2014 AFGROW Workshop Layton, UT.

Transcription

1 Distribution Statement A: Approved for public release: distribution unlimited. Ref# WWA_001; WP PA Case # 75ABW AFGROW Workshop Layton, UT. Sensitivity Study of Parameters Influencing BAMF Predictions within a Deep Residual Stress Field Caused by Cold Expansion Presentation By: Scott Carlson. Research Engineer Southwest Research Institute (SwRI) A-10 Aircraft Structural Integrity (ASIP) Analysis Group Hill AFB, UT Phone: Scott.Carlson@swri.org

2 Acknowledgements USAF A-10 & T-38 Josh Hodges, Robert Pilarczyk APESolutions Tom Mills, Scott P.D. Southwest Research Institute Dallen Andrew 2

3 Agenda Validation Testing of BAMF Compared to Test Data - Carlson, Warner & Andrew Thesis Data - APES CP44 Short Edge Margin Data A Look at Factors of Influence Initial Load Interaction Study Lessons Learned 3

4 Validation Data for BAMF StressCheck 10.1 Allows for Inclusion of Residual Stress as a Crack Face Traction Residual Stress Data Provided by Hill Eng. Inc. Through Contour Method 4

5 2024-T351 Centered Hole Coupons Modeling Parameters Material File 2024-T351 A-10 Mat Max Stress (ksi) Loading Condition Length (in) Width (in) Thickness (in) Hole Diameter (in) Edge Margin Percent Growth P- Level Constant Amplitude Variable Amplitude Variable Amplitude Constant Amplitude Variable Amplitude Shape Type Multi- Point Multi- Point Multi- Point Multi- Point Multi- Point 5

6 2024-T351 Center Hole Data Fatigue Crack Growth Test Data Showing BAMF Prediction for 4.0 Edge Margin Constant Amplitude Max Stress = 25ksi, R=0.1 CX CX CX xifs BAMF Prediction , , , , , , , , , ,000 Life 6

7 2024-T351 Center Hole Data Fatigue Crack Growth Test Data Showing BAMF Prediction for Edge Margin for 4.0 Edge Margin Variable Amplitude 33ksi Max Stress PC-CX PC-CX xifs BAMF Prediction BAMF Prediction with Adjusted IFS ,000 40,000 60,000 80, , ,000 Life 7

8 2024-T351 Center Hole Data Fatigue Crack Growth Testing Data Showing BAMF Prediction for 4.0 Edge Margin Variable Amplitude Max Stress 43.25ksi 0.5 PC-CX PC-CX PC-CX xifs BAMF Prediction Life 8

9 2024-T Edge Margin Fatigue Crack Growth Test Data Showing BAMF Prediction for 1.2 Edge Margin Constant Amplitude Max Stress 25ksi, R=0.1 OFF-CX CA OFF-CX CA xifs Edge Distance (e/d) BAMF Prediction ,000 20,000 30,000 40,000 50,000 60,000 Life (Cycles) 9

10 2024-T Edge Margin Fatigue Crack Growth Test Data Showing BAMF Prediction for 1.2 Edge Margin Variable Amplitude 33ksi Max Stress OFF-CX VA OFF-CX VA xifs Edge Distance (e/d) BAMF Prediction ,000 4,000 6,000 8,000 10,000 12,000 14,000 16, Life (Flight Hours)

11 2024-T351 CP44 Short Edge Margin Modeling Parameters Material File APES Mat File Max Stress (ksi) 28 Loading Condition Variable Amplitude Residual Stress Level Length (in) Width (in) Thickness (in) Hole Diameter (in) Edge Margin Percent Growth P-Level Max Min Min Shape Type Multi- Point Multi- Point Multi- Point 11

12 2024-T351 CP44 Short Edge Margin Fatigue Crack Growth Test Data Showing BAMF Prediction for 1.5 Edge Margin, Dia in, Variable Amplitude 28ksi Max Stress, Min Applied Expansion 0.50 xifs Edge Distance (e/d) CP44AS CP44AS-10 BAMF Prediction Life 12

13 2024-T351 CP44 Short Edge Margin Fatigue Crack Growth Test Data Showing BAMF Prediction for 1.5 Edge Margin, Dia , Variable Amplitude 28ksi Max Stress, Max Applied Expansion xifs CP44AS-05 CP44AS-06 Edge Distance (e/d) 0.30 BAMF Prediction Life 13

14 2024-T351 CP44 Short Edge Margin Fatigue Crack Growth Test Data Showing BAMF Prediction for 1.28 Edge Margin, Dia in, Variable Amplitude 28ksi Max Stress, Max Applied Expansion xifs CP44AS-13 Edge Distance (e/d) CP44AS-14 BAMF Prediction Life 14

