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A380 WING RIB BOOM

CRACK ROOT CAUSES


&
CHANGES
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GENERAL
A380 has 3 main types of rib:
Metallic 7449, Metallic 7010,
Composite Rib Web with metallic 7449 rib feet
Cracking found primarily on hybrid composite/metallic rib booms and some all metallic ribs.
All affected metallic structure made out of 7449

3 main types of Ribs, Metallic 7449, 7010, Hybrid (CFRP web +


metallic 7449 foot boom),
Cracking : mainly on hybrid ribs booms + metallic 7449 rib .
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TYPE OF CRACKS FOUND


Two types of cracks identified.

TYPE 1 CRACKS

INTERGRANULAR FRACTURE
(quasi-static failure)

FATIGUE DRIVEN FRACTURE

Reported: End September 2011

Reported: End January 2012

MEDIUM TERM SIGNIFICANCE

TYPE 2 CRACKS

SHORT TERM SIGNIFICANCE

Two types of cracks identified with different mechanisms and


significance. Type 1 cracks starting from rib foot/stringer/skin
fasteners holes. Type 2 cracks located in the rib foot vertical web.
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TYPE 1 CRACKS
INTERGRANULAR FRACTURE
(quasi-static failure)

All findings are on ribs/rib feet made from 7449 material.


The majority (77%) are on the top skin
The majority (over 90%) are on hybrid booms
Cracks are driven by:
. A high installed build stress loading generating static overload failure once combined
with a certain level of operational loading,
. 7449 material properties in the S-L direction.

Type 1 cracks origin:


essentially to material properties (7449) , combined with stresses
generated during assembly (interference fit installation to wing
skin/stringer).
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TYPE 2 CRACKS
FATIGUE DRIVEN FRACTURE

The majority of cracks appear on ribs 24,26 & 29 between stringer 17 and 25. A smaller number
appear on rib 25 in the same area.

Strong correlation between crack findings and rib manhole locations in ribs.

Some detail features on rib feet act as stress concentrators.

Following inspection results, the majority of crack appears at ribs


24 to 29 mainly at manhole areas.
Two origins have been identified: gaps at rib installation and out of
plane deformation due to thermal loading.
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TYPE 2 CRACKS

Root Causes Thermal effects on Hybrid ribs

The thermal effects have been established throughout the whole wing:
Hybrid Ribs

CFRP
rib
web

Aluminum Alloy
Rib Feet / skin/stgr

Difference in Thermal
Expansion Coefficient
Out of Plane Deformations
Over stresses in Rib Foot
Cracking
(type 2)

The difference in thermal expansion coefficient in between CFRP


rib web and aluminum alloy rib foot generates out of plane
deformations. This results in an over stressing of the rib foot leading
to type 2 cracks.
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TYPE 2 CRACKS

Root Causes Thermal effects on Hybrid ribs

The thermal effects on hybrid ribs explain why the Type 2 cracks
are mainly concentrated under the manhole in the rib.

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SOLUTIONS
TEMPORARY FIX

FINAL FIX

AD (Airworthiness Directive)
Standard Repair

Start end 2012

Replace center section of Rib


Boom for ribs 24, 25, 26, 27, 29.

Replace all Rib booms


Upper/Lower for Hybrid
Ribs (23 ribs per wing)

Repair boom sections made


from 7010 material.

SERIAL SOLUTION
Hybrid ribs
changed to Metallic

New Metallic Rib 24

Replace metallic Ribs 48, 49

Manage a gap of +/- 0.2mm.


Hybrid Rib 24
Interference fit fasteners

Install additional CFRP


Stiffeners at Rib web
(manholes)

7449 Metallic Ribs


changed to 7010

TEXT

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General
Type of cracks found
Type 1 cracks
Type 2 cracks
Solutions

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