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AdvancesintheBondedComposite
Repair
of
Metallic Aircraft Structure
VOLUME
1
A
Edited
by
Alan Baker
Francis Rose
Rhys Jones
ELSEVI
ER
ADVANCES INTHEBONDEDCOMPOSITE
REPAIR OF METALLIC AIRCRAFT
STRUCTURE
Volume
1
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ADVANCES INTHEBONDEDCOMPOSITE
REPAIR OF METALLIC AIRCRAFT
STRUCTURE
Volume
1
Editors
A.A.
Baker
Defence Science and Technology Organisation,
Air Vehicles Division,
Victoria, Australia
L.R.F.
Rose
Department
of
Defince,
Dqfence Science and Technology Organisation,
Air Vehicles Division,
Victoria, Australia
R.
Jones
Mechanical Engineering Department,
Monash University, Victoria, Australia
2002
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Printed inThe Netherlands.
Dr.
Alan Baker
Dr. Alan Baker is Research Leader Aerospace Composite Structures, in Airframes
and Engines Division, Defence Science and Technology
(DSTO),
Aeronautical and
Maritime Research Laboratory and Technical Adviser to the Cooperative Research
Centre-Advanced Composite Structures, Melbourne Australia. He is a Fellow of
the Australian Academy of Technological Sciences and Engineering and an
Adjunct Professor in Department of Aerospace Engineering, Royal Melbourne
Institute of Technology. Dr. Baker is a member of the International Editorial
Boards of the Journals Composites Part A Applied Science and Manufacturing,
Applied Composites and International Journal of Adhesion and Adhesives.
He is recognised for pioneering research work on metal-matrix fibre composites
while at the Rolls Royce Advanced Research Laboratory. More recently, he is
recognised for pioneering work on bondedcomposite repair of metallic aircraft
components for which he has received several awards, including the 1990 Ministers
Award for Achievement in Defence Science.
Dr.
Francis
Rose
Dr. Francis Rose is the Research Leader for Fracture Mechanics in Airframes and
Engines Division, Defence Science and Technology
(DSTO),
Aeronautical and
Maritime Research Laboratory. He has made important research contributions in
fracture mechanics, non-destructive evaluation and applied mathematics. In
particular, his comprehensive design study of bonded repairs and related crack-
bridging models, and his contributions to the theory of transformation toughening
in partially stabilised zirconia, have received international acclaim. His analysis of
laser-generated ultrasound has become a standard reference inthe emerging field of
laser ultrasonics, and he has made seminal contributions to the theory of eddy-
current detection of cracks, and early detection of multiple cracking.
He is the Regional Editor for the
Znternational Journal
of
Fracture
and a member
of the editorial board of
Mechanics
of
Materials.
He was made a Fellow of the
Institute of Mathematics and its Applications,
UK,
in 1987, and a Fellow of the
Institution
of
Engineers, Australia, in 1994. He is currently President of the
Australian Fracture Group, and has been involved in organising several local and
international conferences inthe areas
of
fracture mechanics and engineering
mathematics. He currently serves on the Engineering Selection Panel
of
the
Australian Research Council and of several other committees and advisory bodies.
vi
Biographies
Professor
Rhys
Jones
Professor Rhys Jones joined Monash University in early 1993 and is currently
Professor of Mechanical Engineering, and Head of the Defence Science and
Technology Organisation Centre of Expertise on Structural Mechanics. Professor
Jones’ is best known for his inthe fields of finite element analysis, composite repairs
and structural integrity assessment. Professor Jones
is
the Founding Professor of
both the BHP-Monash Railway Technology Institute and the BHP-Monash
Maintenance Technology Institute. He is heavily involved with both Australian
and overseas industry. In this context he ran the mechanical aspects of the
Australian Governments Royal Commission into the failure at the ESSO plant in
Victoria, and the Tubemakers-BHP investigation into the failure of the McArthur
River gas pipe line inthe Northern Territory.
He is the recipient of numerous awards including the
1982
(Australian)
Engineering Excellence Award, for composite repairs to Mirage 111, the Institution
of Engineers Australia George Julius Medal, for contributions to failure analysis, a
TTCP Award, for contributions to Australian,
US,
UK,
Canada and NZ Defence
Science inthe field of composite structures, and a Rolls-Royce-Qantas Special
Commendation, for his work on F-111 aircraft. Since 1999 Professor Jones has
been Co-Chair of the International Conference (Series) on Composite Structures.
Acknowledgement
The editors are very pleased to acknowledge their appreciation of the great
assistance provided by Drs Stephen Galea and Chun Wang of the Defence Science
and Technology Organisation, Aeronautical and Maritime Research Laboratory,
who made important contributions, inthe collation and editing
of
this
book.
FOREWORD
The introduction of the technology for bondedcomposite repairs of metallic
airframe structures could not have come at
a
more opportune time. Today, many
countries are facing the challenge of aging aircraft in their inventories. These
airframes are degrading due to damage from fatigue cracking and corrosion.
Repair with dependable techniques to restore their structural integrity is
mandatory. The concept of using bondedcomposite materials as a means to
maintain aging metallic aircraft was instituted in Australia approximately thirty
years ago. Since that time it has been successfully applied in many situations
requiring repair. These applications have not been limited to Australia. Canada,
the United Kingdom, and the United States have also benefited from the use of this
technology. The application for the solution of the problem of cracking inthe fuel
drain holes in wing of the
C-141
is credited with maintaining the viability of this
fleet.
