Tài liệu hạn chế xem trước, để xem đầy đủ mời bạn chọn Tải xuống
1
/ 570 trang
THÔNG TIN TÀI LIỆU
Thông tin cơ bản
Định dạng
Số trang
570
Dung lượng
14,32 MB
Nội dung
Bonded Comp
Repair of MetallicAircraftStructure
VOLUME
2
A
.7
Alan Baker
Francis Rose
Rhys
Jones
Edited
by
ECSEVIER
ADVANCES IN THE BONDED COMPOSITE
REPAIR
OF
METALLIC AIRCRAFT
STRUCTURE
Volume
2
Elsevier Science Internet Homepage
-
http://www.elsevier.com
Consult the Elsevier homepage for full catalogue information on
all
books, journals and electronic products and
services.
Elsevier Titles
of
Related Interest
VALERY V. VASILEV
&
EVGENY V. MOROZOV
Mechanics and Analysis
of
Composite Materials
ISBN:
0
08 042702 2
JANG-KYO KIM
&
YIU
WING MA1
Engineered Interfaces
in
Fiber Reinforced Composites
ISBN:
0
08 042695
6
J.G.
WILLIAMS &A. PAVAN
Fracture
of
Polymers, Composites and Adhesives
ISBN:
0
08 043710 9
D.R. MOORE, A. PAVAN
&
J.G.
WILLIAMS
Fracture Mechanics Testing Methods for Polymers Adhesives and Composites
ISBN:
0
08 043689 7
Related Journals:
Composite Structures
-
www.elsevier.com/locate/compstruct
Composites Part A: Applied Science and Manufacturing
-
www.elsevier.com/locate/compositesa
Composites Part
B:
Engineering
-
www.elsevier.com/locate.compositesb
Composites Science and Technology
-
www.elsevier.com/locate.compscitech
Major
Reference Work
Comprehensive Composite Materials
-
www.elsevier.com/locate/isbn/0080429939
To
contact the Publisher
Elsevier Science welcomes enquiries concerning publishing proposals: books, journal special issues, conference
proceedings, etc. All formats and media can be considered. Should
you
have a publishing proposal
you
wish
to
discuss, please contact, without obligation, the publisher responsible
for
Elsevier's Composites and Ceramics
programme:
Emma
Hurst
Assistant Publishing Editor
Elsevier Science Ltd
The Boulevard, Langford Lane Phone:
+44 1865843629
Kidlington,
Oxford
Fax:
+44
1865
843931
OX5
IGB, UK E.mail: e.hurst@elsevier.com
General enquiries, including placing orders, should be directed to Elsevier's Regional Sales Offices -please access the
Elsevier homepage
for
full
contact details (homepage details
at
the
top
of
this page).
Book Butler logo
to
search for more Elsevier books, visit the Books Butler at
http://www.elsevier.com/homepage/
booksbutler/
ADVANCES IN THE BONDED COMPOSITE
REPAIR OF METALLICAIRCRAFT
STRUCTURE
Volume
2
Editors
A.A.
Baker
Defence Science and Technology Organisation,
Air Vehicles Division,
Victoria, Australia
L.R.F. Rose
Department of Defence,
Defence Science and Technology Organisation,
Air Vehicles Division,
Victoria, Australia
R. Jones
Mechanical Engineering Department,
Monash University, Victoria, Australia
2002
ELSEVIER
Amsterdam
-
Boston
-
London
-
New
York
-
Oxford
-
Paris
San Diego
-
San Francisco
-
Singapore
-
Sydney
-
Tokyo
ELSEVIER SCIENCE Ltd
The Boulevard, Langford Lane
Kidlington, Oxford OX5 IGB, UK
0
2002 Elsevier Science Ltd.
All
rights reserved
This work is protected under copyright by Elsevier Science, and the following terms and conditions apply to its use:
Photocopying
Single photocopies of single chapters may be made for personal use as allowed by national copyright laws.
Permission of the Publisher and payment of a fee is required for all other photocopying, including multiple
or
systematic copying, copying for advertising
or
promotional purposes, resale, and all forms of document delivery.
Special rates are available for educational institutions that wish to make photocopies for non-profit educational
classroom use.
Permissions may be sought directly from Elsevier Science via their home page
(httD.iiwww.elsevler.com),
by selecting ‘Customer support’ and the ‘Permissions’. Alternatively you can send an e-mail to:
permissions~eelsevier.co.uk,
or
fax to: (+44) 1865 853333.
In
the USA, users may clear permissions and make payments through the Copyright Clearance Center, Inc., 222
Rosewood Drive, Danvers, MA 01923, USA.; phone
(+I)
978
750
8400, fax:
(+I)
978 750 4744, and in the UK
through the Copyright Licensing Agency Rapid Clearance Service (CLARCS), 90 Tottenham Court Road, London
W IP OLP; phone (+44) 207 63
1
5555; fax: (+44) 207 63
1
5500. Other countries may have a local reprographic rights
agency for payments.
Derivative Works
Tables of contents may be reproduced for internal circulation, but permission of Elsevier Science is required for
external resale
or
distribution of such material.
Permission of the Publisher is required for all other derivative works, including compilations and translations.
Electronic Storage
or
Usage
Permission of the Publisher is required to store
or
use electronically any material contained in this work, including
any chapter
or
part of a chapter.
Except
as
outlined above,
no
part of this work may be reproduced, stored in a retrieval system
or
transmitted in any
form
or
by any means, electronic, mechanical, photocopying, recording
or
otherwise, without written permission of
the Publisher.
Address permission requests to: Elsevier Science Global Rights Department, at the mail, fax and email addresses
note above.
