Transactions of the Institute of Aviation
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ISSN 0509-6669 TRANSACTIONS OF THE INSTITUTE OF AVIATION Scientific Quarterly 1/2009 (196) REVIEW OF AERONAUTICAL FATIGUE INVESTIGATIONS IN POLAND DURING THE PERIOD MAY 2007 TO APRIL 2009 Antoni Niepokólczycki, DSc, Editor Edition is sponsored by Ministry of Science and Higher Education Institute of Aviation Editorial Board Maciej Bossak, Zdobysław Goraj, Marian Jeż, Wojciech Kania, Tadeusz Korsak (Board Secretary), Antoni Niepokólczycki, Wojciech Potkański, Kazimierz Szumański (Board Chairman) Zbigniew Wołejsza ТРУДЫ ИНСТИТУТА АВИАЦИИ НАУЧНОЙ ЖУРНАЛ (КВАРТАЛНИК) 1/2009 (196) ОБЗОР АВИАЦИОННЫЫХ УСТАЛОСТНЫХ РАССЛЕДОВАНИИ В ПОЛЬШЕ В ПЕРИОД С МАЯ 2007 ПО АПРЕЛЬ 2009 Редактор: др Антони Непокулчыцки Publisher: Institute of Aviation Scientific Publicatins Group Al. Krakowska 110/114 02-256 Warszawa, Poland phone: (4822) 846 00 11 ext 442, fax: (4822) 846 44 32 Edition, revision, computer typesetting: Tadeusz Korsak Printers: ALKOR, 05-070 Sulejówek, Krucza 4 CONTENTS 1. INTRODUCTION .......................................................................................................................................... 5 2. HELICOPTERS .............................................................................................................................................. 6 2.1 Static, Fatigue and Durability Tests of Main and Tail Rotor Gearboxes of PZL SW-4 Helicopter ................................................................................................................................................... 6 2.2 Helicopter Structural Integrity Program of Polish Army Mi-24 Hind Helicopters ......... 7 2.3 Modern automated NDE techniques for composite helicopter main rotor blades inspection ................................................................................................................................................... 8 3. AIRPLANE STRUCTURES ......................................................................................................................... 9 3.1 Full-Scale Fatigue Tests of PZL M28 05 SKYTRUCK Aircraft .................................................. 9 3.2 The Fatigue Life Assessment of PZL-130 ORLIK Structure Based on Historical Usage Data.......................................................................................................................... 13 3.3 Static and Fatigue Tests of the A400M Subcomponents ........................................................ 