Advances in the bonded composite repair of metallic aircraft structure, Volume 1

Cover......Page 1
Half Title Page......Page 4
Title Page......Page 6
Copyright......Page 7
Biographies......Page 8
Acknowledgement......Page 9
Foreword......Page 10
Dedication......Page 12
Subscripts/Superscripts......Page 14
Table of Contents......Page 16
19.1. Introduction......Page 34
19.2. Cracking History......Page 36
19.3. Sound Pressure Levels......Page 39
19.4. Random Response Analysis......Page 40
19.5. Stress Intensity Factors......Page 41
19.6. FEA of Cracked Nacelle Inlet......Page 42
19.7. Highly Damped Repairs for Cracked Panels......Page 49
19.8. Aft Fuselage Finite Element Model......Page 60
19.9. Thermal Environment for F/A-18......Page 65
19.10. Analytical Results......Page 66
19.11. Experimental Work......Page 69
19.12. Conclusions for Aft Fuselage Repair......Page 71
20.1. Introduction......Page 74
20.2. Smart Patch Approach......Page 76
20.3. Damage Detection Studies......Page 81
20.4. Laboratory Smart Patch Conceptional Demonstrators......Page 102
20.5. In-Flight Demonstrator......Page 107
20.6. Conclusions......Page 114
21.1. Introduction......Page 118
21.2. Certification of an Adhesively Bonded Repair......Page 120
21.3. Repair Design Information......Page 122
21.4. Analysis and Development Testing......Page 124
21.6. In-Service Management and Inspection......Page 140
21.8. Conclusions......Page 141
22.1. Current Limitations of Crack Patching......Page 146
22.2. Justifying Credit for Patching Efficiency - Fatigue Concerns......Page 147
22.3. Justifying Credit for Patching Efficiency - Environmental Durability Concerns......Page 151
22.4. Justifying Credit for Patching Efficiency - the Smart Patch Approach......Page 157
22.5. Discussion......Page 158
22.6. Conclusions......Page 159
23.1. Introduction......Page 162
23.2. Inspection for Delaminations, Disbonds and Adhesion Failure......Page 167
23.3. Inspections for Cracks in Parent Material beneath Composite Doublers......Page 197
23.4. Quality Control Issues in Service......Page 217
23.5. Conclusions......Page 222
23.6. Acknowledgements......Page 226
24.1. Introduction......Page 230
24.2. Repair Application Technology......Page 233
24.3. Occupational Health and Safety (OHS)......Page 253
24.4. Quality Management......Page 255
24.5. Facilities......Page 257
24.7. Deficient Repair Concepts......Page 258
24.8. Conclusion......Page 260
25.1. Introduction......Page 264
25.2. Aircraft Battle Damage Repair......Page 265
25.3. Comparison of Metallic Mechanically Fastened Repairs to Bonded Composite Repairs for ABDR......Page 268
25.4. Development of a Bonded Composite ABDR System......Page 274
25.5. Application of the DSTO/ABDR System......Page 279
25.6. Conclusions......Page 282
26.1. Introduction......Page 286
26.2. The Task at Hand - a Uniform Approach......Page 287
26.3. Current Approaches to Training and Certification......Page 288
26.4. Formalized Trade Structure......Page 289
26.5. The ARTI Model for Training of Bonded Repair Specialists......Page 290
26.6. Certification of Bonded Repair Specialists......Page 294
26.7. Conclusion......Page 298
27.1. Introduction......Page 300
27.2. Crack Location and Residual Strength......Page 301
27.3. Repair Substantiation Requirements......Page 303
27.4. Validation Strategy......Page 304
27.5. Design Validation (Finite Element Analysis)......Page 305
27.6. Cracked, Patched Model Including Thermal Effects......Page 306
27.7. Repair Substantiation (Representative Specimen Testing)......Page 308
27.9. Repair History......Page 312
27.10. Conclusion......Page 314
28.1. Introduction......Page 316
28.2. Fuselage Door Surround Structure Tests......Page 317
28.3. Fuselage Door Surround Structure Test Results......Page 322
28.4. Component Level Tests: Door Corner Specimen......Page 329
28.5. L-1011 Composite Doubler Installation......Page 335
28.6. FAA and Industry Approvals......Page 343
28.7. Conclusions......Page 344
29.1. Introduction......Page 348
29.2. Reinforcement Design......Page 349
