● Wing replacements only feasible option: 30 new wing sets were purchased.
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 42
Lessons Learned
RAAF structural integrity policy has changed similarly to the USAF’s after
the B-47 accidents in 1958. Since 1990 comprehensive ASIPs have been
established for each fleet. This was a major undertaking due to many types.
Extensive research since 1990 (see slide 44) has shown that QF-based
fatigue crack growth analyses are essential for:
Full-Scale (and component) Fatigue Tests
structural integrity management of a fleet.
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 43
Evolution of aircraft fatigue
requirements and techniques: III
Fatigue (Safe-Life)
Static Strength USAF ASIP
Both
Requirements
only Damage Tolerance
USAF
Quantitative Fractography (QF)
and ASIP: DSTO/RAAF
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 44
Case Histories: Summary
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 45
Continuing Developments: I
Fatigue analyses of conventional airframes
However
corrosion in military aircraft appears to be predominantly ground-
based, while fatigue occurs mainly in flight. This needs further
investigation, since it can have a major impact on service life
management.
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 46
Continuing Developments: II
Material developments for airframes
Tactical aircraft:
composites (35−40%) and lesser percentages of titanium, aluminium and steels.
Helicopters:
higher percentages of composites (up to 80−90%) owing to the importance of
weight savings for vertical lift aircraft.
● Modern trend is to design and build hybrid structures, for example slide 48
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 47
Hybrid airframe example: Airbus A380
CFRP = Carbon Fibre Reinforced Plastic; GLARE = GLAss REinforced aluminium laminates; 2XXX, 6XXX,
7XXX = conventional aluminium alloys; Al-Li = Aluminium-Lithium alloys; LBW = Laser Beam Welding.
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 48
New materials structural integrity implications:
Comparisons with conventional aluminium alloys
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 49
Selected Bibliography: I
1. P. Safarian, 2013, “Fatigue and Damage Tolerance Requirements of Civil Aviation,
Lesson 01 – Introduction, Winter 2014”, University of Washington, Seattle, USA.
2. R.G. Eastin and W. Sippel, 2011, The “WFD rule” − have we come full circle?, USAF
Aircraft Structural Integrity Conference 2011, November 29–December 1, 2011, San
Antonio, Texas.
3. E. S. Wilson, 1995, Developments in RAAF aircraft structural integrity management. In:
“Estimation, Enhancement and Control of Aircraft Fatigue Performance,” eds. J. M.
Grandage and G. S. Jost, Engineering Materials Advisory Services, Warley, UK, Vol. II,
pp. 959−970.
4. S. A. Barter, L. Molent and R.J.H. Wanhill, 2010, Fatigue life assessment for high
performance metallic airframe structures − an innovative practical approach. In:
“Structural Failure Analysis and Prediction Methods for Aerospace Vehicles and
Structures,” ed. S.-Y. Ho, Bentham E-Books, Bentham Science Publishers, Sharjah,
UAR, Chap.1, pp. 1-17.
5. T. Swift, 1987, Damage tolerance in pressurized fuselages. 11th Plantema Memorial
Lecture in: “New Materials and Fatigue Resistant Aircraft Design,’’ ed. D. L. Simpson,
Engineering Materials Advisory Services, Warley, UK, pp. 1–77.
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 50
Selected Bibliography: II
6. C. F. Tiffany, J. P. Gallagher and C. A. Babish, IV, 2010, “Threats to Aircraft Structural
Safety, Including a Compendium of Selected Structural Accidents/Incidents,”
Aerospace Systems Center Technical Report ASC-TR-2010-5002, Wright-Patterson Air
Force Base, Dayton, Ohio.
7. J. M. Ramsden, 1977. The geriatric jet problem. Flight International, Vol. 112, pp. 1201–
1204, 1207.
8. I. C. Howard, 1986, Fracture of an aircraft horizontal stabilizer. In: ‘‘Case Histories
Involving Fatigue and Fracture Mechanics, ASTM STP 918,’’ eds. C. M. Hudson and T.
P. Rich, American Society for Testing and Materials, Philadelphia, pp. 259–276.
9. Aircraft Accident Report, Aloha Airlines, Flight 243, 1989, Boeing 737-200, N73711, Near
Maui, Hawaii, April 28, 1988, NTSB report no. NTSB/AAR-89/03, National Transportation
Safety Board: Washington, DC.
10. U. G. Goranson, 1993, Damage tolerance—facts and fiction. 14th Plantema Memorial
Lecture in: “Durability and Structural Integrity of Airframes,’’ ed. A. F. Blom,
Engineering Materials Advisory Services, Warley, UK, Vol. I, pp. 3–105.
11. N. Athiniotis, S. A. Barter and N. T. Goldsmith, 1991, “Macchi aircraft safety-by-
inspection validation program - A7-076 starboard wing tear-down preliminary report,”
Defect Assessment & Failure Analysis Report No. M21/91, Defence Science and
Technology Aeronautical Research Laboratory, Melbourne, Australia.
National Aerospace Laboratory NLR (Netherlands) and Defence Science and Technology Group DSTG (Australia) 25-9-2015 51
Selected Bibliography: III
12. S. A. Barter, L. Molent and R.J.H. Wanhill, 2012, Typical fatigue-initiating discontinuities
in metallic aircraft structures. International Journal of Fatigue, Vol. 41(1), pp. 11–22.
13. S. A. Barter and L. Molent, 2013, Service fatigue cracking in an aircraft bulkhead
exposed to a corrosive environment. Engineering Failure Analysis, Vol. 34, pp. 181−188.
14. R.J.H. Wanhill, 2013, Aerospace applications of aluminum-lithium alloys. In:
“Aluminum-Lithium Alloys, Processing, Properties and Applications,” eds. N. E.
Prasad, A. A Gokhale and R .J. H. Wanhill, Butterworth-Heinemann, Elsevier Inc.,
Oxford, UK, pp. 503-535.
15. T. Beumler, 2004, Flying GLAREⓇ, a contribution to aircraft certification issues in non-
damaged and fatigue damaged GLAREⓇ structures, Doctor’s Thesis, Delft University of
Technology, Delft, the Netherlands.
16. Federal Aviation Administration, 2009, Composite Aircraft Structure, Advisory Circular
FAA AC-20-107B, U.S. Department of Transportation, Washington, DC.
17. Military Composite Materials Handbook, Volume 3. Polymer Matrix Composites
Materials Usage, Design, And Analysis, 2013, MIL-HDBK-17-3F, U.S. Department of
Defense, The Pentagon, Virginia.
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Questions?
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