THE

ROLE

OF IN

FRETTING AIRCRAFT REPORT

CORROSION RIVET ON TWO HOLE FAA

AND

FRETTING -

FATIGUE

CRACKING GRANT

A STATUS

PROGRAMS*

/ ..... _ _
Charles Mark David Quality and Integrity B. Elliott Moesser HI

W. Hoeppner Design Engineering Center

University Salt Lake

of Utah City, Utah

SUMMARY

Personnel Utah are working fatigue

in the Quality under

and Integrity _om

Design

Engineering to better

Center understand

(QIDEC) the role

at the University of fretting grant grant

of

a two year grant rivet

the FAA

corrosion program programs.

and fretting which was

in aircraft in 1993.

hole cracking. provides

The current a status

program report

follows

a one year of these

completed

This paper

on the results

Recent variation important fretting contacting

effort

has been

focused

on developing with

basic

fretting within

fatigue

models

which

consider This is a very during by the

in the coefficient characteristic fatigue process.

of friction of the QIDEC Copies

time and location because documents

the fretting of friction

interface.

model

coefficient discussed

varies

significantly

of QIDEC

in this paper

can be obtained

the authors.

INTRODUCTION

Fretting small faying enough surfaces

is a process to allow and

in which debris

two bodies

in contact between

are subjected the contacting

to relative (faying)

motion surfaces.

of an amplitude Because called the

resulting

to be trapped to corrosion

debris

are subject

as well as wear,

the process

is sometimes

fretting

The FAA has supported this work through Grants No. 92-G-004 and No. 93-G-068. QIDEC grateful for this support and the efforts of the FAA Grant Monitor, Dr. Thomas Flournoy.

is

241

_ -:_i

-_:i

:i _

corrosion. called

When

one or both The

of the bodies

also undergo action with of wear,

cyclic

tensile and

(fatigue) fatigue

loading, mechanisms

the process often

is in

fretting

fatigue. degradation

simultaneous

corrosion

results

a synergistic more than

of the components based upon

a reduction

in life which

can be an order mechanisms.

of magnitude

would

be expected

the operation

of only

one of the three

Fretting It is a failure potentially safety focused important aircraft

fatigue

is increasingly which

being

recognized leads to high

in the aircraft maintenance Thus,

industry

as a major costs both Aloha could structure small fastened

cause

of failure.

mechanism lead

frequently failure

and inspection it represents The 1988 fretting

and could and a disaster played engines, cyclic in general can link up in of fretting an

to catastrophic Costs associated on fretting

of aircraft

components. fatigue industry

a durability Airlines have (e.g. amplitude joints

problem. new role primary

with fretting in the aircraft

are significant. as it was in any area gear

attention

thought

in that failure. and secondary

1 Fretting structure, materials

can be present and landing

of an aircraft in which

components)

slip between are particularly aircraft

adjacent

contacting

is possible. fatigue Thus,

Rivets

and mechanically damage.

susceptible and create

to fretting catastrophic

and fretting results.

multiple-site it is imperative

This damage the role

structures fatigue

to understand joints.

and fretting

in producing

multiple-site

damage

in riveted

aircraft

RESULTS

FROM

THE

PREVIOUS

GRANT

PROGRAM

Based This report, Applications an National

on a search "Literature to Aircraft Technical

of government

and private

literature

from

1960

to 1992

a report

was prepared. Including Special as

Review Joints" Information

and Preliminary has been Service

Studies

of Fretting

and Fretting

Fatigue

submitted document.

to the FAA

and is being

considered

for publication

The of riveted continuing joints. Due

aircraft

industry For

needs

the ability an extensive

to predict effort

the role was started

and influence during

of fretting

on the fatigue grant program in aircraft best be

life and is

joints. during

this reason,

the previous of fretting analysis

the current

program geometry

to improve of such joints, methods.

quantitative an accurate

prediction quantitative

fatigue could

to the complex

performed

with the use of finite

element

QIDEC Sheffield, Integrity

personnel in April

presented 1993.

four papers These papers

at the International which

Conference

on Fretting

Fatigue Structural

held in

England Society

will be published

by the European

are as follows:

242

Mechanisms The Finite by Mr. Role

of Fretting of Normal Model

Fatigue

(invited

keynote Fretting With

paper)

by Dr. Hoeppner. by Dr. Adibnazari of Friction and Dr. Hoeppner. Over Time and Space

Pressure

in Modeling Fatigue and

Fatigue

Element Moesser,

of Fretting

Variable

Coefficient

Dr. Adibnazari System Useable

Dr. Hoeppner. Electron Microscope by Dr. Elliott and Dr.

