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Module 11A.2(a)
Airframe Structures -
General concepts
Level 2
12 - 08 - 2016 EASA Part 66
EASA P66 MOD 11A.2(a) L2 Training Manual
Aircraft Maintenance College 66
EASA Part 66
Training Manual
For Training Purposes Only
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info@amc66.com
This publication was created by Aircraft Maintenance College Aircraft Maintenance College 66
66, following ATA 104 specifications.
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TABLE OF CONTENTS
1. Airworthiness Requirements For Structural Strength.... 8
1.1 Structural Classification ................................................ 10
1.1.1 Primary Construction ............................................. 10
1.1.2 Secondary Construction ......................................... 12
1.1.3 Tertiary Structure .................................................. 14
1.2 Loads.......................................................................... 16
3. Damage Tolerance....................................................... 26
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LIST OF ILLUSTRATIONS
Access Panel Numbers........................................................33 Static Discharger Installation..............................................55
Aloha 737 Fatigue Failure...................................................25 Stations Diagram...............................................................36
Axis System......................................................................35 Stringer Arrangement Airbus...............................................39
Bending...........................................................................43 Stringer Arrangement Boeing..............................................39
Bending On An Aircraft.......................................................43 Structures Classification.....................................................11
Boeing 787 Stress Test.......................................................17 Tension............................................................................44
Bonding Of Access Panels...................................................58 Torsion.............................................................................41
Comet Crash.....................................................................22 Wheel Shield Boeing 737....................................................15
Comet Pressure Test..........................................................23 Wing Construction.............................................................13
Compression.....................................................................45 Wing Load Test..................................................................17
Corrosion Damage.............................................................19 Wing Stations...................................................................37
Cupal Washers..................................................................57 Zero Point Of Stations........................................................37
Damage Tolerance Graph....................................................27
Dehaviland Comet.............................................................23
Engine Stations.................................................................38
Fail Safe Design................................................................19
Fatigue Demonstration.......................................................24
Fuselage Zones.................................................................32
Lightning Strike On Carbon Fiber.........................................53
Lightning Strike On Fuselage...............................................53
Main Landing Gear.............................................................21
Major Subzones.................................................................31
Major Zones #1.................................................................29
Major Zones #2.................................................................30
Multiple Site Cracking........................................................26
Pressure Zone Drain Valves.................................................49
Primary Bonding................................................................59
Secondary Bonding............................................................60
Secondary Bonding Examples..............................................61
Shear..............................................................................47
Static Discharger...............................................................55
Static Discharger Damaged By Lightning..............................54
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Safety means more than only that the aircraft must Section Regulations
be capable to withstand the most severe loadings it
will encounter during its service life. It should not Section 1 Sub-part A - General
be difficult for the flight crew to control it under all Sub-part B - Flight
circumstances. This means the aircraft should also Sub-part BB - Flight - Emergency Power
show sufficient positive stability during all flight phases or Thrust
and attitudes through out the flight envelope. Sub-part C - Structure
Sub-part D - Design and Construction
EASA Certification Specification (CS) - 25 is based on Sub-part E - Power Plant
Part 25 of the Federal Aviation. Sub-part F - Equipment
Sub-part G - Operating Limitations and
These requirements are applicable for all large aircraft. Information
This means aircraft with a maximum mass not less Sub-part J - Gas Turbine Auxiliary Power
than 5700 kg. Excluded are, reciprocating-engine Unit installations
aircraft, seaplanes and ski planes. Appendices A-J.
EASA CS-25 consists of: Section 2 Acceptable means of compliance and
interpretations
Section 3 Reserved
Section 4 The basic code (part 25 of the federal
aviation regulations of the USA, up to and
including amendment N°53).
From the structural point of view sub-parts C and D
are the most important. They give the applied loads or
the procedures to obtain the applied loads. They also
give requirements for design other than loads.
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1.2 Loads
Normal load on the aircraft and every component
during horizontal cruise flight and maximum weight.
