Damage Tolerance Evaluation

of Antenna Installations

By Patrick Safarian
 Damage Tolerance Analysis
„ Damage tolerance analysis (DTA) is the
application of Fracture Mechanics to assess how
a structure, assumed to be cracked, will respond
to loads (cyclic and static) over time
„ DTA assesses:
„ How a crack(s) will grow over time

„ How the strength of the structure is

affected by the crack(s)
„ Fatigue analysis is the proper approach to assess
the structural durability and identify the critical
details for DTA and set inspection thresholds.
2
 General Requirements
„ FAR 25.1529 requires preparation of
Instructions for Continued Airworthiness (ICA)
in Accordance with Part 25 Appendix H
„ Part 25 Appendix H gives specific requirements
for ICA preparation. requires inclusion of
structural inspection procedures approved under
FAR 25.571
„ 25.571 requires:
„ Damage tolerance evaluation
„ Establishment of inspections or other procedures
necessary to prevent catastrophic failure
„ Inclusion of appropriate inspections or other procedures in
Airworthiness Limitations Section of the ICA
3
 Part 26 Requirement and Applicability
„ New Code of Federal Regulation Part 26.45
and 26.47 mandate the TC and STC holders,
respectively, to develop DT based inspections
for alterations and repairs to alteration in
fatigue critical structures for Part 121 and
129 airplanes having:
„ A maximum type-certificated passenger capacity
of 30 or more OR
„ A maximum payload capacity of 7,500 pounds or
more
„ This rule is known as Aging Aircraft Safety
Rule (AASR)
4
 Part 26 Requirement and Applicability
„ So what is the AASR requirements?
„ To perform a damage tolerance evaluation
on the structure that could contribute to
catastrophic failure due to fatigue. This
includes baselines structures and repairs
and alteration
„ The analysis requirements are similar to
requirements of CFR 25.571 Amendment
24-45

5
 Specific Tasks
„ Overview of the specific tasks:
1. Identify most critical detail(s) of installation
2. Perform crack growth and residual strength analyses
3. Determine inspection threshold and intervals
4. Develop an ICAW
„ Include illustrations, and clearly specify the inspection
detail areas and direction

6
 Physical Characteristics

„ Skin penetration for

antenna cable
„ Doubler attached to
skin with mounting
provisions for antenna
(e.g. nut plates)
„ To enhance the durability of the doubler to skin
attachments it is best to pick up the stringer fasteners
and stabilize the stringers using connecting intercostals
„ New fatigue critical details are introduced
„ Open Holes
„ Filled Loaded Holes
7
 General Assumptions

„ Installation located in skin bounded by frames

and stringers (i.e. longerons)
„ Installation located away from discontinuities
(e.g. doors, windows) and other repairs by at
least one frame bay and 2 stringer bays
„ Biaxial loading due to pressure plus vertical
inertia fuselage bending only (internal shear
neglected)
„ Calculation of the detail stress at the peripheral
fasteners should include the contributions from
membrane and bending stress components due to
eccentricity caused by the doubler
8
 Gross Loading
„ Fuselage subjected to
„ Internal pressure

„ Overall bending and shear associated with gusts,

maneuvers and ground conditions
„ Loads introduced by gear, wing and empennage

„ Calculation of skin stresses due to pressure away from

discontinuities may conservatively be given as
σHoop = ΔpR/t p0
σLongitudinal = ΔpR/2t
σL
where, Δp = pcabin - po pcabin
σH
„ Beneficial effects of frames
and stringers are ignored R
t
9
 Gross Loading (cont’d)
„ Major percentage of hoop stress for majority of
fuselage skin is due to pressure and neglecting other
loading may be reasonable
„ Use minimum skin gauge and standard radius

„ Contribution of fuselage bending to longitudinal stress

may be significant and should NOT be ignored. This is
especially true for installations located on top and aft
of wing.
„ Installing antennas in fuselage locations where primary
loading consists of more than the basic pressure plus
overall fuselage bending should be avoided.
„ Stabilize the skin structure by installing intercostals.
This reduces extra bending stresses in the skin.

