The Second Joint NASA/FAA/DoD

Conference on Aging Aircraft

Charles E. Harris, Editor

Langley Research Center, Hampton, Virginia

Proceedings of a conference sponsored by the

National Aeronautics and Space Administration,

Federal Aviation Administration, U.S. Air Force

Materiel Command, U.S. Naval Air Warfare

Center, and U.S. Army Research Laboratory, and

held in Williamsburg, Virginia

August 31 - September 3, 1998

National Aeronautics and

Space Administration

Langley Research Center

Hampton, Virginia 23681-2199

Available from:

NASA Center for AeroSpace Information (CASI)

7121 Standard Drive

Hanover, MD 21076-1320

(301) 621-0390

National Technical Information Service (NTIS)

5285 Port Royal Road

Springfield, VA 22161-2171

(703) 605-6000
Preface

The purpose of the conference was to bring together world leaders in aviation

safety research, aircraft design and manufacturing, fleet operation and aviati
on

maintenance to disseminate information on current practices and advanced techn

ologies

that will assure the continued airworthiness of the aging aircraft in the mili
tary and

commercial fleets. The conference included reviews of current industry practic

es,

assessments of future technology requirements, and status of aviation safety r

esearch.

The conference provided an opportunity for interactions among the key personne
l in the

research and technology development community, the original equipment manufact

urers,

commercial airline operators, military fleet operators, aviation maintenance,

and aircraft

certification and regulatory authorities. Conference participation was unrest

ricted, with

623 participants from the international aviation community.

Conference Organizing Committee:

Charles E. Harris, General Chairman, NASA Langley Research Center

James C. Newman, Jr., NASA Langley Research Center

William P. Winfree, NASA Langley Research Center

William R. Elliott, WR-ALC/TIED, Robins Air Force Base

John W. Lincoln, ASC/EN, Wright Patterson Air Force Base

Joseph P. Gallagher, WL/CCI, Wright Patterson Air Force Base

Chris C. Seher, FAA, William J. Hughes Technical Center

Alfred L. Broz, FAA, Chief Scientist/Technical Advisor for Nondestructive Eval

uation

Robert G. Eastin, FAA, Chief Scientist/Technical Advisor for Fracture

Mechanics/Metallurgy

Aubrey E. Carter, Technical Operations Center, Delta Air Lines, Inc.

Ulf G. Goranson, Boeing Commercial Airplane Group, The Boeing Company

Amos W. Hoggard, Jr., Douglas Products Division, The Boeing Company

Paul C. Hoffman, NAWCAD, Patuxent River

Feldon D. Bartlett, Jr., Vehicle Structures Directorate, Army Research Laborat

ory

Sonya Herrin, Conference Administrative Manager, Science and Technology Corpor

ation

Sponsoring Organizations:

National Aeronautics and Space Administration, Langley Research Center

Federal Aviation Administration, William J. Hughes Technical Center

United States Air Force, Air Materiel Command

United States Naval Air Warfare Center, Aircraft Division

Unites States Army Research Laboratory

ui
- TABLE OF CONTENTS -

PARTI

Approaches to Fleet Management

Coast Guard Efforts to Deal with Aging Aircraft 1

Doug C. Connor, K. W. Devoe, J. E. Mihelic, M. E. Butt, M. S. Carmel, J. T. Ba

ker, and

P. J. Dwyer, U.S. Coast Guard Aircraft Repair and Supply Center, Elizabetii Ci
ty, NC

Risk Management of a Helicopter Fleet Containing Flight Safety Parts of Unknow

n

Fatigue Strength 11

Robert W. Arden, Westar Corporation, St. Louis, MO

Tracking Aircraft Structural Repairs from a Fleet Risk Management and

Economic Standpoint ,, ,^^^ 21

Robert D. Giese, Grant D. Herring, and James F. Bookman, Ogden Air Logistics C
enter,