Limit Loads are the maximum loads expected in
service. FAR Part 25 (and most other regulations)
specifies that there be no permanent deformation of
the structure at limit load.
Ultimate loads are defined as the limit loads times a
safety factor. In Part 25 the safety factor is specified
as 1.5. The structure must be able to withstand the
ultimate load for at least 3 seconds without failure.
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2. FAIL-SAFE DESIGN
The fail-safe design principle uses multiple load paths Fail-safe design is a good philosophy, and worked well
to ensure structural integrity. lf one load path cracks for many decades. In fact, fail-safe design still provides
completely through, or sustains accidental damage, the basis for most new airplane designs.
the remaining load paths carry the additional load. This
type of design is common on modern jet airplanes. However, operational experience shows that some of
the assumptions of fail-safety do not hold true.
Examples include:
Cracks usually develop in several elements at the same
-- M ultiple stringers and ribs in wings. Multiple wing time, making the alternate load paths weaker. This
panels is called “multiple site cracking”. Corrosion weakens
-- Multiple stringers and frames in fuselage alternate load paths, and accelerates crack growth.
construction. This construction also breaks the (see figure 6 and figure 7)
fuselage skin into redundant panels
-- Bonded and bolted fittings (often called back- To compensate for these deficiencies in fail-safe
to-back fittings), and bonded and bolted landing design, the damage tolerance philosophy was
gear beams developed.
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2.1 Safe-Life
The discovery of fatigue cracks, and failures of major
structural elements on airplanes in the late 1930s and
early 1940s, forced the development of the safe-life
design principle. The safe-life design principle requires
that major structural elements be replaced after a
fixed number of flight cycles. These parts cannot be
repaired or refurbished to extend the components life.
The basis for safe-life design is fatigue analysis.
The safe-life of a structure is that number of events,
such as flights, landings, or flight hours, during which
there is a low probability that the strength will degrade
below its design ultimate value due to fatigue cracking.
These parts cannot be repaired or refurbished to
extend the components life.
Safe life design is based on the prediction that the risk
of fatal failure is zero or negligible.
The basis for safe life design is fatigue analyses. One
example is the landing gear (see figure 8)
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2.1.1 Fatigue
Soon after the first jet transport aircraft (Comet)
started flying in the early 1950s, three of them broke
apart in the air under mysterious circumstances, two
of them in relatively non-turbulent air. An extremely
thorough investigation disclosed that the cause of the
break-ups was metal fatigue brought about by the
flexing of the structure during the pressurization and
depressurization cycles.
When the British Comets were put into service with
their pressurization of 8 PSI, real problems arose.
The continued flexing of the structure caused by the
pressurization and depressurization cycles fatigued
the metal to such an extent that a crack developed
at a square come of a cut-out in the structure, and
the large amount of pressure differential caused the
structure to virtually explode. When the cause of the
structural failure was determined, new emphasis was
placed on fail-safe design of aircraft structures. Stress
risers, or portions of the structure where eliminated.
Joints and connections were carefully pre-stressed to
minimize the cyclic stresses from the flight loads.
The life of a structure may depend more on how it is However, if loads of from 0 to 111 kN were applied, it
loaded than on the total number of times it is loaded, would last about 25,000 cycles. Loadings from 111 kN
or on the maximum amount of the loads themselves. tension to 111 kN compression (commonly called plus
This is best shown by loading a 5 cm2 bar of aluminium to minus 111 kN) it would fail at about 4,000 cycles.
alloy that breaks at 370kN when loaded once.