10
 Gross Loading (cont’d)
„ Vertical fuselage inertia bending adds to longitudinal
skin stress is assumed to vary as shown:
Lift
ANTENNA LOCATION

Front
Spar nzW

L
σL = ΔpR/2t + nzσ1G,max
LONGITUDINAL

S
STRESS

σL = ΔpR/2t + nz (L/S) σ1G,max

FUSELAGE LOCATION
11
 σ1g,max Estimate
„ Assumed to occur at maximum bending
location at top of fuselage over the wing
„ Assume zero margin design and conservatively
neglect aerosuction, relief valve setting,
Nz > 2.5, etc. unless specifically known
„ Based on the above and Nz = 2.5,
FTU, B = 1.5 (ΔPR/2t + σ2.5 g)
σ1g,max = (FTU, B/1.5 - ΔPR/2t)/2.5
ΔP = normal operating pressure at max design altitude, psi
FTU, B = B-basis ultimate tension allowable (ref. MMPDS)
12
 Local Loads/Stresses
1) Skin holes used for doubler attachment will get
induced fastener bearing loading in addition to basic
stress

0 0

σBP σBR σ

σ σ

13
 Local Loads/Stresses (cont’d)
„ First row of fasteners in multi row design will have most
critical combination of bearing and bypass stress
LOAD

σ σ
„ Calculate the fastener loads by a various method
available, such as 1D FEA tool, or see Tom Swift’s paper

14
 Local Loads/Stresses (cont’d)
2) In addition to induced fastener bearing, bending
stresses due to eccentricity cause by doubler
thickness should be taken into accounted
Notice the skin
Doubler bending due to
eccentricity cause
by the doubler.
Skin Max skin stress is
at the faying
surface in the first
fasteners row.

σ σ

15
 Fatigue Evaluation
„ Identify critical locations using fatigue evaluation
„ High stress concentrations in the structure and high
load transfer points in the joint should be identified,
„ Fatigue lives be determined
„ Location for crack growth analysis be determined

16
 Crack Growth Scenarios- Threshold
„ Crack growth scenarios to be considered should be
described and supporting rationale be given
„ Fatigue analysis
„ Consider factors such as
„ Installation design, Detail being considered, Inspection
method/procedures to be used for hidden parts
„ Threshold should be the least of
„ ¼ of the unfactored fatigue life of the details
„ ½ the life of rogue flaw size to critical length
„ Ref. SACO Damage Tolerance Guidelines
„ The threshold is calculated as the airplane total cycles
unless
„ The Doubler picks up new holes, or
„ Uses existing holes that are zero-timed
17
 Initial (Rogue) Flaw Assumptions-
For Setting Threshold

0.005”
0.005”

0.05”

18
 Continuing Damage-
For Setting Threshold
0.005” + Δa1
0.005” + Δa1
D

e A1 = e + D + 2(.005 + Δa1)

End of Stage 1
0.005” + Δa1 + Δa2
0.005” + Δa1 +Δa2
D

e A2 = 3e + D + 2(.005 + Δa1 + Δa2)

End of Stage 2

19
 Inspection Threshold

acrit
CRACK LENGTH, a

Inspection Threshold
(Nthreshold)

0.05”
Nthreshold = Ncr /2

Ncr/2 Ncr
CYCLES, N
20
 Crack Growth Scenarios-
Setting Intervals
„ Determine the detectable crack size based on
the inspection technique
„ An acceptable way to model MSD would be to
assume detectable cracks exist at every equally
critical detail; e.g. both sides of each hole in a row
of equally critical holes

Detectable crack at every equally critical hole (Total of 10 in this schematic)

21
 Crack Growth Scenarios-
Setting Intervals
„ Using residual strength analysis compute the
critical crack length
„ Choose the shorter length of the net section yield
and LEFM results
„ For MSD situations most often the critical crack

length is based on net section yield

If Δp=8.9 psi, R=128”, pitch=1.2, dia=0.188”, t=0.062”,
KA= 130 Ksi*in**0.5, FTU=62 Ksi and FTY=42 Ksi show that
the critical crack length is 0.242”?
Fastener Pitch

aCritical
(Typical 10 locations)