Hill Air Force Base, UT

Influence of Undetected Hidden Corrosion on Structural Airworthiness of

Aging Jet Transports , . , 29

Aydin Akdeniz and Girindra K. Das, Boeing Commercial Airplane Group, Seattle,
WA

Achieving Total System Aging Aircraft Solutions 39

Steven M. Enloe, Boeing Information, Space and Defense Systems, Wichita, KS

Eurofighter 2000 Structural Health and Usage Monitoring: An Integrated Approac

h 46

Stephen R. Hunt and Iain G. Hebden, British Aerospace Military Aircraft and

Aerostructures, Preston, Lancashire, United Kingdom

FSIP: The C/KC-135 Functional Systems Integrity Program 56

James Pappas, Jr., OC-ALC/LCRA, Tinker AFB, OK; Ralph R. Ward, Jr., Boeing Inf
ormation
Space and Defense Systems, Oklahoma City, OK

An Application of Fracture Mechanics Principles in Determining a Service Life

Enhancement Interval for The US Navy's C-2 Outer Wing 63

Alex R. Hocson and Tommy N. White, Naval Aviation Depot North Island, San Dieg
o, CA

Determining and Attaining Realistic Inspection Thresholds to Meet Durability a

nd

Damage Tolerance Requirements 70

Len Reid, Jude Restis, and Tom Swift, Fatigue Technology, Inc., Seattle, WA

Support of Composite Structures on Naval Aircraft 79

Paul Mehrkam, Naval Air Systems Command, Patuxent River, MD

Aging of Aircraft Transparencies 91

Michael P. Bouchard, Daniel R. Bowman, and Thomas J. Whitney, University of Da

yton

Research Institute, Dayton, OH

Effects of Corrosion Inhibiting Lubricants on Avionics Reliability 101

William H. Abbott, Battelle Columbus, Columbus, OH

Effective Method of Working Out an Optimum Inspection Schedule 116

Veniamin L. Raikher, Central Aerohydrodynamics Institute, Zhukovsky,

Moscow region, Russia

An Engineering Approach for the Assessment of Widespread Fatigue Damage in

Aircraft Structures 1 24

Marc Balzano, Jean-Yves Beaufils, and Alain Santgerma, Aerospatiale Aeronautiq

ue,

Toulouse, France

Transport Risk Assessment Containing Widespread Fatigue Damage: TRACWFD

Analyses of Longitudinal and Circumferential Splice Joints to Determine the On

set of

Widespread Fatigue Damage and Its Probability of Occurrence 132

Robert E. Kurth, Battelle Memorial Institute, Columbus, OH; Catherine A. Bigel
ow,

FAA William J. Hughes Technical Center, Atlantic City International Airport, N

J

Operation and Maintenance of the Space Shuttle Orbiter 145

Frank V. Daniels, Boeing North American Reusable Space Systems, Downey, CA

Composite Repair of Aging Metallic Structure P- Version 3D Finite Element Appr

oach 1 53

Arnold Nathan, Israel Aircraft Industries, Ben Gurion International Airport, I

srael

Ensuring Damage Tolerance of Aging Aircraft Structures 163

Grigory I. Nesterenko, Central Aerohydrodynamics Institute, Zhukovsky,

Moscow region, Russia

Technologies for Inspection, Maintenance, and Repair

Repair Development for Fatigue Cracks in the F-5E Vertical Stabilizer 1 73

Jennifer S. Elmore and Edwin L. Rosenzweig, Naval Air Warfare Center, Patuxent
River, MD;

Penelope Ulander and Douglas Perl, Naval Aviation Depot, North Island, San Die
go, CA

Air Force Cost of Corrosion Maintenance Study 1 83

Richard Kinzie, AFRL/MLS-OL, Robins AFB, GA; Garth Cooke, NCI Information Syst
ems,

