Can pitting corrosion change the location of fatigue failures in aircraft?
Source abstract
Abstract
Abstract In this paper we hypothesize that pitting corrosion can alter the location of fatigue failures in aircraft. This is in addition to the reductions in fatigue life it causes. The investigation began by developing a predictive Monte Carlo model of the fatigue behavior of low-kt specimens of the aluminum alloy 7010-T7651. The model’s fatigue life predictions were an excellent match to experimental fatigue life data from previous DSTO research for the same specimen geometry and material. The model was then used to predict the proportion of failures due to pitting corrosion as a function of the location of the corrosion strike. These predictions were compared to the results of an experimental trial of specimens which had been corroded at the same offset locations. The predicted and experimental proportions of failures were in close agreement. The paper concludes with a discussion of an integrated model of corrosion pit nucleation and growth followed by fatigue crack growth to failure. The purpose of this integrated model is to give the Royal Australian Air Force an end-to-end model to predict the damaging effects of pitting corrosion on aircraft structural integrity.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Fatigue and fracture mechanics · Probabilistic and Robust Engineering Design · Mechanical Failure Analysis and Simulation
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (51)
Show source-provided references
1. Wikipedia. F-111 Aardvark Operators. ; 2012 [accessed 23.11.12].
2. Wikipedia. Boeing B-52 Stratofortress. ; 2012 [accessed 23.11.12].
3. Kinzie RC. USAF Cost of Corrosion Maintenance. In: Sixth Joint FAA/DoD/NASA Conference on Aging Aircraft, San Francisco CA, USA, FAA/DoD/NASA; 2002.
4. The failure of an F/A-18 trailing edge flap hinge10.1016/1350-6307(94)90001-9 ↗
5. Bray GH, Bucci RJ, Golden PJ, Grandt Jr. AF. Effect of Prior Corrosion on Fatigue Performance of Toughness Improved Fuselage Skin Sheet Alloy 2524-T3. In: Fatigue in the Presence of Corrosion, Corfu, Greece, RTO; 1998.
6. Effect of corrosion severity on fatigue evolution in Al–Zn–Mg–Cu10.1016/j.corsci.2009.10.006 ↗
7. Driving forces for localized corrosion-to-fatigue crack transition in Al–Zn–Mg–Cu10.1111/j.1460-2695.2011.01568.x ↗
8. Cole GK, Clark G, Sharp PK. The implications of corrosion with respect to aircraft structural integrity. DSTO-RR-0102, [Research Report] Melbourne, DSTO; 1997.
9. Crawford BR, Loader C, Sharp PK, Clark G, Urbani C, Hay D, et al. Structural Integrity Assessment of Corrosion in Aircraft Structures. DSTO-RR-0294, Melbourne, DSTO; 2005.
10. The EIFS distribution for anodised and pre-corroded 7010-T7651 under constant amplitude loading10.1111/j.1460-2695.2005.00912.x ↗
11. Predicting fatigue life of pre-corroded 2024-T3 aluminum10.1016/j.ijfatigue.2003.10.011 ↗
12. Prior corrosion and fatigue of 2024-T3 aluminum alloy10.1016/j.corsci.2005.11.008 ↗
13. Modeling the effects of prior exfoliation corrosion on fatigue life of aircraft wing skins10.1016/j.ijfatigue.2003.08.005 ↗
14. Mills T, Sharp PK, Loader C. The Incorporation of Pitting Corrosion Damage into F-111 Fatigue Life Modelling. DSTO-RR-0237, [Research Report] Melbourne, DSTO; 2002.
15. Pao PS, Feng JCR, Gill SJ. Fatigue Crack Initiation from Corrosion Pits in Aluminium Alloys. In: 3rd Joint FAA/DoD/NASA Conference on Aging Aircraft, Albuquerque, NM USA, FAA/DoD/NASA; 1999.
16. Paul CA. Modeling the effect of prior corrosion on fatigue life using the concept of equivalent stress concentration. [Masters] Dayton, OH, University of Dayton; 2001.
17. Effect of pitting corrosion on fatigue crack initiation and fatigue life10.1016/S0013-7944(98)00101-5 ↗
18. Effects of pitting corrosion on the fatigue behaviour of aluminium alloy 7075-T6: modelling and experimental studies10.1016/S0921-5093(00)01216-8 ↗
19. Multiple fatigue crack growth in pre-corroded 2024-T3 aluminum10.1016/j.ijfatigue.2005.06.026 ↗
20. Initiation and shape development of corrosion-nucleated fatigue cracking10.1016/j.ijfatigue.2006.10.010 ↗
21. Mills T, Honeycutt KT. Holistic Structural Integrity Analysis for Corrosion in a Hub on a Transport Aircraft Frame. In: Corrosion Fatigue and Environmentally Assisted Cracking in Aging Military Vehicles. Neuilly-Sur-Seine Cedex, France, NATO-RTO; 2011.