22
 Crack Growth Scenarios-
Setting Intervals
„ Using LEFM principals grow the cracks from
detectable length to the critical length
„ Cycle by cycle crack growth or simplified equivalent
stress crack growth methods can be employed
„ Programs available include NASGRO, AFGROW,
FractureResearch, CRACKS9x, user developed programs or
combinations of features from the listed programs.
„ Find the most critical cracking scenario(s) using S-N
curves & analyze different crack sequence scenarios
„ The most critical inspection program should be
applied to ALL fatigue critical details,
„ e.g. inspect the most critical (outer) row in longitudinal
and circumfrential directions of a rectangular doubler
23
 Crack Growth Scenarios-
Setting Intervals
„ The period to grow a detectable crack to its critical
size is know as the detectable crack growth life
„ Based on the confidence in the crack growth life
prediction (loads, stresses, β, material properties, etc.) a
suitable factor between 2 and 4 should be used to
determine the inspection intervals. For example:
„ Use a factor of 4 when there is no airplane full-scale
fatigue test data and there is no airplane loads
substantiation through a flight & ground loads survey
„ Use a factor of 3 when there has been an airplane
fatigue test but no loads survey or when there has
been an airplane loads survey but no fatigue test
„ In the event that both airplane fatigue testing and a
loads survey has been accomplished, use a factor of 2
24
 Crack Growth Stresses

„ Equivalent once per flight cycle used:

TYPICAL EQUIVALENT
CYCLE

„ Most OEM’s have their approach to calculate the

equivalent cycles
„ Boeing uses a modified Minor’s rule approach

25
 Crack Growth Stresses (cont’d)
„ Longitudinal cracks,
σHoop,min = 0
σHoop,max = ΔPR/t
„ Circumferential cracks, Use 1.5 for large transports, e.g.
Boeing, and 1.3 for small transports,
σLong,min = 0 e.g. Gulfsteam, airplane models

σLong,max = σ1.5 g,max = 1.5 σ1.0g,max + ΔPR/2t

σLong,max = 0.4 (FTU, B + ΔPR/2t) (aft of front spar)
σLong,max = 0.4 ((L/S)F
(L/S) TU, B + ΔPR/2t) (fwd of front spar)
ΔP = normal operating pressure at max design altitude + 0.5psi
(aerosuction)
„ Use the bending stress correction provided in the class
to adjust for the bending stress created due to
installation of the antenna doubler
26
 Crack Growth Stresses (cont’d)
„ Finite element analysis of a 6” tall antenna on a 0.04”t skin &
a 0.056”t doubler subject to hoop and longitudinal loading
„ Fasteners do pick up the adjacent stringers

Antenna
Skin

Antenna
Base
Doubler
Stringer

Model includes skin, stringer, doubler, Note the difference in the skin out of
antenna, 8.6 psi internal pressure and plane displacements caused by
5 psi side pressure load on the antenna presence of the doubler.
27
 Crack Growth Stresses (cont’d)
„ Max principal stress contour indicates membrane
stress of 17.2 Ksi and Max fiber stress of 25.3 Ksi

Membrane + bending Membrane principal

principal stress contour stress contour

„ Similar analysis indicates that the increased stresses for antennas

less than 6” tall are mainly due to the eccentricity caused by the
doubler. In this case the max membrane stress stayed the same (17.2
Ksi) and the max fiber stress increased to 25.0 Ksi.
28
 Joints with eccentricities
„ Secondary bending
„ Caused by step in neutral
line
„ Bending moment depends on
„ Step size (eccentricity)
„ Thickness
„ Load transfer
„ Overlap length (row
distance)
„ Loads on Joint
„ Tensile stresses
„ Secondary bending
„ Contact surface: Tensile
stress + bending stress
„ Outer surface: Tensile
stress - bending stress
29
 Joints with eccentricities (cont’d)
„ Tensile and bending stresses in the skin at the doubler edge:
6” Antenna
Pressure = 8.6 psi (8.0 psi for 0.036"t skin)
Dblr
R (in.) Skin 0.040 0.050 0.056 0.063 0.071 0.080 0.090 0.095 0.100 0.125
0.036 tensile 17,506 17,638 17,770 17,910 18,055
0.036 bending 25,807 26,264 26,383 26,411 26,329
0.040 tensile 16,833 17,013 17,135 17,267 17,404 17,577 17,721 17,832 17,891 18,142
0.040 bending 24,912 25,450 25,620 25,705 25,687 25,694 25,619 25,849 25,914 26,145
74
0.050 tensile 13,563 13,624 13,711 13,818 13,927
0.050 bending 20,418 20,587 20,691 20,712 20,855
0.063 tensile 10,886 10,968 11,053 11,141
0.063 bending 16,211 16,455 16,633 16,735
0.063 tensile 14,605 14,751 14,876 15,003 15,062 15,119
0.063 bending 21,686 21,713 21,797 21,813 21,794 21,765
0.071 tensile 13,028 13,135 13,246 13,297 13,347 13,565
100
0.071 bending 19,057 19,163 19,200 19,203 19,200 19,120
0.080 tensile 11,639 11,739 11,787 11,834 12,048
0.080 bending 17,363 17,477 17,518 17,597 17,773

