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At least 127 records · Page 7

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NASA NTRS1999

Evaluation of the Self-Nulling Rotating Eddy Current Probe System

In order to detect multi-site fatigue cracks located under flush-head rivets, automated eddy current equipment is required. To assure a reliable system, the eddy current probe must be centered easily over the installed rivets. To meet these requirements, the NDE Group at NASA LaRC developed the Self-Nulling Rotating Eddy Current Probe System (SNRECPS) which will be referred to as RPS in this document. The system was evaluated at the FAA, NDI Validation Center, in Albuquerque, New Mexico. The system was capable of detecting a 0.032 inch long crack with a 90/95% PoD. Further evaluations were conducted at Boeing in Long Beach, California. These evaluations included fatigue cracks and notches in a range from 0.025 to 0.100 inch long under flush-head aluminum rivets, and titanium or steel flush-head fasteners. The results of these tests are reported herein. Subsequently, the system was loaned to the USAF Structures Laboratory for the purpose of detecting and measuring short cracks under flush-head rivets in a variety of fatigue test specimens. The inspection task was to detect and plot crack growth from numbered fasteners in lettered rows. In January, 1998, the system was taken to Northwest Airlines Maintenance Base, in Atlanta, to inspect a DC-9, for multi-site cracks in three circumferential splices. The aircraft had 83,000 cycles. The inspection was conducted at 30 kHz from longeron 5 left to longeron 5 right. The system was calibrated using a 0,030 EDM first layer notch. The instrument gain was set to 19 mV from the notch. The reject level was set at 10 mV and the unflawed fasteners yielded a signal amplitude of 2 to 3 mV. Only one fastener location, out of about 2,500 tested, yielded a signal of 58 mV. The rivet was removed and visually evaluated. It appeared to be a slight gouge in the counter-sink zone. No fatigue cracks were detected. The same fastener locations were also inspected using the Boeing MAUS system at 60 kHz. No cracks were detected. Thus far, the rotating probe eddy current system has been found to be very user friendly and capable of detecting first layer cracks on the order of 0.030 inch long or longer.

Hagemaier, Don↗

NASA NTRS2003

Damage Tolerance of Integral Structure in Rotorcraft

The rotorcraft industry has rapidly implemented integral structures into aircraft to benefit from the weight and cost advantages over traditionally riveted structure. The cost to manufacture an integral structure, where the entire component is machined from a single plate of material, is about one-fifth that of a riveted structure. Furthermore, the integral structure can weigh only one-half that of a riveted structure through optimal design of stiffening structure and part reduction. Finally, inspection and repair of damage in the field can be less costly than riveted structure. There are no rivet heads to inspect under, reducing inspection time, and damage can be removed or patched readily without altering the primary structure, reducing replacement or repair costs. In this paper, the authors will investigate the damage tolerance implications of fielding an integral structure manufactured from thick plate aluminum.

Forth, Scott C.↗

NASA NTRS1997

Rotating flux-focusing eddy current probe for flaw detection

A flux-focusing electromagnetic sensor which uses a ferromagnetic flux-focusing lens simplifies inspections and increases detectability of fatigue cracks about circular fasteners and other circular inhomogeneities in high conductivity material. The unique feature of the device is the ferrous shield isolating a high-turn pick-up coil from an excitation coil, The use of the magnetic shield is shown to produce a null voltage output across the receiving coil in the presence of an unflawed sample. A redistribution of the current flow in the sample caused by the presence of flaws, however, eliminates the shielding condition and a large output voltage is produced, yielding a clear unambiguous flaw signal. By rotating the probe in a path around a circular fastener such as a rivet while maintaining a constant distance between the probe and the center of a rivet, the signal due to current flow about the rivet can be held constant. Any further changes in the current distribution, such as due to a fatigue crack at the rivet joint, can be detected as an increase in the output voltage above that due to the flow about the rivet head.

Wincheski, Russell A.↗

NASA NTRS1994

Classification of Magneto-Optic Images using Neural Networks

A real time imaging system with a neural network classifier has been incorporated on a Macintosh computer in conjunction with an MOI system. This system images rivets on aircraft aluminium structures using eddy currents and magnetic imaging. Moment invariant functions from the image of a rivet is used to train a multilayer perceptron neural network to classify the rivets as good or bad (rivets with cracks).