Inc., Fairborn, OH

Development of Novel Inspection Systems — Anticipating Operator Requirements 1

93

Christopher D. Smith, FAA William J. Hughes Technical Center, Atlantic City In

ternational

Airport, NJ

Expansion of the WR-ALC Fatigue-Arrest Composite Repair Capability 201

Steven F. Adams, WR-ALC/TIEDD, Robins AFB, GA

VI
Laser-Based Ultrasonics for Crack Detection 224

Pavel Fomitchov, Alexei Kromine, Sridhar Krishnaswamy, and Jan D. Achenbach,

Northwestern University, Evanston, IL

Reliability Study of Magneto-Optic Imaging (MOI) Inspection of C-5 Aircraft Fu

selage 230

Jay L. Fisher, Gary L. Burkhardt, Jeffrey S. Stolte, Janet P. Buckingham,

Peter C. Mckeighan, and Jack Fitzgerald, Southwest Research Institute, San Ant
onio, TX;

George Burkhardt, SA-ALC/TIESM, Kelly Air Force Base, TX

Quantitative Investigation of Surface and Subsurface Cracks Near Rivets in Riv

eted

Joints Using Acoustic, Electron and Optical Microscopy 240

Zayna M. Connor, M. E. Fine, and J. D. Achenback, Northwestern University, Eva

nston, IL

Non-Contact Ultrasonic NDE Systems for Aging Aircraft 244

Robert E. Green, Jr. and B. Boto Djordjevic, Center for Nondestructive Evaluat
ion,

The Johns Hopkins University, Baltimore, MD

Evaluation of the Self-Nulling Rotating Eddy Current Probe System 252

Donald Hagemaier and Kent Rengel, Boeing, Long Beach, CA; Buzz Wincheski and

Min Namkung, NASA Langley Research Center, Hampton, VA

Thermal Wave NDI of Disbonds and Corrosion in Aircraft 265

Xiaoyan Han, L. D. Favro, and R. L. Thomas, Wayne State University, Detroit, M

I

Aging of Airframe Materials: Probability of Occurrence Versus

Probability of Detection 275

D. Gary Harlow and Robert P. Wei, Lehigh University, Bethlehem, PA

Crack Detection and Monitoring of Aging Airframes 284

Neal Phelps, U.S. Air Force, Ogden Air Logistics Center, Hill Air Force Base,
UT;

Scott May, U.S. Air Force; Eric Haugse, Tamara Leeks and Pat Johnson,

Boeing Phantom Works;Steve Ziola and John Dorighi, Digital Wave Corporation
Multi-Element Ultrasonic Linear Arrays for Rapid Lap-Joint Inspection 294

Robert A. Smith and Stephen J. Willsher, Defence Evaluation and Research Agenc
y,

Farnborough, United Kingdom

Use of Acoustic Emission Monitoring to Detect, Locate and Measure

Multiple Site Damage (MSD) Fatigue Crack Growth Underneath Rivet Heads 303

Stuart L. McBride, AEMS Acoustic Emission Monitoring Service, Inc., Kingston,

Ontario, Canada; Jason P. Scott, Carleton University, Ottawa, Ontario, Canada;

Graeme F. Eastaugh, National Research Council Canada, Ottawa, Ontario, Canada

Bonded Repair Techniques Using Sol-Gel Surface Preparations 313

Kay Y. Blohowiak, Kenneth A. Krienke, and Joseph H. Osborne, Boeing Phantom Wo

rks,

Seattle, WA; James J. Mazza, AFRL/MLSA, Wright-Patterson AFB, OH;

Georgette B. Gaskin and Jonahira R. Arnold, Naval Aviation Systems Team,

Patuxent River, MD; William S. DePiero and Joseph Brescia, US Army

TACOM-ARDEC, Picatinny Arsenal, NJ

vii
A New Non-Contacting NDT System for Detection of Disbonds in Composite and

Metal Structures ■ ■ " » ■ 321

John M. Webster and T. Thevar, Holographies, Inc., Long Island City, NY; J. Me
w,

University of Portsmouth, Milton Campus, United Kingdom

A Smart Patch Approach for Bonded Composite Repair/Reinforcement of Primary

Airframe Structures 328

Alan A. Baker, Stephen C. Galea, and Ian G. Powlesland, Defence Science and Te
chnology

Organisation DSTO - Aeronautical and Maritime Research Laboratory, Fishermens

Bend,

Victoria, Australia

Evaluation of Commercial Thermography Systems for Quantitative Composite

Inspection Applications -'39

Mike T. Valley, Dennis R. Roach, and Larry R. Dorrell, Sandia National Laborat
ories,
Albuquerque, NM; Dennis M. Ashbaugh, SAIC, Albuquerque, NM; Roy T. Mullis,