20 3.4 In-service Flaw Detection and Quantification in the Composites Structures of Aircraft .......................................................................................................................... 22 3.5 Investigations into Glider Landing Gear Load Spectrum ....................................................... 27 4. MATERIALS TESTING ............................................................................................................................ 33 4.1 Strength Testing and Analysis of Fatigue Crack Growth in Selected Aircraft Materials .......................................................................................................... 33 4.2 Experimental and Theoretical Investigations of Fatigue Crack Growth in D16 Alloy ............................................................................................................................................ 43 4.3 The Effect of a Complex Stress State on Fatigue Crack Propagation and the Orientation of the Cracking Plane in VT3-1 Aeronautical Titanium Alloy ..................... 44 4.4 Deterministic Approach to Predicting the Fatigue Crack Growth in the 2024-T3 Aluminium Alloy under Variable Amplitude Loading ............................ 45 4.5 Capacity of Fractographic Analysis for Load-Time History Reconstruction and Fatigue Crack Growth Rate Estimation for the 2024-T3 Aluminium Alloy .......... 46 5. JOINTS .......................................................................................................................................................... 47 5.1 Methods for FEM Analysis of Riveted Joints of Thin-Walled Aircraft Structures with Submodelling Technique. ................................................................................. 47 5.2 Stress Measurements Around Rivets with X-ray Dyffractometry ...................................... 51 5.3 An Experimental Investigation on the Fatigue Performance of Riveted Lap Joints ........................................................................................................................... 58 5.4 Fatigue Damage of Rivet Joints in the Condition of Stable Cyclic Load ............................ 60 6. OTHER RELEVANT WORKS ................................................................................................................. 