30
 Joints with eccentricities (cont’d)
„ Plot of tension and bending stresses in the skin at the doubler
edge for various thicknesses with a 6” antenna:

74 " Radius

28,000
25,000
0.036 tensile
22,000 0.036 bending
σ 19,000 0.040 tensile
16,000 0.040 bending
0.050 tensile
13,000
0.050 bending
10,000
0.063 tensile
0

0
0.063 bending
03

04

05

06

07

08

09

10

11

12

13
0.

0.

0.

0.

0.

0.

0.

0.

0.

0.

0.
Doubler Thickness

31
 Joints with eccentricities (cont’d)
„ Plot of tension and bending stresses in the skin at the doubler
edge for various thicknesses with a 6” antenna:

100" Radius

24,000

21,000 0.063 tensile

0.063 bending
18,000 0.071 tensile
σ
15,000 0.071 bending
0.080 tensile
12,000
0.080 bending
9,000
0

0
0
06

07

08

09

10

11

12

13
0.

0.

0.

0.

0.

0.

0.

0.
Doubler Thickness

32
 Joints with eccentricities
„ Tensile and bending stresses in the skin at the doubler edge:
12” Antenna
Pressure = 8.6 psi (8.0 psi for 0.036"t skin)
Doubler
R (in.) Skin 0.040 0.050 0.056 0.063 0.071 0.080 0.090 0.100 0.125
0.036 tensile 18,455 18,240 18,122 17,998 17,875
0.036 bending 28,596 28,141 27,667 26,994 27,027
0.040 tensile 16,670 16,763 16,894 17,261 17,173
0.040 bending 27,901 27,678 27,349 26,714 26,150
R = 74"
0.050 tensile 13,329 13,428 13,533 13,641 13,756
0.050 bending 21,962 21,658 21,218 21,619 21,535
0.063 tensile 10,752 10,842 10,933 11,025
0.063 bending 16,683 17,145 17,547 17,883
0.063 tensile 14,612 14,557 14,671 14,796 14,910
0.063 bending 22,480 22,385 22,170 22,077 22,146
0.071 tensile 12,876 12,971 13,077 13,175 13,385
R = 100"
0.071 bending 19,612 19,413 19,529 19,613 19,588
0.080 tensile 11,475 11,565 11,649 11,832
0.080 bending 17,003 17,164 17,255 17,399

33
 Joints with eccentricities
„ Plot of tension and bending stresses in the skin at the doubler
edge for various thicknesses with 12” antenna:

74" Radius

31,000
0.036 tensile
28,000
0.036 bending
25,000 0.040 tensile
22,000 0.040 bending
σ
19,000 0.050 tensile
16,000 0.050 bending
0.063 tensile
13,000
0.063 bending
10,000
5

5
03

04

05

06

07

08

09
0.

0.

0.

0.

0.

0.

0.
Doubler Thickness

34
 Joints with eccentricities
„ Plot of tension and bending stresses in the skin at the doubler
edge for various thicknesses with 12” antenna:

100" Radius

25,000

22,000 0.063 tensile

0.063 bending
19,000
0.071 tensile
σ
16,000 0.071 bending
0.080 tensile
13,000 0.080 bending

10,000
0
0

0
0

0
0

0
10

12
06

07

08

09

11

13
0.

0.

0.

0.

0.

0.

0.