15 Study of Variables Location of vs. Exit Correct Residual Stress Orientation Incorrect Residual Stress Orientation Percent Applied Expansion Percent Growth 10% Adjustment to RS Field Initial Flaw Sizes Material File 15

16 Orientation of Residual Stress Field 0.50 Fatigue Crack Growth Test Data Showing BAMF Prediction for 1.5 Edge Margin, Variable Amplitude 28ksi Max Stress, Max Applied Expansion Showing Difference in Life Due to Nucleation Location xifs Edge Distance (e/d) CP44AS-05 CP44AS-06 Correct Nucleation Location Incorrect Nucleation Location ,000 20,000 30,000 40,000 50,000 60,000 70,000 Life 16

17 Percent Applied Expansion Fatigue Crack Growth Test Data Showing BAMF Prediction for 4.0 Edge Margin Constant Amplitude 25ksi, R= %, 3.67% & 4.16% Applied Expansion A-10 Material File, xin IFS CX CX CX xifs 3.17% Applied Expansion 3.67% Applied Expansion 4.16% Applied Expansion , , , , , , , , , ,000 Life (cycles) 17

18 90%, 100%, 110% Residual Stress Fatigue Crack Growth Test Data Showing BAMF Prediction for 4.0 Edge Margin Constant Amplitude 25ksi, R=0.1 Comparing Adjustment to Residual Stress Field for 3.67% Applied Expansion 0.6 BAMF Prediction 90% RS Field BAMF Prediction with Measured RS Field 0.5 BAMF Prediction 110% RS Field , , , , , , ,000 Life (cycles) CX CX CX xifs 18

19 Material File Fatigue Crack Growth Test Data Showing BAMF Prediction for 4.0 Edge Margin Constant Amplitude 25ksi, R=0.1 Comparing Material File Inputs for Same Material CX CX CX xifs Other Material File A-10 Material File , , , , , , , , , , Life (cycles)

20 Initial Flaw Size Fatigue Crack Growth Test Data Showing BAMF Prediction for 1.5 Edge Margin, Variable Amplitude 28ksi Max Stress, Max Applied Expansion IFS x409 IFS x28 Edge Distance (e/d) xifs CP44AS-05 CP44AS ,000 20,000 30,000 40,000 50,000 60,000 70, Life

21 Percent Growth in AFGROW Fatigue Crack Growth Test Data Showing BAMF Prediction for 4.0 Edge Margin Constant Amplitude 25ksi, 3%, 4% and 5% Growth Percentage A-10 Material File, xin IFS 3% Growth Prediction 4% Growth Prediction 5% Growth Prediction CX CX CX xifs , , , , , , , , , ,000 Life (cycles)

22 CP44 SOLR Study BAMF Provides Platform for Investigation into SOLR Values - Naturally evolved crack shapes match test Marker Banding Profile for CP44-09 Dia=0.4375, 1.28 Edge Margin, Max Residual Stress, Max Spectrum Stress = 28ksi 0.2 Outline Crack Origins Crack Linking Lines Primary Marks Secondary Crack Fronts Edge Distance (e/d) Bore ,840" 27,064" 32,640" 0" 4800" (in) 22

23 CP44 Dia in Hole Fatigue Crack Growth Test Data Showing BAMF Prediction with No SOLR and SOLR Correlation Study for CP44, Max Residual Stress, IFS Normalized, Max Spectrum Stress 28ksi, Dia=0.375 Edge Margin 1.5 BAMF Prediction no SOLR AFGROW Prediction with Betas Test Data AFGROW Predition with SOLR = 1.45 AFGROW Prediction with SOLR = 1.60 Edge Distance (e/d) Life (Flight Hours)

24 CP44 Dia in Hole Fatigue Crack Growth Test Data Showing BAMF Prediction with No SOLR and SOLR Correlation Study for CP44, Max Residual Stress, IFS Normalized, Max Spectrum Stress 28ksi, Dia= Edge Margin 1.28 BAMF Prediction No SOLR AFGROW Prediction with BAMF Betas - No SOLR AFGROW Prediction with BAMF Betas - SOLR = 1.6 Test Data Dia= Max RS IFS-13 Edge Distance (e/d) ,000 10,000 15,000 20,000 25,000 30,000 35,000 Life (Flight Hours) 24

25 Lessons Learned Establish Protocol for Residual Stress Measurements Location of vs. Exit Additional Research into SOLR for Spectrum Loading Still Looking into Short Crack Growth Rate Mismatch Pay Attention to the DETIALS!!!!! 25

26 Questions? 2013 Carlson 26