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DTA Guidelines For Antenna Installations
DTA Guidelines For Antenna Installations
DTA Guidelines For Antenna Installations
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
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
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
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
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
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
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
TYPICAL EQUIVALENT
CYCLE
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
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
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
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
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
0.063 bending
24,712 24,328 23,719 22,999 23,509
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
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
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
42
Residual Strength Loading
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
47
Walker Equation
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
7050-T7651 & T7451 Plate L-T & T-L 1.32927 x 10-9 0.57452 3.55242
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)
Ultrasound (UT)
53
Detectable Crack Sizes (cont’d)
TABLE 2. Detectable Crack Sizes Associated with Inspection Techniques (Reference [4])
Reference: SACO
3 to 5x Magnification
Painted Surface None
Guidelines, Table 1
3 to 5x Magnification 0.125
Without Magnification 0.250
Painted Surface None
54
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