63 6.1 Experimental crack propagation analysis of the compressor blades working in high cycle fatigue condition. ....................................................................................................... 63 6.2 Thermal Fatigue Problems of Turbine Casing ........................................................................... 70 REVIEW OF AERONAUTICAL FATIGUE INVESTIGATIONS IN POLAND MAY 2007 – APRIL 2009 3 ʠʝʓʔʟʕʏʜʗʔ 1. ʑʑʔʓʔʜʗʔ.................................................................................................................................................... 5 2. ʑʔʟʡʝʚʔʡʪ................................................................................................................................................. 6 2.1 ʠ˕˃˕ˋ˚ˈ˔ˍˋˈǡ ˖˔˕˃ˎˑ˔˕ː˞ˈ ˋ ˒˓ˑ˅ˈˇˈːˋˢ ˋ˔˒˞˕˃ːˋˌ ː˃ ˒˓ˑ˚ːˑ˔˕˟ ˓ˈˇ˖ˍ˕ˑ˓ˑ˅ ˑ˔ːˑ˅ːˑˆˑ ˋ ˘˅ˑ˔˕ˑ˅ˑˆˑ ˓ˑ˕ˑ˓˃ ˅ˈ˓˕ˑˎˈ˕˃ PZL SW-4 ............................... 6 ʹǤʹ ʞ˓ˑˆ˓˃ˏˏ˃ ˔˕˓˖ˍ˕˖˓ːˑˌ ˙ˈˎˑ˔˕ːˑ˔˕˟ˋ ˇˎˢ ˅ˈ˓˕ˑˎˈ˕ˑ˅ ʛˋ-ʹͶ ˒ˑˎ˟˔ˍˑˌ ˃˓ˏˋˋ7 ʹǤ͵ ʠˑ˅˓ˈˏˈːː˞ˈ ˃˅˕ˑˏ˃˕ˋˊˋ˓ˑ˅˃ːː˞ˈ ˏˈ˕ˑˇ˞ NDE ˇˎˢ ˋː˔˒ˈˍ˙ˋˋ ˍˑˏ˒ˑˊˋ˕ː˞˘ ˅ˈ˓˕ˑˎˈ˕ː˞˘ ˎˑ˒˃˔˕ˈˌ ːˈ˔˖˜ˈˆˑ ˅ˋː˕˃..................................................... 8 ͵Ǥ ʠʡʟʢʙʡʢʟʪ ʠʏʛʝʚʔʡʏ........................................................................................................................ 9 ͵Ǥͳ ʞˑˎːˑˏ˃˔˛˕˃˄ː˞ˈ ˋ˔˒˞˕˃ːˋˢ ː˃ ˔ˑ˒˓ˑ˕ˋ˅ˎˈːˋˈ ˖˔˕˃ˎˑ˔˕ˋ ˔˃ˏˑˎˈ˕˃ PZL M28 05 SKYTRUCK .................................................................................................... 9 ͵Ǥʹ ʝ˙ˈːˍ˃ ˔˓ˑˍ˃ ˔ˎ˖ˉ˄˞ ˒˓ˋ ˖˔˕˃ˎˑ˔˕ː˞˘ ː˃ˆ˓˖ˊˍ˃˘ ˔˕˓˖ˍ˕˖˓˞ ˔˃ˏˑˎˈ˕˃ PZL-130 ORLIK ˑ˒ˋ˓˃ˢ˔˟ ː˃ ˋ˔˕ˑ˓ˋ˚ˈ˔ˍˋˈ ˇ˃ːː˞ˈ ˑ˄ ˋ˔˒ˑˎ˟ˊˑ˅˃ːˋˋ.................. 13 3.3 ʠ˕˃˕ˋ˚ˈ˔ˍˋˈ ˋ ˖˔˕˃ˎˑ˔˕ː˞ˈ ˋ˔˒˞˕˃ːˋˢ ˒ˑˇˍˑˏ˒ˑːˈː˕ˑ˅ ˔˃ˏˑˎˈ˕˃ A400M ...... 20 3.4 ʓˈ˗ˈˍ˕ˑ˔ˍˑ˒ˋ˚ˈ˔ˍˑˌ ˋ ˍˑˎˋ˚ˈ˔˕˅ˈːːˑˌ ˃ː˃ˎˋˊ ˅ ˔ˎ˖ˉ˄ˈ ˍˑˏ˒ˑˊˋ˕ː˞˘ ˃˅ˋ˃˙ˋˑːː˞˘ ˔˕˓˖ˍ˕˖˓ ................................................................................................................... 22 ͵Ǥͷ ʗ˔˔ˎˈˇˑ˅˃ːˋˢ ˅ ˔˒ˈˍ˕˓ ː˃ˆ˓˖ˊˍˋ ˒ˑ˔˃ˇˑ˚ːˑˆˑ ˖˔˕˓ˑˌ˔˕˅˃ ˒ˎ˃ːˈ˓˃....................... 27 ͶǤ ʗʠʞʪʡʏʜʗʔ ʛʏʡʔʟʗʏʚʝʑ............................................................................................................. 33 ͶǤͳ ʗ˔˒˞˕˃ːˋˈ ˒˓ˑ˚ːˑ˔˕ˋ ˋ ˃ː˃ˎˋˊ ˓˃ˊ˓˃˔˕˃ːˋˢ ˕˓ˈ˜ˋː˞ ˖˔˕˃ˎˑ˔˕ˋ ˅ ˅˞˄˓˃ːː˞˘ ˃˅ˋ˃˙ˋˑːː˞˘ ˏ˃˕ˈ˓ˋ˃ˎ˃˘................................................................................ 