Nath, Shridhar↗

NASA NTRS1993

Optical characterization of LDEF contaminant film

Dark brown molecular film deposits were found at numerous locations on the Long Duration Exposure Facility (LDEF) and have been documented in great detail by several investigators. The exact deposition mechanism for these deposits is as yet unknown, although direct and scattered atomic oxygen, and solar radiation interacting with materials outgassing products have all been implicated in the formation process. Specimens of the brown molecular film were taken from below the flange of the experimental tray located at position D10 on the LDEF. The tray was one of two, comprising the same experiment, the other being located on the wake facing side of the LDEF satellite at position B4. Having access to both trays, we were able to directly compare the effect that orientation with respect to the atomic oxygen flux vector had on the formation of the brown molecular film deposits. The film is thickest on surfaces facing toward the exterior, i.e. the tray corner, as can be seen by comparing the lee and wake aspects of the rivets. The patterns appear to be aligned not with the velocity vector but with the corner of the tray suggesting that flux to the surface is due to scattered atomic oxygen rather than direct ram impingement. The role of scattered flux is further supported by more faint plume patterns on the sides of the tray. The angle of these plumes is strongly aligned with the ram direction but the outline of the deposit implies that incident atoms are scattered by collisions with the edges of the opening resulting in a directed, but diffuse, flux of atomic oxygen to the surface. Spectral reflectance measurements in the 2 to 10 micron (4000 to 1000 wavenumbers) spectral range are presented for the film in the 'as deposited' condition and for the free standing film. The material was analyzed by FTIR (Fourier Transform Infrared) microspectroscopy using gold as the reference standard. The 'as deposited' specimen was on an aluminum rivet taken from beneath the tray flange while the free film was obtained by chipping some of the material from the rivet. The transmission spectrum over the 2 to 10 micron range for the free film is presented. This spectrum appears to be essentially the same as that presented by Crutcher et.al. for films formed at vent sites which faced into the ram direction and suggested to originate from urethanes and silicones used on the LDEF. Banks et. al. state that silicones, when exposed to atomic oxygen, release polymeric scission fragments which deposit on surfaces and form a glassy, dark contaminant layer upon further atomic oxygen exposure and solar irradiation.

Blakkolb, Brian K.↗

NASA NTRS1942

Summary of Results of Tests Made by Aluminum Research Laboratories of Spot-welded Joints and Structural Elements

Available information concerning spot welding as a means of joining aluminum-alloy parts has been summarized and comparisons have been made of the relative merits of spot-welded and riveted aluminum-alloy structural elements. The results indicated that spot welding was as satisfactory as riveting insofar as resistance to static loads is concerned. Spot welds showed slightly lower resistance to impact loads but definitely lower resistance to repeated loads than rivets.

HARTMANN E C↗

NASA NTRS1999

The Growth of Multi-Site Fatigue Damage in Fuselage Lap Joints

Destructive examinations were performed to document the progression of multi-site damage (MSD) in three lap joint panels that were removed from a full scale fuselage test article that was tested to 60,000 full pressurization cycles. Similar fatigue crack growth characteristics were observed for small cracks (50 microns to 10 mm) emanating from counter bore rivets, straight shank rivets, and 100 deg counter sink rivets. Good correlation of the fatigue crack growth data base obtained in this study and FASTRAN Code predictions show that the growth of MSD in the fuselage lap joint structure can be predicted by fracture mechanics based methods.

Piascik, Robert S.↗

NASA NTRSDate not supplied

Demonstration of How Manufacturing Innovations Challenge Conventional Structural Design

For almost 100 years, commercial aircraft have been fabricated using riveted aluminum alloy structures. Aside from refining aircraft designs for better aerodynamic efficiency, improving alloy compositions, and automating assembly steps, fuselage construction remains largely unchanged today. The intent of the lightweight metallic fuselage prototype undertaken in NASA’s Advanced Air Transport Technology project was to demonstrate innovative forming and joining processes that advance the design paradigm, i.e. achieve high-rate manufacturing and reduce assembly time/costs. Over the past decade, researchers at NASA Langley Research Center have evaluated the potential to modify the flow forming process to produce near-net shaped cylinders, integrally stiffened along the cylinder axis, for space launch vehicles. The production of integral stiffeners in a formed aluminum cylinder, the size of the Space Shuttle external tank, replaced machined thick plate and welding steps to eliminate > 500,000 pounds of machining chips and ~ 0.5 miles of welds. The flow forming method, called the Integrally Stiffened Cylinder (ISC) process, was successfully demonstrated up to the 10-foot diameter scale, which laid the groundwork for the current investigation of metallic fuselage structures. Using the ISC process as the basis for the re-design of a metallic fuselage eliminates hundreds of thousands of holes and rivets, while significantly reducing assembly time and crack initiation sites in the integral structure. However, the ISC process is not currently configured to fabricate circumferential ring frames for carrying fuselage internal pressure loads. Consequently, a trade study was performed to assess existing and advanced manufacturing processes, including additive manufacturing, forming, and welding. The approach with the lowest barriers to success, while simultaneously improving manufacturing time and cost, was to use formed ring frame segments attached to the ISC via Refill Friction Stir Spot Welding (RFSSW). The RFSSW process is five times faster than drilling, reaming, and riveting and provides similar mechanical performance. Finishing the fuselage structure with conventional windows, floor beams, and floor panels can then be accomplished using incumbent assembly methods, thereby maximizing reuse of existing infrastructure for aircraft construction. Structural analyses were performed to assess and optimize the geometric variables of integrated skin and stiffener configurations. A cost benefit and manufacturing rate analysis was also performed to compare against the current state-of-the-art for single aisle transport class aircraft. The resulting structure offers a weight reduction that rivals current graphite-epoxy composite fuselage structures. The projected manufacturing rate is close to double current metallic fuselages and six times faster than current composite manufacturing practices. The damage tolerance properties of a monocoque fuselage structure have yet to be assessed, but past integral airframe structural work has exploited geometric features to blunt or turn cracks. This concept offers promise that integrated structures can meet stringent aircraft durability specifications. An important benefit is that such aluminum fuselage structures may be inspected and repaired using established practices and existing expertise. Finally, pursuit of advanced manufacturing processes for future aluminum fuselages minimizes waste and the structure is 100% recyclable at the end-of-life for maximum sustainability.