0.
Doubler Thickness

35
 Joints with eccentricities
„ Tensile and bending stresses in the skin at the doubler edge:
18” Antenna
Pressure = 8.6 psi

Doubler

R (in.) Skin 0.071 0.080 0.090 0.100 0.125

0.063 tensile 14,120 14,246 14,374 14,495 14,781

0.063 bending
24,712 24,328 23,719 22,999 23,509

0.071 tensile 12,580 12,657 12,772 12,876 13,085

100
0.071 bending
21,923 21,509 20,917 20,545 21,297

0.080 tensile 11,254 11,356 11,450 11,640

0.080 bending
18,859 18,304 18,516 19,231

36
 Joints with eccentricities
„ Plot of tension and bending stresses in the skin at the doubler
edge for various thicknesses with 18” antenna and 100” radius
fuselage:

25,000

22,000 0.063 tensile

0.063 bending
19,000 0.071 tensile
σ
16,000 0.071 bending
0.080 tensile
13,000 0.080 bending

10,000
0

0
07

08

09

10

11

12

13
0.

0.

0.

0.

0.

0.

0.
Doubler Thickness

37
 Joints with eccentricities (cont’d)
„ To account for the combined effects of
tensile, bending and bearing stress components
for crack growth analysis you can use
AFGROW software
„ Choose the tension and bending stress fraction
according to the skin tensile and bending stresses
calculated at the edge of the doubler, as provided
in the previous tables.
„ Calculate the bearing stress due to load transfer
through each critical fastener row.
„ Use AFGROW “help” to properly enter each of the
3 stress components.

38
 Joints with eccentricities (cont’d)
„ Figure below shows comparison for the two primary cracks at the
joints with eccentricity and the respective fracture surfaces.
„ The MSD growth model using the tension and bending stresses from
the previous data demonstrates good correlation with the striation data
Fwd (Crack 1) Aft (Crack 4)
0.2 0.12

0.18
0.1
0.16 MSD Simulation
Striation Count
0.14 0.08
AFGROW Strip

Crack Length
0.12
Crack Length

0.1 0.06

0.08
0.04
0.06

0.04 0.02

0.02

0 0
0 10000 20000 30000 40000 50000 60000 0 10000 20000 30000 40000 50000 60000

Airframe Cycles Airframe Cycles

Ref: D. Steadman, R. Ramakrishnan and M. Boudreau, (2006), "Simulation of Multiple Site Damage
Growth", 9th Joint FAA/DoD/NASA Aging Aircraft Conference, Atlanta, GA., pp 12

39
 Fatigue Analysis
„ How to handle combination of tensile & bending in fatigue?
„ Method 1: A convenient and simple method to handle the
combination of tensile and bending stresses in joints such
as antenna installations is outlines here:
„ For notched details, such as open hole and joint details, the best
approach is to adjust Kt to include the combined effects of tension
and bending. Then using one or the other stress as the reference
stress to determine a fatigue margin.
„ For instance, if you were analyzing a hole detail with a tension
Ktg of 3.2 and a bending Ktg of 2.2 (from Peterson's textbook or
a similar source), in case Ft=10 Ksi and Fb=5 ksi (taking the
stresses to be the GAG gross stresses at the hole)
„ GAG fpeak at the hole = 3.2×10 + 2.2×5 = 43 ksi

„ Then, the effective Ktg = 43/10 = 4.3, if the reference stress is

taken as the tension component of the stress.
40
 Fatigue Analysis (cont’d)
„ This method works reasonably well when
analyzing joint details, as long as the bending-to-
tension (membrane) stress ratios are close to
constant for the most damaging flight
conditions, and the bending stresses are not the
dominant stresses, since most fatigue manual’s
notched and open hole values and load transfer
factor curves are all based on tension data.
„ In our example, using this approach, S-N curves
would be conservatively adjusted by the ratio of
3.0/4.3 = 0.698 (3.0 is taken as the 'reference' for
Ktg in S-N curves). This seems like a large
knockdown, but note that the reference stress
would be the tension component only (no bending).
41
 Fatigue Analysis (cont’d)
„ Method 2: Empirical prediction method (Fokker)
„ S-N data available for reference joints
„ Similarity principle: Similar peak stresses in different joints give
similar fatigue lives
„ Peak stresses depend on load transfer, by-pass load and
secondary bending S =KS
peak t tension

γ is percent load transmitted K t = γK t , pin + (1 − γ )K t ,hole ,tension + k B K t ,hole ,bending

to the other sheet in the
critical row (R1/p)
S bending
kB =
Stension
„ Other parameters included in S-N curve
⇒ Joints should be similar
„ Other rational approaches can be proposed.