The concept for composite repair of metallic aircraft is simple. Thebonded repair
reduces stresses inthe cracked region and keeps the crack from opening and
therefore from growing. This is easy to demonstrate in a laboratory environment. It
is another thing to do this inthe operational environment where many factors exist
that could adversely affect the repair reliability. The researchers at the Aeronautical
and Maritime Research Laboratory in Australian realized there were many
obstacles to overcome to achieve the desired reliability of the process. They also
realized that failures of the repair on operational aircraft would mean loss of
confidence and consequently enthusiasm for the process. They proceeded slowly.
Their deliberate approach paid
off
in that they developed a process that could be
transitioned to aircraft use by engineers and technicians. The essential ingredient
for application of this technology is discipline. When the applicator of this process
maintains the discipline required for the process and stays within the bounds of
appropriate applications, then the repair will be successful.
This book, edited by Drs A.A. Baker, L.R.F. Rose and R. Jones, includes the
essential aspects
of
the technology for composite repairs. The editors have chosen
some of the most knowledgeable researchers inthe field of bonded repairs to
discuss the issues with the many aspects of this technology. Included are discussions
on materials and processes, design of repairs, certification, and application
considerations. These discussions are sufficiently in-depth to acquaint the reader
with an adequate understanding of the essential ingredients of the procedure. The
application case histories are especially useful in showing the breadth
of
the
possible uses of the technology.
vii
[...]... bonded repair technology, as indicated inthe foreword, and, indeed, was the Chairman of an international group addressing certification issues This report is referenced in Chapter 1 It is rare to find in science and engineering, such a giant inthe field who was so modest, approachable and friendly Jack was regarded both as a supportive father figure and the expert to be convinced on all airworthiness... reserved 2 Advancesin ihe bondedcomposite repair of metallic aircrafi structure metallic patches The requirements for future research and development are then discussed, based, in part, on a recent USAF study on ageing aircraft [2] Before introducing repair issues, some brief background is provided inthe next section on the key issues and terminology associated with the design and maintenance of... Testing of Generic Bonded Joints P.D Chalkley, C.H Wang and A.A Baker 103 5.1 103 103 104 104 106 108 109 1 I4 115 120 123 124 125 5.2 5.3 5.4 Introduction Damage-tolerance regions in a bonded repair 5.1.1 The generic design and certification process 5.1.2 The DOFS 5.2.1 Stress state inthe DOFS 5.2.2 Experimental method 5.2.3 Experimental results The skin doubler specimen Stress state inthe skin doubler... Large area repairs in a production environment Conclusions References mix 987 987 988 988 989 994 995 Chapter 4 Case History: Composite Patch Reinforcement of T-38 Lower Wing 0 Skin M.M Ratwani, J Helbling, B Heimerdinger and N.M Ratwani 997 Introduction Validation testing 40.2.1 Test specimen description 40.2.2 Composite reinforcement fabrication and bonding 40.2.3 Strain gage installation 40.2.4... published This book described the status of the technology, inthe late 198Os, on bondedcomposite repair of conventional metallic, adhesively bonded metallic and fibre -composite airframe components Because over the last fourteen years the technology has progressed considerably and become widely exploited, a decision was made to produce this follow-up book AdvancesinBondedComposite Repairs of Metallic... standardization 26.2.2 Building a database of reliable repairs - “We’re all in this together” Current approaches to training and certification Formalized trade structure 26.4.1 The purpose of a trade structure 26.4.2 A four-tiered trade structure - the ARTI model The ARTI model for training of bonded repair specialists Certification of bonded repair specialists 26.6.1 The Boeing wedge test (BWT) - an... operation of the aircraft Inspection, damage assessment, and repair requirements differ significantly between these classified structures Even within a single component, the allowable damage type and size (and consequently acceptable repair actions) may vary according to the criticality of the damaged region The component is generally zoned by the original equipment manufacturer (OEM) inthe structural... comprehensive coverage of the current research and technology highlighting advancesin capabilities, and case histories of recent applications It is intended to be useful both to researchers inthe field and to practicing aerospace engineers Contributions to the book are largely drawn from the Defence Science and Technology Organisation, Australia, where this technology was pioneered inthe early 1970s Significant... is provided on structural problems in ageing aircraft and on the requirements for repairs A case is then made for use of adhesively bondedcomposite (fibre-reinforced plastic or metal-laminate) reinforcements for repairs as compared to standard mechanical procedures, based on mechanically fastened 1 Baker, A.A., Rose, L.R.F and Jones, R (eds.) Advances i theBondedComposite Repairs of Metallic Aircraft... materials and loading arrangement 10.7.2 Shape optimisation before reinforcement 10.7.3 Iterative reinforcement design 10.7.4 Discussion In- plane shaping effects 10.8.1 Geometry, loading and modelling considerations 10.8.2 Determination of Kt from FEA output 10.8.3 Uniaxial loading and patches with aspect ratios of 2:l 10.8.4 Uniaxial loading and other patch aspect ratios 10.8.5 Analogy with hole -in- a-plate . problem of cracking in the fuel
drain holes in wing of the
C-141
is credited with maintaining the viability of this
fleet.
The concept for composite repair. restore their structural integrity is
mandatory. The concept of using bonded composite materials as a means to
maintain aging metallic aircraft was instituted