29.3. Selection and Evaluation of Materials......Page 352
29.4. Selection and Evaluation of the Reinforcement......Page 353
29.5. Doubler Application Technology......Page 357
29.6. Doubler Fitment......Page 358
29.7. Fitment to Fleet Aircraft......Page 359
29.8. Conclusions......Page 360
30.1. Introduction......Page 362
30.2. FE Analysis of Bulkhead and Reinforcement......Page 363
30.4. Experimental Test Program......Page 367
30.5. Trial Installation of Reinforcement to Full-Scale Fatigue Test Article......Page 369
30.6. Discussion......Page 370
30.8. Acknowledgments......Page 372
31.1. Introduction......Page 374
31.2. Damage Tolerance Analysis......Page 375
31.3. Repair Options......Page 377
31.4. Design of the Bonded Repair......Page 378
31.5. FEM Model of the Patched Crack......Page 382
31.6. Conclusions......Page 386
32.2. Damage Tolerance Analysis......Page 388
32.3. Repair Options......Page 390
32.4. Design of the Bonded Repair......Page 392
32.6. Bonded Repairs......Page 395
References......Page 398
33.1. Introduction......Page 400
33.2. Load Cases......Page 401
33.3. Design and Stress Analysis......Page 402
33.4. Static Testing and Repair Validation......Page 406
33.5. Certification and Implementation to Aircraft......Page 408
33.6. Conclusions......Page 409
34.1. Introduction......Page 410
34.2. Design Studies......Page 411
34.3. Repairs to RAF Aircraft......Page 412
34.4. Repairs to EH101 Development Airframe Full Scale Fatigue Test Specimen......Page 416
34.5. Acknowledgements......Page 421
35.1. Introduction......Page 422
35.3. Repair Analysis......Page 424
35.4. Repair Design Validation......Page 429
35.5. Non-Destructive Inspection......Page 436
35.6. Current Status of DC-10/MD-11 Commercial Aircraft Repairs......Page 437
36.2. Background......Page 440
36.3. Repair Considerations......Page 443
36.5. Doubler Design and Analysis......Page 444
36.6. Doubler Manufacturing and Installation Procedures......Page 449
36.7. Doubler Fractographic Analysis......Page 452
36.8. Fleet Experience......Page 454
36.10. Conclusions......Page 457
36.11. Composite Repair Lessons Learned......Page 458
36.12. Acknowledgements......Page 459
Appendix A: Material Properties......Page 460
37.1. Introduction......Page 462
37.2. Demonstrator Doublers......Page 463
37.3. In-Service Environment and Repair Location......Page 465
37.4. Bond Durability and Surface Treatment......Page 467
37.5. Case Study Results......Page 468
37.6. Discussion and Lessons Learnt......Page 473
37.7. Conclusions......Page 475
38.2. Defect Description......Page 476
38.3. Justification of Approach......Page 477
38.5. Repair Procedure......Page 481
38.6. Continuing Airworthiness/Inspection......Page 482
39.1. Background......Page 486
39.2. Examples of Applicability to Large Areas......Page 487
39.3. Current State of the Technology......Page 488
39.4. Process Areas Requiring Adaptation......Page 490
39.5. Large Area Repairs in a Production Environment......Page 492
39.6. Conclusions......Page 497
40.1. Introduction......Page 500
40.2. Validation Testing......Page 502
40.3. Test Results......Page 504
40.4. Comparison between Test Results and Analytical Predictions......Page 508
40.6. Conclusions......Page 510
41.1. Background......Page 512
41.2. Repair Design......Page 515
41.3. Installation Development......Page 518
41.4. Industrialization and Repair......Page 519
41.5. Success and Failures......Page 520
41.6. Other Applications......Page 523
41.7. Cost Savings......Page 527
41.8. Additional Research......Page 528
41.9. Lessons Learned......Page 532
41.10. Summary......Page 535
42.1. Introduction......Page 538
42.2. Materials Development and Characterisation......Page 541
42.3. Installation of Composite Reinforcement......Page 545
42.4. Reinforcement Efficiency Assessment......Page 547
42.5. Service Performance......Page 549
42.6. Technology Improvement......Page 550
42.8. Conclusion......Page 551
42.9. Acknowledgement......Page 552
Index......Page 554
Back Cover......Page 570