33 ͶǤʹ ʬˍ˔˒ˋ˓ˋˏˈː˕˃ˎ˟ːˑ ˋ ˕ˈˑ˓ˈ˕ˋ˚ˈ˔ˍˋˈ ˋ˔˔ˎˈˇˑ˅˃ːˋˢ ˓˃ˊ˓˃˔˕˃ːˋˢ ˕˓ˈ˜ˋː˞ ˖˔˕˃ˎˑ˔˕ˋ ˅ ˔˒ˎ˃˅ˈ ͳ.............................................................................................. 43 4.3 ʬ˗˗ˈˍ˕ ˑ˕ ˔ˎˑˉːˑˆˑ ː˃˒˓ˢˉˈːːˑˆˑ ˔ˑ˔˕ˑˢːˋˢ ː˃ ˖˔˕˃ˎˑ˔˕ː˞ˈ ˕˓ˈ˜ˋː˞ ˋ ˑ˓ˋˈː˕˃˙ˋˋ ː˃ ˒ˎˑ˔ˍˑ˔˕ˋ ˍ˓ˈˍˋːˆ ˅ ˃˅ˋ˃˙ˋˑːː˞ˏ ˕ˋ˕˃ːˑ˅ˑˏ ˔˒ˎ˃˅ˋˈ VT3-1 ..... 44 4.4 ʓˈ˕ˈ˓ˏˋːˋ˓ˑ˅˃ːː˞ˌ ˒ˑˇ˘ˑˇ ˍ ˒˓ˑˆːˑˊˋ˓˖ˡ˜ˋ˘ ˓˃ˊ˓˃˔˕˃ːˋˈ ˕˓ˈ˜ˋː˞ ˖˔˕˃ˎˑ˔˕ˋ ˅ ˃ˎˡˏˋːˋˈ˅ˑˏ ˔˒ˎ˃˅ˈ ʹͲʹͶ-T͵ ˒ˑˇ ː˃ˆ˓˖ˊˍˑˌ ˔ ˒ˈ˓ˈˏˈːːˑˌ ˃ˏ˒ˎˋ˕˖ˇˑˌ........................................................................................................................... 45 ͶǤͷ ʔˏˍˑ˔˕˟ ˗˓˃ˍ˕ˑˆ˓˃˗ˋ˚ˈ˔ˍˑˆˑ ˃ː˃ˎˋˊ˃ ˇˎˢ ˓ˈˍˑː˔˕˓˖ˍ˙ˋˋ ˋ˔˕ˑ˓ˋˋ ʑ˓ˈˏˢ Ȃ ʜ˃ˆ˓˖ˊˍ˃ ˋ ˑ˙ˈːˍ˃ ˔ˍˑ˓ˑ˔˕ˋ ˓˃ˊ˓˃˔˕˃ːˋˢ ˕˓ˈ˜ˋː˞ ˖˔˕˃ˎˑ˔˕ˋ ˇˎˢ ˃ˎˡˏˋːˋˈ˅ˑˆˑ ˔˒ˎ˃˅˃ ʹͲʹͶ-T3 .......................................................................................... 46 ͷǤ ʠʝʔʓʗʜʔʜʗʮ .......................................................................................................................................... 47 ͷǤͳ ʛˈ˕ˑˇ˞ ˇˎˢ ˃ː˃ˎˋˊ˃ ʛʙʔ ˊ˃ˍˎˈ˒˃ːː˞˘ ˔ˑˈˇˋːˈːˋˌ ˃˅ˋ˃ˋˑːː˞˘ ˕ˑːˍˑ˔˕ˈːː˞˘ ˔˕˓˖ˍ˕˖˓ ˔ ˕ˈ˘ːˋˍˑˌ ˒ˑˇˏˑˇˈˎˋ˓ˑˑ˅˃ːˋˢ........................................... 47 ͷǤʹ ʗˊˏˈ˓ˈːˋˢ ˖˔ˋˎˋˢ ˅ˑˍ˓˖ˆ ˊ˃ˍˎˈ˒ˑˍ ˔ ˇ˞˗˓˃ˍ˕ˑˏˈ˕˓ˋ˚ˈ˔ˍˑˌ ˓ˈː˕ˆˈːˑ˅˔ˍˑˌ ˔ːˋˏˍˑˌ ................................................................................................................. 51 ͷǤ͵ ʬˍ˔˒ˋ˓ˋˏˈː˕˃ˎ˟ː˞ˈ ˋ˔˔ˎˈˇˑ˅˃ːˋˢ ː˃ ˒˓ˈˇ˔˕˃˅ˎˈːˋˋ ˖˔˕˃ˎˑ˔˕ˋ ˊ˃ˍˎˈ˒˃ːː˞˘ ˒ˈ˓ˈˍ˓˞˕˞˘ ˔ˑˈˇˋːˈːˋˌ.................................................................................. 58 ͷǤͶ ʞˑ˅˓ˈˉˇˈːˋˈ ˖˔˕˃ˎˑ˔˕ˋ ˊ˃ˍˎˈ˒˃ːː˞˘ ˔ˑˈˇˋːˈːˋˌ ˅ ˔ˑ˔˕ˑˢːˋˋ ˔˕˃˄ˋˎˋˊˋ˓ˑ˅˃ːːˑˌ ˙ˋˍˎˑ˅ˑˌ ː˃ˆ˓˖ˊˍˋ............................................................................... 60 Ǥ ʓʟʢʒʗʔ ʢʛʔʠʡʜʪʔ ʟʏʐʝʡʪ.......................................................................................................... 63 Ǥͳ ʬˍ˔˒ˋ˓ˋˏˈː˕˃ˎ˟ː˞ˌ ˃ː˃ˎˋˊ ˓˃˔˒˓ˑ˔˕˓˃ːˈːˋˢ ˕˓ˈ˜ˋː ˎˑ˒˃˕ˑˍ ˍˑˏ˒˓ˈ˔˔ˑ˓˃ ˓˃˄ˑ˕˃ˡ˛˚˞˘ ˅ ˖˔ˎˑ˅ˋˋ ˅˞˔ˑˍˑˆˑ ˙ˋˍˎ˃ ˖˔˕˃ˎˑ˔˕ˋ Ǥ ....................... 63 6.2 ʞ˓ˑ˄ˎˈˏ˞ ˕ˈ˓ˏ˃ˎ˟ːˑˌ ˖˔˕˃ˎˑ˔˕ˋ ˍˑ˓˒˖˔˃ ˕˖˓˄ˋː˞....................................................... 70 4 TRANSACTIONS OF THE INSTITUTE OF AVIATION NO. 196 1. INTRODUCTION This review gives the summary of work performed in Poland in the area of aeronautical fatigue during the period from May 2007 to April 2009. The various contributions to this review come from the following sources: Institute of Aviation, Warsaw; Air Force Institute