Fractographic examination of coupons representing aircraft structural joints with and without hole cold expansion

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DOIResolve DOI: http://doi.org/10.1016/j.engfailanal.2012.12.008
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TypeArticle
Journal titleEngineering Failure Analysis
ISSN1350-6307
Volume30
Pages7490; # of pages: 17
SubjectAircraft structural joints; Failure analysis; Hole cold expansion; Interference fit fasteners; Spectrum fatigue testing
AbstractIn an effort to establish the potential benefits of hole cold expansion and interference fit fasteners for long term fatigue performance, coupons representing three types of aircraft structural joints were designed, manufactured and assembled. These joints, manufactured using 7075-T6 aluminium alloys for main members and 7075-T73 for doublers or spacers, were representative of: No Load Transfer joints, simulating " non-structural" joints, such as brackets, supports for conduits, fuel lines, and wire bundles. Medium Load Transfer joints, simulating symmetrical doubler, stiffener and rib joints; and High Load Transfer joints, simulating symmetrical splices in major load carrying members. The joints were assembled using Hi-Lok™ interference fit fasteners, with and without hole cold expansion, and were fatigue tested to complete failure using a representative mission mix service load spectrum for a coastal patrol aircraft wing fatigue sensitive location. The failure surfaces were examined with the aid of an optical microscope at various magnifications. The fractographic descriptions for the three types of joints examined document the crack nucleation sites, mechanisms of crack formation, and extent of damage at catastrophic failure, including the effects of manufacturing, such as direction of hole cold expansion and direction of interference fit fastener insertion. Examination of fracture surfaces for fractographic evidence provides researchers and engineers with valuable insights into the failure process, which will enable them to perform more accurate and representative life predictions of joint performance. © 2013 Elsevier Ltd.
Publication date
LanguageEnglish
AffiliationAerospace; National Research Council Canada
Peer reviewedYes
NPARC number21270421
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Record identifierf7240ef0-5d40-4249-ad91-f7280108a93b
Record created2014-02-10
Record modified2016-05-09
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