22. Simulation of fatigue crack growth in components with random defects10.1016/j.engfracmech.2007.04.006 ↗
23. A post-processor for fatigue crack growth analysis based on a finite element stress field10.1016/j.cma.2007.09.012 ↗
24. LINKftr. About LINKpfat. ; 2013 [accessed 10.1.13].
25. The fatigue limit: an analytical solution to a Monte Carlo problem10.1016/j.ijfatigue.2013.06.015 ↗
26. A numerical investigation of the interaction and coalescence of twin coplanar semi-elliptical fatigue cracks10.1016/0142-1123(89)90003-0 ↗
27. Variation of the stress intensity factor along the crack front of interacting semi-elliptical surface cracks10.1007/s004190000113 ↗
28. Elastic–plastic analysis of small defects-voids and inclusions10.1016/0013-7944(84)90110-3 ↗
29. van der Walde · 2005
30. Effect of proximity and dimensions of two artificial pitting holes on the fatigue endurance of aluminum alloy AISI 6061-T6 under rotating bending fatigue tests
31. Wavemetrics – scientific graphing, data analysis, curve fitting & image processing software. ; 2013 [accessed 13.9.13].
32. ASTM. E466-96(2002)e1 Standard Practice for Conducting Force Controlled Constant Amplitude Axial Fatigue Tests of Metallic Materials. In: ASTM Annual Book of Standards. ASTM; 2002.
33. Urbani C. Analysis by FEM of fatigue test coupon (a work in progress). Melbourne, AU. CSIRO; 2002.
34. Harter J. AFGROW Program. ; 2003 [accessed 07.01.08].
35. Newman · 1986
36. Crawford BR, Loader C, Hay D, Urbani C, Spence S. Initiation and Growth of Fatigue Cracks from Pits in Pre-Corroded 7010-T7651. In: Structural Integrity Forum; 2006.
37. Suresh S. Fatigue of Materials. 1st ed. Cambridge Solid State Science Series. In: Davis EA, Ward IM, editors. Cambridge UK, Cambridge University Press; 1991.
38. DeBartolo EA. A Material-Based Model of Initial Damage States for Predicting Fatigue Life. [PhD Thesis], Purdue University; 2000.
39. Castillo E. Extreme Value Theory in Engineering. Statistical Modeling and Decision Science, vol. 1. In: Lieberman G, Olkin I, editors. San Diego, Academic Press; 1988.
40. E112-10 Standard Test Methods for Determining Average Grain Size. In: ASTM Annual Book of Standards. Vol. 03.01. Philadelphia, PA, American Society of Testing and Materials; 2010.
41. A geometric approach to modeling microstructurally small fatigue crack formation: I. Probabilistic simulation of constituent particle cracking in AA 7075-T65110.1088/0965-0393/16/6/065007 ↗
42. A geometric approach to modeling microstructurally small fatigue crack formation: II. Physically based modeling of microstructure-dependent slip localization and actuation of the crack nucleation mechanism in AA 7075-T65110.1088/0965-0393/18/4/045004 ↗
43. A geometric approach to modeling microstructurally small fatigue crack formation: III. Development of a semi-empirical model for nucleation10.1088/0965-0393/19/3/035008 ↗
44. Approximate is better than “Exact” for interval estimation of binomial proportions
45. Analysis and prediction of microstructural effects on long-term fatigue performance of an aluminum aerospace alloy10.1016/S0142-1123(97)00044-3 ↗
46. Magnusen PE, Bucci RJ, Hinkle AJ, Brockenbrough JR, Konish HJ, Miyasato SM. Final Report: The Role of Microstructure on the Fatigue Durability of Aluminum Aircraft Alloys. [Final Report] Arlington, VA, Alcoa Technical Center; 1996.
47. Multiple fatigue crack growth in pre-corroded 2024-T3 aluminum10.1016/j.ijfatigue.2005.06.026 ↗
48. Characterization of pitting damage and prediction of remaining fatigue life10.1016/j.ijfatigue.2007.02.020 ↗
49. On the effect of random defects on the fatigue notch factor at different stress ratios10.1016/j.ijfatigue.2011.07.011 ↗
50. Colwell JM, Khan JH, Will G, Fairfull-Smith KE, Bottle SE, George GA, et al. Prognostic tools for lifetime prediction of aircraft coatings: paint degradation; Advanced Materials Research, 138, 2010. p. 137–49.10.4028/www.scientific.net/AMR.138.137 ↗
51. Trueman, Trathen P., Begbie K., Davidson L., Hinton B. The development of a corrosion prognostic health management system for Australian Defence Force aircraft; Advanced Materials Research, 38, 2008. p. 182–200.10.4028/www.scientific.net/AMR.38.182 ↗