A Fretting Hoeppner.

Fatigue

in a Scanning

Additionally, Aircraft Fatigue Joints" which

Dr. Hoeppner Dr. Hoeppner

and Dr. Adibnazari presented

co-authored 1993

a paper

titled

"Fretting

Fatigue

in

to the June

International

Committee

of Aeronautical

in Sweden.

OVERVIEW

OF THE

CURRENT

GRANT

PROGRAM

QIDEC 1993

is currently

working The

under objectives

FAA

Grant

93-G-068

which

was

received

in late

September

and will last two years.

of the program

are as follows:

Construct, Perform joints.

calibrate a sensitivity

and verify study

a computer

simulation which

model could

of a riveted influence

joint. fretting fatigue in riveted aircraft

on some

parameters

Model Establish damage

the nucleation a design threshold

of fretting method

damage

at riveted

aircraft

joints. of the likelihood that the fretting fatigue

that will allow

an assessment

will be exceeded. of the design approaches used by industry to alleviate fretting corrosion and

Conduct fretting

an assessment fatigue. experimental all methods liaison activities

Develop Make

techniques and fmdings

that allow applicable

assessment

of fretting aircraft FAA

fatigue

in riveted

joints.

to a global other

reliability programs,

model. aircraft industry activities and

Maintain ASTM

with FAA with respect

technical

personnel,

to fretting.

To accomplish

these

objectives,

the program

has been

organized

into the following

major

tasks:

Develop with time

and verify

basic

fretting

fatigue

models interface.

which

consider

variation important

in the coefficient (and varies

of friction a the

and location

within

the fretting model

This is a very coefficient

to our knowledge significantly during

unique) fretting

characteristic fatigue process.

of the QIDEC

because

of friction

243

Determinethe coefficient of friction and faying

models. Plan aircraft and conduct joints. an examination gained joint. to develop fretting from of riveted the basic a sensitivity study on some

surface

sealant

materials

data

necessary

as input

to the

of the parameters

which

affect

fretting

fatigue

in riveted

Plan With model

and conduct knowledge of a riveted

joints

used

in service. models, develop and verify a fretting fatigue

fretting

fatigue

Use the results community.

of this program

fatigue

design

methods

useful

to the aviation

Report

results

of this program

to the aviation

community

through

the FAA

and the open

literature.

This understanding fatigue

is one

of several

research

programs community integrity.

being

conducted

by QIDEC synergistic is being Group within

that are leading effects conducted in coordination QIDEC, which of wear,

to improved corrosion and

throughout

the aviation structural

of the adverse Related Defense research

mechanisms Airplane

on aircraft Company

for the Boeing with the U. S.

Commercial Air Force. benefit hubs.

and the Boeing funding

and Space research designer

Non-aviation

programs include

fretting-related implant

will indirectly

the aviation

industry,

an orthopedic

and a manufacturer

of truck and trailer

STATUS

OF THE

PROGRAM

Major included Grant No.

advances

are being from

made

in development finite element This

of the basic program, switch was

fretting

fatigue

model. work advantage and three

Recent under

activity FAA

the transition 92-G-004, capability were

the ANSYS

used

in preliminary to take Two

to the ADINA of the ADINA using

program. code available

necessary of Utah. were used

of the dimensional

increased models available work, methods fretted

at the University These models being proved

constructed program

the ADINA

code.

to verify by QIDEC.

that the commercially As part of this

ADINA

can be used codes were

with the methods developed which of friction development

developed

Fortran

and C-shell

the applicability

of planned

analytical between the on

for predicting surfaces. Basic of materials

changes fretting data

in coefficient fatigue when model

as a function activities

of time and location will continue with

emphasis

incorporation

it is determined.

