A Review of Damage Tolerant Design, Certification and Repair in Metals Compared to Composite Materials

Abstract:

A review of some of the various fatigue models introduced over the years for both metallic materials, in particular aluminium alloys followed by fatigue and durability concerns associated with composite materials. The move towards light weight and high stiffness structures that have good fatigue durability and corrosion resistance has led to the rapid move from metal structures to composite structures. With this brings the added concern of certifying new components as the damage mechanisms and failure modes in metals differ significantly than composite materials such as carbon fiber reinforced polymers (CFRP). The certification philosophy for composites must meet the same structural integrity, safety and durability requirements as that of metals. Hence this is where the challenge now lies. Substantial work has been conducted in the reparability of composite structures through bonding using various adherend thicknesses and joint types and has been shown to have higher durability than mechanically fastened repairs for thin adherends however these are currently unacceptable repair methods as they cannot be certified. Repairs are designed on the basis that the repair efficiency can be predicted and should be designed conservatively with respect to the various failure modes and include the surrounding structure.

• Periodical: Advanced Materials Research (Volumes 891-892)
• Pages: 1597-1602
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.891-892.1597
• Online since: March 2014
• Authors: Nabil Chowdhury, Wing Kong Chiu, John Wang
• Keywords: Bolted Joint, Bonded Joints, Damage Tolerance, Fatigue, Hybrid Joints, Repair

References

[1] T. Zhao, J. Zhang and Y. Jiang, A Study of Fatigue Crack Growth of 7075-T651 Alluminium Alloy, vol. 30, International Journal of Fatigue, 2008, pp.1169-1180.

DOI: 10.1016/j.ijfatigue.2007.09.006

[2] R. Jones and S. Pitt, Damage Tolerance and Airworthiness, pp.104-111, (2012).

[3] F. Taheri, D. Trask and N. Pegg, Experimental and Analytical Investigation of Fatigue Characteristics of 350WT steel Under Constant and Variable Amplitude Loadings, J Marine Structures, pp.69-91, (2003).

DOI: 10.1016/s0951-8339(02)00004-7

[4] S. R. Johnston, G. P. Potirniche, S. R. Daniewicz and M. F. Horstemeyer, Three-dimensional Finite Element Simulations of Microstructurally Small Fatigue Crack Growth in 7075 Aluminium Alloy, Fatigue Fracture Engineering Material Structures, vol. 29, pp.597-605, (2006).

DOI: 10.1111/j.1460-2695.2006.01035.x

[5] M. Nakada, Y. Miyano and N. Sekine , Accelerated Testing for Long Term Durability of GFRP Laminates for Marine Use, Composites Part B Engineering, vol. 35, pp.497-502, (2004).

DOI: 10.1016/j.compositesb.2003.11.006

[6] J. Hart-Smith, Bolted and Bonded Joints, in ASM Handbook Volume 21, 1998, pp.167-176.

[7] M. Goland and E. Reissner, The Stresses in Cemented Joints, Journal of Applied Mechanics , vol. 11, pp. A17-A27, (1944).

DOI: 10.1115/1.4009336

[8] L. J. Hart-Smith, Analysis and Design of Advanced Composite Bonded Joints, NASA CR-2218, Douglas Aircraft Company, (1974).

[9] L. J. Hart-Smith, Design & Analysis of Adhesive-Bonded Joints, First Air Force Conference Fibrous Composites in Flight Vehicle Design, Air Force Flight Dynamics Laboratory, (1972).

[10] Goh, J.Y., Georgiadis, S., Orifici, A.C., and Wang, C.H., Effects of Bondline Flaws on the Damage Tolerance of Composite Scarf Joints,. Composites Part A: Applied Science and Manufacturing, vol. 55, pp.110-119, (2013).

DOI: 10.1016/j.compositesa.2013.07.017

[11] Wang, C.H. and Gunnion, A.J., On the Design Methodology of Scarf Repairs to Composite Laminates., Composites Science and Technology, vol. 68(1), pp.35-46, (2008).

DOI: 10.1016/j.compscitech.2007.05.045

[12] Wang, C.H. and Gunnion, A.J., Optimum shapes of scarf repairs., Composites Part A: Applied Science and Manufacturing, vol. 40(9), pp.1407-1418, (2009).

DOI: 10.1016/j.compositesa.2009.02.009

[13] J.H. Kweon, J.W. Jung, T.H. Kim, J.H. Choi and D.H. Kim, Failure of Carbon Composite-to-Aluminium Joints with Combined Mechanical Fastening and Adhesive Bonding, Composite Structures, vol. 75, pp.192-198, (2006).

DOI: 10.1016/j.compstruct.2006.04.013

[14] C. T. Sun, K. Bhawesh, P. Wang and R. Sterkenburg, Development of Improved Hybrid Joints for Composite Structures, Composite Structures, vol. 35, pp.1-20, (2005).