WR/ALC, Robins Air Force Base, GA

Hidden Corrosion Detection Technology Assessment 349

Wally C. Hoppe, University of Dayton Research Institute, Dayton, OH

Pre-Corroded Fastener Hole Multiple Site Damage Testing 359

Joe Luzar, Boeing Information, Space & Missile Systems, Wichita, KS; Patrick
S. Johnson,

Boeing Phantom Works, Seattle, WA

Advanced Corrosion Resistant Coatings for Outer Mold Line Applications 369

Joseph H. Osborne and Kay Y. Blohowiak, Boeing Phantom Works, Seattle, WA;

S. Ray Taylor and Chad Hunter, University of Virginia, Charlottesville, VA;

Gordon Bierwagon and Brendon Carlson, North Dakota State University, Fargo, N
D;

Joshua Du and Matthew Damron, Chemat Technology, Inc., Northridge, CA;

Michael S. Donley, Air Force Research Laboratory, Wright-Patterson AFB, OH

Effect of Aircraft Washing on the Life of Corrosion Prevention Compounds 378

Krishnakumar Shankar, Australian Defence Force Academy, Canberra, Australia;

Natasha Tindall, Royal Australian Navy, Naval Air Station, Nowra, Australia; B
ruce Hinton

and Maria Salagaras, Defence Science and Technology Organisation, Aeronautical

and

Maritime Research Laboratory, Melbourne, Australia

PART 2

Structural Analysis Methods

On the Assessment of the Criticality of Crack Scenarios with Respect to Widesp

read

387

Fatigue Damage

Peter Horst, Technical University of Braunschweig, Braunschweig, Germany

vui
The Growth of Multi-Site Fatigue Damage in Fuselage Lap Joints 397

Robert S. Piascik, NASA Langley Research Center, Hampton, VA; Scott A. Willar
d,

Lockheed Engineering and Sciences Company, Hampton, VA

Residual Strength Pressure Tests and Nonlinear Analyses of Stringer- and Frame
-

Stiffened Aluminum Fuselage Panels with Longitudinal Cracks 408

Richard D. Young, Marshall Rouse, Damodar R. Ambur, and James H. Starnes, Jr.,

NASA Langley Research Center, Hampton, VA

Residual Strength Analysis of Skin Splices with Multiple Site Damage 427

J. E. Ingram, Y. S. Kwon, K. J. Duffie, and W. D. Irby, Lockheed Martin Aerona

utical

Systems Company, Marietta, GA

Fatigue Crack Growth Predictions in Riveted Joints 437

Scott A. Fawaz, Air Force Research Laboratory, Wright-Patterson AFB, OH;

J. Schijve, Delft University of Technology, Delft, The Netherlands

Nonplanar Fatigue Crack Growth in 7075-T73 Aluminum 452

Scott C. Forth and Leroy H. Favrow, United Technologies Research Center,

East Hartford, CT; William D. Keat, Union College, Schenectady, NY

Quantifying Spectrum Loading Effects on Fatigue Crack Growth 462

H. Lewis Zion, Georgia Tech Research Institute, Smyrna, GA; W. Steven Johnson,

Georgia Institute of Technology, Atlanta, GA; Dale L. Ball, Lockheed Martin Ta

ctical

Aircraft Systems, Fort Worth, TX; Richard A. Everett, Jr., U.S. Army Vehicle

Structures Directorate, Hampton, VA

Analytical Framework for Assessment of Corrosion and Fatigue in Fuselage Lap J

oint 472

Dale Cope, Patrick Johnson, Angela Trego, and J. Doug West, Boeing Informatio
n, Space,