aluminum↗

NASA NTRS1974

Improved circuit-board interconnectors

One component serves three functions, electrical interconnections, thermal control, and mechanical integrity, at same time. Several versions of design: (1) Insulated support plate contains holes; (2) Alternate support plate configuration uses rivets instead of pins; and (3) Another configuration includes leaf-spring contacts instead of pins or rivets.

Martin, J. H.↗

NASA NTRS1972

Effect of polymer coatings on fatigue strength of aluminum alloy 2024 box beams

Previous investigators have shown that polymer coatings raise the fatigue strength of metals tested in air to about the same level as that of uncoated specimens tested in vacuum. The results are given of tests to determine if a polymer coating would improve the fatigue strength of built-up aluminum alloy members simulating aircraft construction. Aluminum alloy 2024-T4 riveted box beams were subjected to constant amplitude fatigue tests in air as well as in salt water fog. The coating did not improve the fatigue strength of beams tested in either environment. This is believed to result from the fact that most failures originated at rivet holes, which were isolated from both the coating and the environment.

Nordmark, G. E.↗

NASA NTRS1973

Impact resistance of spar-shell composite fan blades

Composite spar-shell fan blades for a 1.83 meter (6 feet) diameter fan stage were fabricated and tested in a whirling arm facility to evaluate foreign object damage (FOD) resistance. The blades were made by adhesively bonding boron-epoxy shells on titanium spars and then adhesively bonding an Inconel 625 sheath on the leading edge. The rotating blades were individually tested at a tip speed of 800 feet per second. Impacting media used were gravel, rivets, bolt, nut, ice balls, simulated birds, and a real bird. Incidence angles were typical of those which might be experienced by STOL aircraft. The tests showed that blades of the design tested in this program have satisfactory impact resistance to small objects such as gravel, rivets, nuts, bolts, and two inch diameter ice balls. The blades suffered nominal damage when impacted with one-pound birds (9 to 10 ounce slice size). However, the shell was removed from the spar for a larger slice size.

Graff, J.↗

NASA NTRS1979

Fastener for thin fragile materials

Two-piece fastener is ideal for securing thin delicate parts that might be damaged by conventional fasteners, such as rivets or upset collars. Strength of new fastener approaches that of riveted connection. Easily fabricated, fastener consists of plastic button and spring-steel collar. Parts have large contact area to distribute loads on delicate assemblies and low profile so that they fit into narrow spaces. Fastener is suitable for materials ranging in density from sheet metal to fabric sandwiches.

Sokol, S.↗

NASA NTRS1983

Design, fabrication, installation and flight service evaluation of a composite cargo ramp skin on a model CH-53 helicopter

The installation of a composite skin panel on the cargo ramp of a CH-530 marine helicopter is discussed. The composite material is of Kevlar/Epoxy (K/E) which replaces aluminum outer skins on the aft two bays of the ramp. The cargo ramp aft region was selected as being a helicopter airframe surface subjected to possible significant field damage and would permit an evaluation of the long term durability of the composite skin panel. A structural analysis was performed and the skin shears determined. Single lap joints of K/E riveted to aluminum were statically tested. The joint tests were used to determine bearing allowables and the required K/E skin gage. The K/E skin panels riveted to aluminum edge members were tested in a shear fixture to confirm the allowable shear and bearing strengths. Impact tests were conducted on aluminum skin panels to determine energy level and damage relationship. The K/E skin panels of various ply orientations and laminate thicknesses were then impacted at similar energy levels. The results of the analysis and tests were used to determine the required K/E skin gages in each of the end two bays of the ramp.