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3. DAMAGE TOLERANCE
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4.1 Zonal Identification Systems Major zones are identified by hundred as follows
(see figure 16):
The location identification system is used to pinpoint
the various locations in an airplane. The station -- 00
1 FUSELAGE LOWER SECTION
numbers make it possible to indicate the location of -- 200 FUSELAGE TOP SECTION
the center of gravity, the distribution of the load, the -- 300 STABILIZERS
location of the compartments and of parts. To localize -- 400 NACELLES
parts more easily and to localize where work must be -- 500 LEFTWING
done, the airplane is divided into: -- 600 RIGHTVV1NG
-- 700 LANDING GEAR
-- Major zones
-- 800 DOORS
-- Major sub-zones
-- Unit zones
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Major sub-zones are identified by the ten of the majors Where necessary, the uneven zone number refers to
zones (see figure 17). A three-digit number identifies the left-hand zone, and an even number indicates a
unit zones. An example of a location identification right-hand zone. Large construction sections, including
system is 212 (See figure 18): doors and control surfaces, have their own zone
numbers.
-- 200: Upper half of body (major zone)
-- 10: Cockpit (major sub-zone)
-- 2: Zone number on the right-hand side
(unit zone)
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The number of the zone in which the panel is installed -- =top (upper) surface
T
followed by a two-letter suffix identifies access doors -- B=bottom (lower) surface
and panels. These two letters are used to indicate the -- R=right side
doors and panels. -- L=left side
-- Z=internal
The first letter indicates which access door or panel it -- F=floor panel
is, starting from the reference axis (A=first, B=second, -- W=sidewall panel
..., G=seventh, etc.). The second letter indicates the -- C=ceiling panel
access door or panel location (see figure 20):
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4.2 Station Identification Systems Other manufacturers use the following abbreviations:
In order to determine a particular location in an -- X Sta. (X Stations) - the X coordinate
airplane, it is divided into three (imaginary) planes that -- Y Sta. (Y Stations) - the Y coordinate
are at angle of 90° to each other (see figure 21). -- Z Sta. (Z Stations) - the Z coordinate
The first plane cuts the airplane horizontally (based on
There is a number following these abbreviations, which
a cross section). These planes are called water lines or
indicates the distance of the part from the zero point.
Z stations.
For airplanes built by Boeing, these distances are given
The second plane cuts the airplane vertically (based on in inches, airplanes built by Airbus, in centimeters.
a cross section). These planes are called buttock lines
The zero point of the Sta. (X Sta.) is in front of, behind
or X stations.
or on the point of the fuselage nose (see figure 22). In
The third plane cuts the airplane vertically (based cases where the station number 0 is behind the point
on a side view). These are called body stations or Y of the nose, the station number that are in front of the
stations. By means of these three planes, any and zero point have a minus sign, for instance: Sta. - 60.4.
every point in the airplane can be given an X, a Y and
The zero point of the W.L. (Z Sta.) depends on the
a Z coordinate. Some airplane manufacturers use
type of airplane. The zero point of the W.L. in a B-747
abbreviations for these coordinates as follows:
is 91 inches below the lowest point.
-- Sta. (body stations) - the X coordinate
The zero point of the B.L. (Y Sta.) is the centerline of
-- B.L. (buttock lines) - the Y coordinate
the airplane (see figure 23). Looking in the direction of
-- W.L. (water lines) - the Z coordinate
flight, there are left-hand and right-hand buttock lines.
The left-hand buttock lines are identified by a minus
sign and the right-hand ones with a plus sign.
The wings, horizontal and vertical stabilizers, and
powerplants of most airplane types have their own
location identification system.
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figure 26, Stringer Arrangement Airbus figure 27, Stringer Arrangement Boeing
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5.2 Bending
Bending is also made up of tension and compression.
The wing of the airplane in figure 29 is under a
bending stress. When the airplane is on the ground,
the top skin of the wing is under a tensile stress and
the bottom skin is under a compressive stress. In flight
these forces are the opposite. The top skin is under
a compressive stress and the bottom skin is under a
tensile stress.
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5.3 Tension
Tension tries to pull an object apart. Consider the
hoist in figure 31. The chain is under tension, or more
properly stated, it has a tensile stress in it.
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5.4 Compression
Compression tries to squeeze the ends of an object
together. The rivet in figure 32 is distorted or strained
by a compressive stress between the rivet gun and the
bucking bar.
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5.5 Shear
A shear stress tries to slide an object apart. The rivet
bolt in figure 33 is subject to a shear stress. The force
on one sheet puts a tensile stress in the rivet toward
the right while the fixed other sheet puts a tensile
stress into the bolt toward the left. These two tensile
stresses act beside each other rather than opposite
each other, and the result is a force that tries to shear
the rivet, or to slide it apart.
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Consideration needs to be given to the construction of Firewalls prevent the spread of fire from hot sections of
the fuselage where it may be necessary to increase its the aircraft such as engine nacelles and APU housing.
structural integrity.
Some system fluid lines, ducting and controls have to
For example: be routed through the aircraft structure. This weakens
the structure so the manufacture will keep this in mind
The installation of brackets for the attachment during the design stage and keep it to a minimum.
of system components such as hydraulic system
reservoirs, fuel filter modules and system shut off Control cables are used extensively throughout the
valves etc. aircraft to operate different aircraft systems, these
control cables will be routed through the aircraft
Increasing structural strength will be required in areas structure and special consideration will need to be
of high load; landing gear and engine attachments given to the routing of these cables to protect the
would be a good example of this. aircraft structure from the cables. This is accomplished
by the use of grommets, fairleads and pressure seals.
Not only is the routing of control cable important,
the routing of hydraulic system fluid lines, electrical
cables, fuel lines, pneumatic system ducting and
air-conditioning distribution must be considered and
provisions made for the attachment and correct routing
of these system components.
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figure 35, Lightning Strike On Fuselage figure 36, Lightning Strike On Carbon Fiber
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Static discharging
The aircraft behaves like a Faraday Cage. During flight
the aircraft can become charged with static electricity,
caused by the constant rubbing of the air molecules
against the fuselage. Static dischargers placed at
specific position at the aircraft structure discharge the
static electricity off the aircraft. Static electricity, which
is not discharged by the static dischargers, can cause
interference in the communications (HF, VHF) and
navigation systems.
Another effect of the static dischargers: Although not
a design feature; in case of lightning strike they can
lead the electrical energy off the aircraft. In this case
the static dischargers might be damaged but they are
easy to change. After a lightning strike the dischargers
must be inspected for damage. It is however possible
that the lightning exited the aircraft via another part
of the structure and none of the static dischargers are
damaged.
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9. AIRCRAFT BONDING
Normally the structure of an aircraft consists of Different manufacturers use different methods to
metallic assemblies which ensure an excellent electric dissipate the electrical charge on composite structures.
conductibility; however certain insulating intermediate These are a few different methods:
parts stop the continuity in large zones. The continuity
is restored by means of strips, screws or grounding -- A luminium wires may be woven into the top layer
lugs fitted between metallic assemblies. Hinged parts of composite fabric. This is usually done with
(control surfaces, doors, hatches, etc.), removable fiberglass or Kevlar and not with carbon/graphite
parts (unhinged inspection doors, etc.), are provided -- A fine aluminium screen may be laminated under
with one or several bonding means shunting each the top layer of fabric. lf this method is used
part where conductibility may be interrupted. For on a carbon/graphite component, it is usually
particular zones such as fuel tanks, engines and APU, sandwiched between two layers of fiber glass to
the bondings provide an efficient circulation of static prevent a galvanic potential
potential; bonding strips and screws are connected to -- A thin aluminium foil sheet may be bonded to the
the main structure. outer layer of composite during the manufacturing
process
External protruding parts, metallic or not, are provided -- Aluminium may be flame sprayed onto the
with electrical leads connected to the main structure. component. This is molten aluminium that is
Antennas and other equipment are not bonded due to sprayed on like paint. Some companies will just
the fact that a flash of lightning could damage only the paint the component with an aluminized paint
element struck without endangering the other parts of -- In some structures, a piece of metal is bonded
the aircraft. to the composite to allow the dissipation of the
electrical charge out to another metal component
or static discharger
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