Development faying surface sealant

of the experimental materials data

methods

and hardware

to determine

the coefficient

of friction

and

necessary

as input

to the models

is progressing

on schedule.

A rough

244

analysisof a rivetedjoint was conductedto determinethe expected variability

and relative friction Collecting was data displacements are desirable such data within a riveted joint. From this analysis for relative slip an order of magnitude less than

of normal

surface that

tractions of

it was determined that reported to meet. coefficient design tests was

coefficient

in the literature. Significant of friction developed effort data at

will present

a challenge,

but one which methods A preliminary faying

we are working for determining test apparatus surface sealant

expended

developing

and analyzing as low

possible

relative being

displacements refined. Methods

as two microns.

and is

and equipment

for conducting

also will be developed.

QIDEC planning

is in the process study joints

of developing on parameters used in service"

a partnership important portions

with an industrial fatigue

representative aircraft

to help joints", that such

with and the a

the "sensitivity of riveted

to fretting

in riveted

"examination partnership

of the program.

We are optimistic

will be beneficial

to both parties.

As part QIDEC Lehigh personnel University

of the requirement attended and attended made

to maintain

liaison

with the FAA at the FAA/NASA

and other

aircraft

industry in November

activities, 1993 at

and made 1994,

presentations when QIDEC USAF

conferences

March

was the host organization. Structural Integrity Program

Additionally, Conference,

QIDEC where the

representatives Director

the December a presentation.

1993

of QIDEC

CONCLUDING

REMARKS

The this important disseminate

Quality research

and Integrity

Design

Engineering

Center community

is pleased

to have

the opportunity every

to conduct effort to

for the FAA as they

and the aviation

in general.

We will make

our findings

are developed.

REFERENCE

1. Brewer,

John

C.:

Fretting

Issues

for the Aging

Aircraft

Program,

U.S.

DOT/FAATC,

Oct.

1991.

245

BIBLIOGRAPHY

OF QIDEC

REPORTS

AND

PAPERS

Copies Dr. Charles Engineering FAX: (801)

of the following

reports

and papers of Utah,

can be obtained

by providing

your

name

and address

to

B. Elliott, Building 581-8692;

III, University Room email: 3209,

Department City, Utah

of Mechanical 84112; phone:

Engineering, (801) 585-6429;

Merrill

Salt Lake

elliott@me.mech.utah.edu.

Hoeppner, Fretting

D. W., and Fretting 1993. D. W.:

Adibnazari, Fatigue

S. and Moesser, Including Special

M. W.: Applications

Literature

Review

and

Preliminary Submitted

Studies to the FAA

of

to Aircraft

Joints.

in November Hoeppner, International Adibnazari, Presented Moesser, With

Mechanisms

of Fretting Fatigue, The

Fatigue.

Invited

keynote

paper

presented

at the

Conference S. and

on Fretting D. W.:

Sheffield,

England, Pressure

April

1993. Fretting April Fatigue. 1993. Fatigue Conference

Hoeppner,

Role

of Normal Fatigue,

in Modeling England, Model

at the International M. W., Adibnazari,

Conference

on Fretting

Sheffield, Element Presented

S. and Hoeppner, of Friction Over Time

D. W.:

Finite

of Fretting

Variable

Coefficient Fatigue,

and Space. 1993. Fatigue

at the International

on Fretting Elliott,

Sheffield,

England, D. W.:

April

C. B. III and Hoeppner, Presented

A Fretting

System

Useable Fatigue,

in a Scanning Sheffield,

Electron April

Microscope. 1993. Hoeppner, International

at the International

Conference

on Fretting

England,

D. W.

and Adibnazari,

S.:

Fretting Fatigue

Fatigue

in Aircraft

Joints. Sweden,

Presented June 1993.

to the

Committee

of Aeronautical

in Stockholm,

iii

246

iii: