Thesis: M.S., Massachusetts Institute of Technology, Department of Aeronautics and Astronautics, 1975 / Includes bibliographical references. / by Richard F. Harris. / M.S. / M.S. Massachusetts Institute of Technology, Department of Aeronautics and Astronautics

Helicopter load histories applied to notched metal samples are taken as examples, and their fatigue lives are predicted by using a simplified version of the local strain approach. This simplified method requires an input load history in the form of the rain-flow matrix and places bounds on the fatigue life. A peak-valley reconstructed history is generated based on the standard spectrum Helix. A second history studied is a more irregular one based on actual flight data. lt is used to generate three reconstructed histories based on three principles: peak-valley, to-from, and rain-flow. Emphasis is given to the rain-flow reconstruction method, and different reconstruction methods based on rain-flow cycle counting are presented. Life predictions are presented for all of the above cases, and the comparison with test data and other considerations suggest that the most promising reconstruction approach is one based on rain-flow cycle counting. Finally, a method is presented which reconstructs a history with the same rain-flow cycles and also the same distribution of relative time increments between adjacent peaks and valleys. This reconstructed history gives the same fatigue life as the original history. / Ph. D.

Experiments were conducted to measure the three-dimensional static and free vibrational response of two graphite-epoxy, thin-walled, open section frames. The frames are semi-circular with a radius of three feet, and one specimen has an I cross section and the other has a channel cross section. The flexibility influence coefficients were measured in static tests for loads applied at midspan with the ends of the specimens clamped. Natural frequencies and modes were determined from vibrational tests for free and clamped end conditions. The experimental data is used to evaluate a new finite element which was developed specifically for the analysis of curved, thin-walled structures. The formulation of the element is based on a Vlaysov-type, thin-walled, curved beam theory. The predictions from the finite element program generally correlated well with the experimental data for the symmetric I-specimen. Discrepancies in some of the data were found to be due to flexibility in the â clamped' end conditions. With respect to the data for the channel specimen, the correlation was less satisfactory. The finite element analysis predicted the out-of-plane response of the channel specimen reasonably well, but large discrepancies occurred between the predicted in-plane response and the experimental data. The analysis predicted a much more compliant in-plane response then was observed in the experiments. / Master of Science

This thesis presents a new modeling framework and application methodology for the study of aircraft structures. The framework provides a ‘cradle-to-grave’ approach to structural analysis of a component, where structural integrity encompasses all phases of its lifespan. The methodology examines the holistic structural design of aircraft components by integrating fatigue and damage tolerance methodologies. It accomplishes this by marrying the load inputs from a fatigue analysis for new design, into a risk analysis for an existing design. The risk analysis incorporates the variability found from literature, including recorded defects, loadings, and material strength properties. The methodology is verified via formal conceptualization of the structures, which are demonstrated on an actual hydraulic accumulator and an engine nacelle inlet. The hydraulic accumulator is examined for structural integrity utilizing different base materials undergoing variable amplitude loading. Integrity is accomplished through a risk analysis by means of fault tree analysis. The engine nacelle inlet uses the damage tolerance philosophy for a sonic fatigue condition undergoing both constant amplitude loading and a theoretical flight design case. Residual strength changes are examined throughout crack growth, where structural integrity is accomplished through a risk analysis of component strength versus probability of failure. Both methodologies can be applied to nearly any structural application, not necessarily limited to aerospace.

In an attempt to find a way of improving the damage tolerance of composite bonded repairs to metallic aircraft structures, the effect of using conventional crack growth retardation techniques in conjunction with bonded repairs was experimentally investigated. Hence, an experimental test program was set up to determine whether fatigue crack growth under bonded repairs is retarded further by giving the crack to be repaired a crack growth retardation treatment prior to repair patch application. In addition, it was set up to determine the influence of a bonded repair on the effectiveness of a crack growth retardation method. Centrally cracked aluminium plates were used. Stop drilling followed by cold hole expansion and the application of single overloads were selected as retardation treatments. Two patch materials were considered; boron/epoxy and Glare 2. Further test variables were the aluminium alloy and the plate thickness. Fatigue testing was carried out under constant amplitude loading and baseline results were determined first. In addition to optically monitoring the crack growth, local and global out-of-plane deformations were visualised with holographic interferometry and shadow moire??. Furthermore, the stress intensity factors under the repair patch were examined with strain gauges and measurement of the central crack opening displacement. Disbonds and fracture surfaces were studied after residual strength tests. The crack growth results obtained showed that retardation treatments decrease crack growth rates under a repair patch and that the effectiveness of a retardation treatment is increased by the patch. Although identical crack growth rates were observed under boron/epoxy and Glare 2 patches, the reinitiation period after the retardation treatment lasted longer when Glare 2 patches were applied. Analytical predictions of the extent of retardation based on existing models showed that the conjunctive effect of retardation treatments and bonded repairs was underestimated. A sustained reduction in crack growth rates was observed under bonded repairs with a prior overload retardation treatment. It was concluded that the damage tolerance of bonded repairs is increased by the application of a crack growth retardation treatment because the crack growth is retarded further. These findings indicate that the range of cracks in aircraft for which bonded repairs can be considered is expanded and that economic benefits can be obtained.

The investigation contained herein is a part of a larger, long-term project: The Development of SMART Aircraft Bolts. Structural failures, at highly stressed components, arc common in some of the aircraft used by the South African Air force. The strength of one such component, the wing bolts on the C-130 aircraft, is analysed and compared to the stress distribution in a bolt which has a small hole drilled through the centre of the bolt (which will be used to insert a sensing device). The results of this analysis will be used as input into further phases of the project, e.g., SMART material selection and the development of sensing devices. Due to the complex physics of a bolted joint, advanced analysis of the bolt under conservative loading was performed, after conducting thorough research into bolted joint design and analysis methods, in order to provoke the final recommendations. / Thesis (M.Sc.)-University of Natal, Durban, 2000.

Aviation is known to have some of the most stringent structural health monitoring standards in the world. An example of this would be the fact that certain bolts in the aircraft assembly must be periodically removed and inspected for fatigue damage. This can be a very costly endeavour: a case in point being the Hercules C130 aircraft, which requires approximately 200 man hours of down-time for the inspection of the bolts that attach the wings to the fuselage. The substitution of TRIP (Transformation Induced Plasticity) steel bolts for the current HSLA steel (AISI 4340) from which the bolts are manufactured, allows the bolt to act in the capacity of load bearing member as well as damage detector. This unique feature is a consequence of the transformation characteristic exhibited by TRIP steels when they are strained: an irreversible change within their microstructure from paramagnetic austenite parent phase to permanent ferromagnetic state occurs in direct proportion to the peak strain. This property allows us to establish a relationship from which the service life of the component can be determined. A prototype of a smart aircraft bolt and washer system has been developed, where the bolt acts as damage detector and the washer effectively examines the health of the bolt by reading the changing magnetic susceptibility of the bolt. This study presents both material development and product development phases of the Smart Aircraft Bolt prototype. A prediction of transformation characteristic due to deformation is carried out using finite element analysis (mechanical model) and a constitutive model (strain induced martensitic transformation kinetics) to predict the best situation for the smart washer. In addition, experimental work is performed in the form of cyclic temperature testing (with and without external loading) and tension-tension fatigue testing. For both sets of experimental testing, two positions of washer placement are tested. A correlation between volume fraction of martensite present and remaining life, is therefore possible. / Thesis (M.Sc.Eng.)-University of KwaZulu-Natal, Durban, 2008.

In an attempt to find a way of improving the damage tolerance of composite bonded repairs to metallic aircraft structures, the effect of using conventional crack growth retardation techniques in conjunction with bonded repairs was experimentally investigated. Hence, an experimental test program was set up to determine whether fatigue crack growth under bonded repairs is retarded further by giving the crack to be repaired a crack growth retardation treatment prior to repair patch application. In addition, it was set up to determine the influence of a bonded repair on the effectiveness of a crack growth retardation method. Centrally cracked aluminium plates were used. Stop drilling followed by cold hole expansion and the application of single overloads were selected as retardation treatments. Two patch materials were considered; boron/epoxy and Glare 2. Further test variables were the aluminium alloy and the plate thickness. Fatigue testing was carried out under constant amplitude loading and baseline results were determined first. In addition to optically monitoring the crack growth, local and global out-of-plane deformations were visualised with holographic interferometry and shadow moire??. Furthermore, the stress intensity factors under the repair patch were examined with strain gauges and measurement of the central crack opening displacement. Disbonds and fracture surfaces were studied after residual strength tests. The crack growth results obtained showed that retardation treatments decrease crack growth rates under a repair patch and that the effectiveness of a retardation treatment is increased by the patch. Although identical crack growth rates were observed under boron/epoxy and Glare 2 patches, the reinitiation period after the retardation treatment lasted longer when Glare 2 patches were applied. Analytical predictions of the extent of retardation based on existing models showed that the conjunctive effect of retardation treatments and bonded repairs was underestimated. A sustained reduction in crack growth rates was observed under bonded repairs with a prior overload retardation treatment. It was concluded that the damage tolerance of bonded repairs is increased by the application of a crack growth retardation treatment because the crack growth is retarded further. These findings indicate that the range of cracks in aircraft for which bonded repairs can be considered is expanded and that economic benefits can be obtained.

In the last two decades, the emphasis in aircraft maintenance has been on developing online structural health monitoring systems to replace conventional non destructive inspection techniques which require considerable down-time, human effort and cost. Vibration based damage detection is one of the most promising techniques for implementation in Structural Health Monitoring (SHM). In vibration based methods, the presence of damage is detected by monitoring changes in one of the dynamic parameters of the structure, resonant frequencies, modeshapes or damping characteristics. Compared to modeshape based methods, frequency based methods have the advantage that measurements need to be taken only at a single location. Previous developments on frequency based techniques have relied on Finite Element Model updating; analytical techniques have hitherto been restricted to beams due to the complexity in developing equations for cracked two dimensional structures. In this thesis the analytical approach using an energy formulation is extended to plates with through-thickness cracks, where modeshapes from either numerical modelling or experimental measurements can be employed to determine the energy of vibration. It is demonstrated that by using a hybrid approach, incorporating experimentally measured modeshapes along with measured changes in frequencies, the damage parameters can be estimated without resorting to theoretical modelling or numerical analysis. The inverse problem of finding the crack location, size and orientation from measured changes in frequencies is addressed using minimisation techniques. The forward problem and the inverse algorithm is first validated using numerical simulation and experimental testing of beams with edge cracks and centre cracks. The application of the methodology to the two dimensional case is then validated by numerical simulation and experimental modal analysis of plates with through thickness cracks. A statistical procedure is developed for determination of the 90/95 probability of crack detection and the minimum detectable crack size in both cases. It is demonstrated that the measurement of frequency changes can be successfully employed to detect and assess the location and size of cracks in beams and plates, using modeshapes from theory, Finite Element Analysis.

Thesis (Ph. D.)--Electrical and Computer Engineering, Georgia Institute of Technology, 2008. / Committee Chair: Michaels, Jennifer; Committee Member: Habetler, Thomas; Committee Member: Jacobs, Laurence; Committee Member: Michaels, Thomas; Committee Member: Vachtsevanos, George.