Lowry, D. W.↗

NASA NTRS1985

The design of repairable advanced composite structures

This paper addresses the repair of advanced composite structures by mechanical fasteners or by adhesive bonding. It is shown that many of today's composite designs are unreasonably difficult to repair. Conversely, the knowledge to design repairable structures is already available, if only it is applied during the initial design stage. Bolted or riveted repairs require only the avoidance of extremely orthotropic composite fiber patterns; those near the quasi-isotropic layup are the most suitable. Mildly orthotropic fiber patterns are appropriate for structures in which there is a dominant load direction. Thick composite structures are shown to require bolted or riveted repairs while thin structures favor adhesively bonded permanent repairs, although provisions can be easily made for temporary mechanical repairs. The reasons why integrally stiffened cocured composite designs are usually impractical to repair are explained and alternative repairable design concepts are presented.

Hart-Smith, L. J.↗

NASA NTRS1992

Stress concentrations for straight-shank and countersunk holes in plates subjected to tension, bending, and pin loading

A three dimensional stress concentration analysis was conducted on straight shank and countersunk (rivet) holes in a large plate subjected to various loading conditions. Three dimensional finite element analysis were performed with 20 node isoparametric elements. The plate material was assumed to be linear elastic and isotropic, with a Poisson ratio of 0.3. Stress concentration along the bore of the hole were computed for several ratios of hole radius to plate thickness (0.1 to 2.5) and ratios of countersink depth to plate thickness (0.25 to 1). The countersink angles were varied from 80 to 100 degrees in some typical cases, but the angle was held constant at 100 degrees for most cases. For straight shank holes, three types of loading were considered: remote tension, remote bending, and wedge loading in the hole. Results for remote tension and wedge loading were used to estimate stress concentration for simulated rivet in pin loading. For countersunk holes only remote tension and bending were considered. Based on the finite element results, stress concentration equations were developed. Whenever possible, the present results were compared with other numerical solutions and experimental results from the literature.

Shivakumar, K. N.↗

NASA NTRS1991

NASA airframe structural integrity program

NASA has initiated a research program with the long-term objective of supporting the aerospace industry in addressing issues related to the aging commercial transport fleet. The interdisciplinary program combines advanced fatigue crack growth prediction methodology with innovative nondestructive examination technology with the focus on multi-site damage (MSD) at riveted connections. A fracture mechanics evaluation of the concept of pressure proof testing the fuselage to screen for MSD has been completed. Also, a successful laboratory demonstration of the ability of the thermal flux method to detect disbonds at riveted lap splice joints has been conducted. All long-term program elements have been initiated and the plans for the methodology verification program are being coordinated with the airframe manufacturers.

Harris, Charles E.↗

NASA NTRS1943

Tests of Aluminum-alloy Stiffened-sheet Specimens Cut from an Airplane Wing

The specimens used in the present tests were cut from an actual airplane wing of the stressed-skin type. The specimens thus obtained were not representative of the usual type of laboratory specimens because the stiffeners were not exactly parallel nor evenly spaced and, in one case, the skin consisted of pieces of sheet of different thicknesses. The test data obtained indicate that the buckling strain of stiffened curved sheet can be computed with reasonable accuracy by the equation given by Wenzek. The ultimate loads of the specimens when tested as flat sheet were within +/-11 percent of the product of the compressive yield strength and the cross-sectional area of the stiffeners. A rivet spacing equal to 98 times the sheet thickness was a source of weakness, and rivet spacings up to 36 times the sheet thickness appeared satisfactory.

Holt, Marshall↗

NASA NTRS1994

The characterization of widespread fatigue damage in fuselage structure

The characteristics of widespread fatigue damage (WSFD) in fuselage riveted structure were established by detailed nondestructive and destructive examinations of fatigue damage contained in a full size fuselage test article. The objectives of this were to establish an experimental data base for validating emerging WSFD analytical prediction methodology and to identify first order effects that contribute to fatigue crack initiation and growth. Detailed examinations were performed on a test panel containing four bays of a riveted lap splice joint. The panel was removed from a full scale fuselage test article after receiving 60,000 full pressurization cycles. The results of in situ examinations document the progression of fuselage skin fatigue crack growth through crack linkup. Detailed tear down examinations and fractography of the lap splice joint region revealed fatigue crack initiation sites, crack morphology, and crack linkup geometry. From this large data base, distributions of crack size and locations are presented and discussions of operative damage mechanisms are offered.

Piascik, Robert S.↗