42
 Residual Strength Loading

„ Residual Strength Requirements for Damage

Tolerance Evaluation are Given in
25.571(b)(5)(i)&(ii) NOT 25.365
„ Two Conditions Must be Considered
„ Condition (i) - Normal Pressure Combined with
Limit Flight Loads
„ Condition (ii) - Factored Pressure Loading Only

43
 Residual Strength Loading (cont’d)
„ Up thru amendment 25-86
„ Condition (i)
Δp + paero + limit symmetric maneuver at Vc or,
‘‘ + limit gust up to Vc or,
‘‘ + limit roll maneuver up to Vc or,
‘‘ + Limit yaw maneuver up to Vc
,whichever is greater
„ Condition (ii)
1.1 Δp + paero 1g
where,
Δp = normal operating differential pressure
paero = aerodynamic pressure associated with limit condition being
considered
paero1g = aerodynamic pressure for 1g flight

44
Residual Strength Loading (cont’d)

„ Amendment 25-96
„ Condition (i) - Same as before except limit
symmetric maneuver at all speeds up To Vc

„ Condition (ii) -
1.15 (Δp + paero 1g)

45
 Residual Strength Stresses
„ Longitudinal cracks,
σHoop, Res = (1.1 Δp + 0.5)R/t (Pre-amendment 25-45)

„ Circumfrential cracks
σLong, Res = ΔPR/2t + Nz σ1g,MAX (aft of front spar)
σLong, Res = ΔPR/2t + Nz(L/S)σ1g,MAX (fwd of front spar)
Δp = normal operating pressure at maximum design altitude
ΔP = normal operating pressure at maximum design altitude
plus 0.5 – 1.0 psi for aerosuction
Nz = maximum design limit load factor (at least 2.5 but not
greater that 3.8)

46
 Crack Growth Rate

Region I – Growth rate decreases asymptotically with decreasing ΔK. Below a

threshold value of ΔK (i.e. ΔKTH) there is no growth.
Region II – Growth rate and ΔK follow a Log-Log linear relationship and can
be reasonably approximated using the Paris Equation where;
m = Slope of line
C = Intercept of da/dN axi
Region III – Growth rate increases asymptotically with increasing ΔK.

47
 Walker Equation

„ Walker modified the

Paris equation so
that stress ratio
R Increasing
effects could be
approximated

da/dN = C [(1.0-R)q Kmax]p

Log da/dN

Log ΔK
48
 da/dN vs. ΔK 2024-T3 Sheet
(Walker Constants C=6.76E-10, p=3.72, q=.6445)
1000.000
DELTA K R = .05 TABULAR DATA
( KSI-IN1/2)
DELTA K R = .40 TABULAR DATA
( KSI-IN1/2)
DELTA K R = .80 TABULAR DATA
( KSI-IN1/2)
DELTA K R = .05 WALKER EQN
( KSI-IN1/2)
DELTA K R = .40 WALKER EQN

ΔK (ksi(in)**1/2)
( KSI-IN1/2) 100.000
DELTA K R = .80 WALKER EQN
( KSI-IN1/2)

10.000

1.000
1.00E-08 1.00E-07 1.00E-06 1.00E-05 1.00E-04 1.00E-03 1.00E-02 1.00E-01 1.00E+00

da/dN (in/cycle)
49
 Walker Equation Coefficients & Exponents
TABLE 1. Walker Equation* Coefficients and Exponents for Room Temperature, Laboratory Air Ambient Conditions

ALLOY FORM DIRECTION C q p

2014-T6 Sheet L-T 9.66482 x 10-10 0.57937 3.78906

2024-T3 & -T42 Sheet L-T 6.76125 x 10-10 0.64647 3.71980

2024-T3 & T42 Sheet T-L 9.01566 x 10-10 0.62910 3.68842

2024-T351/T3511 Plate/Extrusion L-T 8.86005 x 10-10 0.67178 3.71010

7050-T7452 Forging L-T & T-L 1.08344 x 10-9 0.68746 3.72313

7050-T74511 & T76511 Extrusion L-T 1.98718 x 10-9 0.76890 3.60885

7050-T7651 & T7451 Plate L-T & T-L 1.32927 x 10-9 0.57452 3.55242

7075-T6 Sheet L-T 1.11737 x 10-9 0.60750 3.79719

7475-T7351 & T7651 Plate L-T 1.05576 x 10-9 0.60418 3.54815

7475-T761 Sheet L-T 1.11412 x 10-9 0.66473 3.74701

* da/dN = C[(1.0 – R)qKmax]p where, da/dN = crack growth rate, in./cycle

Kmax = maximum (i.e. peak) stress intensity, ksi(in)1/2
R = stress ratio, Kmin/Kmax