Notice
No responsibility is assumed by the Publisher for any injury and/or damage
to
persons
or
property as a matter of
products liability, negligence
or
otherwise,
or
from any use
or
operation of any methods, products, instructions
or
ideas contained in the material herein. Because of rapid advances in the medical sciences, in particular, independent
verification of diagnosis and drug dosages should be made.
First Edition 2002
Library of Congress Cataloging in Publication Data
A catalog of record from the Library of Congress has been applied for
British Library Cataloguing in Publication Data
A
catalogue record from the British Library has been applied for
ISBN: 0-08-042699-9
@
The paper used for this publication meets the requirements of ANSIiNISO 239.48-1992 (Permanence
of
Paper).
Printed in The Netherlands.
BIOGRAPHIES
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 bonded composite repair of metallicaircraft
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 in the 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
International 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 in the 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 in the 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 in the 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 in the 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, in the collation and editing of this book.
FOREWORD
The introduction of the technology for bonded composite 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 bonded composite materials as a means
to
maintain aging metallicaircraft 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 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 of metallicaircraft is simple. The bonded repair
reduces stresses in the 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 in the 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 in the 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
[...]... of repairing such cracked structures a bonded composite repair would be preferred The benefits of such a repair are reflected in the time required to carry out the repair For example, the inlet nacelle repair typically requires a repair time of 60 h for the mechanical repair and approximately 15-25 h for the bonded repair In the case of the repair to the aft fuselage the time for the mechanical repair. .. This repair also requires engine removal and installation which takes a three man team approximately 8 h followed by engine ground runs 53 1 Baker, A.A., Rose, L.R.F and Jones, R (eds.), Advances in the Bonded Composite Repairs of MetallicAircraftStructure Crown Copyright 0 2002 Published by Elsevier Science Ltd All rights reserved 532 Advances in the bonded composite repair of metallicaircraft structure. .. 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 Aim of book Classification of aircraft structures for inspection and repair Design and certification of airframe structures 1.2.1 Problems with ageing metallic airframe components 1.2.2 Repair requirements 1.3.1 Repair levels Repair procedures The case for adhesively bonded repairs Composite versus metallic patches Scope of applications Some experimental comparisons... Acknowledgements References Chapter 35 Case History: Repair Applications On DC-lO/MD-11 Aircraft D Roach 35.1 35.2 35.3 35.4 35.5 35.6 Introduction Repair development and validation tasks to support on -aircraft installation 35.2.1 Repair design Repair analysis Repair design validation Nondestructive inspection Current status of DC-lO/MD-l 1 commercial aircraft repairs Chapter 36 Case History: CF-116 Upper... validation Certification and implementation to aircraft Conclusions References xxvii 898 899 903 905 906 906 Chapter 34 UK Applications P Poole 907 34.1 34.2 34.3 907 908 909 909 91 1 912 913 918 918 34.4 34.5 Introduction Design studies Repairs to RAF aircraft 34.3.1 Secondary structure repairs 34.3.2 Primary structure repairs 34.3.3 Birdstrike protection Repairs to EHlOl development airframe full scale... 9.6 9.7 9.8 9.9 9.10 9.11 9.12 xvii 9.2.2 Repair of cracks in aircraft wing skin Initial design guidelines Comparison with experimental results for non rib stiffened panels Repair of thick sections 9.5.1 Experimental results Repair of cracked holes in primary structures Repair of cracked lugs 9.7.1 Numerical analysis 9.7.2 Experimental test 9.7.3 Discussion Repairs to interacting surface flaws Material... Risks to aircraft Quality management Facilities Training and certification Deficient repair concepts Conclusion References Chapter 25 Rapid Application Technology: Aircraft Battle Damage Repairs R Bartholomeusz, P Pearce and R Vodicka 76 1 25.1 25.2 761 762 762 763 '764 25.3 Introduction Aircraft battle damage repair 25.2.1 Battle damage 25.2.2 ABDR criteria 25.2.3 Types of ABDR Comparison of metallic. .. bonded repair was designed for the inlet nacelle area, based on a standard repair design procedure, and implemented on an existing cracked aircraft While in the past boron fibre/epoxy resin patches have been extremely successful, in repairing cracked metallic secondary and primary structures [2], (see also Chapters 13 and 16) in this case significant crack growth occurred after the application of the repair. .. Application Technology for Adhesive Bonded Repairs M Davis 727 24.1 727 730 730 73 1 732 '742 748 7 50 75 1 752 752 752 752 754 755 755 757 757 24.2 24.3 24.4 24.5 24.6 24.7 24.8 introduction 24.1.1 Management of repair technology Repair application technology 24.2.1 Materials selection 24.2.2 Surface preparation 24.2.3 Heating procedures for on -aircraft repairs 24.2.4 Repair pressurisation Occupational health... analysis Repair options Design of the bonded repair FEM model of the patched crack Conclusions References Chapter 32 Case History: F-16 Fuel Vent-hole Repairs C Guijt and J Mazza 859 859 860 860 862 862 864 864 864 865 866 866 867 867 868 869 869 869 871 87 1 872 874 875 879 883 884 885 Introduction Damage tolerance analysis Repair options 32.3.1 Mechanically fastened aluminum patch Design of the bonded repair . book
Classification of aircraft structures for inspection and repair
1.2.1.
1.2.2.
Repair requirements
1.3.1.
Repair levels
Repair procedures
The.
http://www.elsevier.com/homepage/
booksbutler/
ADVANCES IN THE BONDED COMPOSITE
REPAIR OF METALLIC AIRCRAFT
STRUCTURE
Volume
2
Editors
A.A.
Baker
Defence