and Defense Systems, Wichita, KS

Mathematical Model to Predict Fatigue Crack Initiation in Corroded Lap Joints

482

Gerhardus H. Koch, CC Technologies Laboratories, Inc., Dublin, OH; Le Yu and

Noriko Katsube, The Ohio State University, Columbus, OH; Clare A. Paul,

AFRL/VASE, Wright Patterson AFB, OH

Analytical and Test Evaluations on the Linkup of Multiple Cracking in

Stiffened Fuselage Panels 493

David Y. Jeong, U.S. Department of Transportation, Cambridge, MA; John G. Baku

ckas, Jr.,

Federal Aviation Administration, William J. Hughes Technical Center, Atlantic

City

International Airport, NJ; Gopal Samavedam, Foster-Miller, Inc., Waltham, MA

Benefits of Improved Fuselage Skin Sheet Alloy 2524-T3 in

Multi-Site Damage Scenarios 503

Gary H. Bray, Robert J. Bucci, Michael Kulak, and Charles J. Warren, Aluminum

Company of American, Alcoa Center, PA; Alten F. Grandt, Jr., Patrick J. Golde
n,

and Darren G. Sexton, Purdue University, W. Lafayette, IN

IX

Fracture Analysis of the FAA/NASA Wide Stiffened Panels 513

B. R. Seshadri, J. C. Newman, Jr., D. S. Dawicke, and R. D. Young, NASA Langle
y

Research Center, Hampton, VA

Improved Engineering Methods for Determining The Critical Strengths of

Aluminum Panels with Multiple Site Damage in Aging Aircraft 525

Bert Smith, Adil Mouak, Perry Saville, Roy Myose, and Walter Horn, Wichita

State University, Wichita, KS

Corrosion Pillowing Cracks in Fuselage Joints 535

Nicholas C. Bellinger, Jerzy P. Komorowski, and Ron W. Gould, Institute for

Aerospace Research, Ottawa, Ontario, Canada

Towards a Predictive Design Methodology for Composite Laminate Patches Based

on Physical Modeling of Failure Processes 545

Peter W. R. Beaumont, Cambridge University Engineering Department, Cambridge,

United Kingdom; James M. Greer, Jr., United States Air Force Academy, USAF Aca
demy, CO

A CTOD Approach to Assess Stable Tearing Under Complex Loading Conditions 555
Claudio Dalle Donne, German Aerospace Center DLR, Cologne, Germany

Residual Strength Predictions with Crack Bulging 565

David S. Dawicke, NASA Langley Research Center, Hampton, VA; A. S. Gullerud

and R. H. Dodds, Jr., University of Illinois, Urbana, IL; R. W. Hampton,

NASA Ames Research Center, Moffett Field, CA

A Mixed-Mode I/II Fracture Criterion and Its Application in

Crack Growth Predictions 575

Michael A. Sutton, Xiaomin Deng, and Fashang Ma, University of South Carolina,

Columbia, SC; James C. Newman, Jr., NASA Langley Research Center, Hampton, VA

Yield-Strip Models for Residual Strength of MSD Damaged Curved and Flat Panels
584

Karl-Fredrik Nilsson, Aeronautical Resarch Institute of Sweden, Bromma, Sweden

Boundary Correction Factors for Elliptical Surface Cracks Emanating From

Countersunk Rivet Holes 598

Anisur Rahman, Drexel University, Philadelphia, PA; John G. Bakuckas, Jr.,

Catherine A. Bigelow, and Paul W. Tan, FAA William J. Hughes Technical Center,

Atlantic City International Airport, NJ

Stable Tearing and Buckling Responses of Unstiffened Aluminum Shells with

Long Cracks 610

James H. Starnes, Jr. and Cheryl A. Rose, NASA Langley Research Center, Hampto
n, VA

Fracture Mechanics of Thin, Cracked Plates Under Tension, Bending and

Out-Of-Plane Shear Loading 627

Alan T. Zehnder, C.-Y. Hui, Yogesh Potdar, Cornell University, Ithaca, NY;

Alberto Zucchini, ENEA, Bologna, Italy

Residual Strength Prediction of Fuselage Structures with Multiple Site Damage

635

Chuin-Shan Chen, Paul A. Wawrzynek, and Anthony R. Ingraffea, The Cornell

University Fracture Group, Ithaca, NY