50
 Critical Crack Size
RESIDUAL STRENGTH

Lesser of:
1) acrit = (1/π)(KA/σC β)2
σYield 2) Net Section Yield

σC KA

σRES

acrit
CRACK SIZE, a
51
 Detectable Crack Sizes
„ Most common inspection techniques are:
„ General Visual (Surveillance)
„ Detail Inspection
„ Special Inspection
„ High frequency eddy current (HFEC)

„ Low frequency eddy current (LFEC)

„ Medium frequency eddy current (MFEC)

„ Ultrasound (UT)

„ In Table 1 of SACO Damage Tolerance Guidelines

guidance for detectable crack size for most of
these techniques are provided
„ Use OEM NDI procedure manual to specify the
technique procedure
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 Detectable Crack Sizes (cont’d)
„ Examples from Boeing NDI procedure manual to
specify the technique (use any approved spec’s):
„ 727 NDT manual Part 6
„ LFEC: 53-30-00 Figure 5
„ HFEC: Surface & around fastener 51-00-00 Fig 4 or Fig 23
„ HFEC: Open Hole 51-00-00 Fig 16 or Fig 11 (only for
t>0.062”, needs less space than fig 16)
„ Recommended Minimum detectable crack lengths:
„ HFEC: 0.20” Gen Area, 0.10” + Fastener diameter
„ MFEC: 0.50” Gen Area, 0.25” @ fastener
„ 0.15” @ fastener (727 NDT Part 6 53-30-27 Fig 17)
„ LFEC: 0.20” C’snk & 0.25” Button-head (0.04<t<0.089)
„ 727 NDT Part 6 53-30-27 Fig 13 refers to 53-30-00 Fig 9

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 Detectable Crack Sizes (cont’d)
TABLE 2. Detectable Crack Sizes Associated with Inspection Techniques (Reference [4])

Method Description Detectable Crack Length

(inch)
Visual Unpainted Surface*: 1.0 or Hole-to-Edge

Reference: SACO
3 to 5x Magnification
Painted Surface None

Damage Tolerance Penetrant Unpainted Surface:

Guidelines, Table 1
3 to 5x Magnification 0.125
Without Magnification 0.250
Painted Surface None

Magnetic Particle Unpainted Surface:

3 to 5x Magnification 0.0625
Without Magnification 0.125
Painted Surface:
Without Magnification 0.250
X-RAY Uncovered length of crack 0.75 or Hole-to-Hole or
Radiography in aluminum (not covered Hole-to-Edge
by a steel member)
Ultrasonic Shear-Wave Crack at fastener hole using 0.125 Long x .0625 Deep
(Angle Beam) mini probe (0.25 x 0.25
inch element) at 5 to 10
Mhz
Crack in Clevis or Lug 0.125 Long x 0.0625 Deep

Ultrasonic Longitudinal Bolts ¼ to 1/3 Diameter

Wave (Straight Beam)
Crack at Fastener Hole 0.125

Bolt Hole Eddy Current Edge Corner Crack 0.030 x 0.030

(Faster Removed)
Inside Diameter Surface 0.060 Long x .030 Deep

Eddy Current Surface Probe Crack at Fastener 0.0625 Uncovered Length

Crack away from fastener 0.125

* Only primer is allowed on unpainted surfaces.

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 Damage Tolerance Assessment of an
Antenna Installation-
Instruction for Continuous Airworthiness (ICAW)
„ For each repair develop an Instruction for
Continued Airworthiness, which contains:
„ Airplane data
„ Complete definition of the repair location and
inspection directions
„ Inspection threshold
„ Inspection technique, including the call out of the
NDI procedure or the description for the DVI
„ Intervals of the repeated inspections
„ Replacement time, if any
„ Additional information, instructions or limitations

55
 Damage Tolerance Assessment of an
Antenna Installation- ICAW
„ Some useful repair notes:
1. Confirm that the surrounding structure is corrosion and damage
free per applicable SRM inspection instructions.
2. Maintain a minimum outside trim radius of 0.38 inch and a
minimum inside trim radius of 0.50 inch unless otherwise
approved by engineering.
3. Stop drilling of cracks must be accomplished per SRM. This
typically includes an eddy current inspection to accurately
locate the end of the crack and a minimum stop drill diameter of
0.25 inch at the end of the crack, followed by an open hole eddy
current inspection, followed by a minimum 1/16 inch oversize of
the stop drill hole.
NOTE: Stop drilling a crack with no further repair action does
not constitute a repair and will not be granted FAA approval
except under extremely limited circumstances.
4. Perform a surface eddy current inspection of all trimmed edges
and an open hole eddy current inspection of fastener holes to
confirm a crack free condition. Use the appropriate non-
destructive testing (NDT) instruction manual and procedure.
56
 Damage Tolerance Assessment of an
Antenna Installation- ICAW
„ Some useful repair notes (Continue):
5. Freeze plugging of holes must be accomplished as described in
the applicable SRM.
NOTE: The SRM only describes the method for installing
freeze plugs. Engineering approval is required for freeze plug
installation at any location.
6. Chamfer or break sharp edges.
7. Maintain a 63 RHR or better surface finish to all reworked and
new surfaces.
8. Treat all repair parts and all bare aluminum surfaces or existing
structure and apply one coat of primer per applicable SRM
and/or Standard Overhaul Procedures Manual (SOPM)
instructions. Use the appropriate primer depending upon
whether the surface is exposed to the airstream. In corrosion-
prone areas, two coats of primer should be used. Allow to dry
between coats.

57
 Damage Tolerance Assessment of an
Antenna Installation- ICAW
„ Some useful repair notes (continue):
9. Observe minimum bend radius listed in the applicable SRM or
other industry reference when forming repair parts from sheet
stock. It is usually advisable to form in either the annealed or
quenched condition and then heat treat. If the minimum bend
radius is exceeded, perform an NDT inspection (Level 3 dye
penetrant inspection or better, or a surface eddy current
inspection) to ensure a crack free condition.
10. Brush or bath cadmium plate corrosion resistant steel (CRES)
parts and prime with two coats of primer per applicable SRM
and/or SOPM instructions. Allow primer to dry between coats.
11. Add fillers or tapered shims as required to limit pull-up to 0.010
inch for flat stock repairs, such as skin doublers, and 0.005 inch
at all other locations. Fabricate from 2024-T3 or 7075-T6 clad
material.
12. Maintain 2D edge margin and 4-6D center-to-center spacing for
all new fasteners.
NOTE: Larger edge margins may be required at certain
locations such as door cutout corners. Consult with engineering
for approval
58
 Damage Tolerance Assessment of an
Antenna Installation- ICAW
„ Some useful repair notes (Continue):
13.Fill all voids and install all repair parts with corrosion resistant
faying surface sealant per the applicable SRM.
14.Install all fasteners and mating hardware per the applicable
SRM. Replace initial fasteners with same type repair fastener.
Oversize initial fasteners up to 1/32 inch if required to meet
hole size and condition requirements.
15.Fastener substitutions are allowed only as specified in the
applicable SRM, or as otherwise defined with engineering
approval.
16.If the fastener location includes steel or titanium parts, install
hex drive bolts in close ream holes. If the fastener location
includes only aluminum parts, install in transition fit holes unless
otherwise instructed. Install per the applicable SRM.
17.Install all bolts, including hex drive bolts, wet with corrosion
resistant faying surface sealant.
18.For increased corrosion protection, or in corrosion-prone areas,
organic corrosion preventive compound may be applied per the
applicable SRM.
59
 Summary
„ Antenna installations require DTA
„ Overview of the specific tasks:
1. Identify most critical detail(s) of installation
2. Perform crack growth and residual strength analyses
3. Determine inspection threshold and intervals
4. Develop an ICAW
„ In absence of OEM stress use conservative estimates
„ Consider Longitudinal and Circumfrential stresses
„ Fastener load transfer and skin bending due to eccentricity

„ To establish inspection threshold use the least of

„ ½ of rogue flaw life and ¼ of unfactored fatigue life
„ To establish repeat inspection intervals
„ Determine the critical crack length at the critical row/location
„ Use LEFM grow a detectable crack to the critical length
„ Establish an ICAW with all maintenance actions
60