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AE693 Aircraft Structural Integrity
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Prakash Mangalgiri
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Visiting Professor, AE Dept
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Formerly at ADA.
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(Also at GM-R&D, NASA, IISc, TELCO)
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Aircraft Structural Integrity
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Module 1 : Introduction &Motivation
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Module
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Introduction & Motivation
• What is structural integrity?
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• What are the issues? & Concerns?
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– Fatigue - a major concern in metallic structures
– Impact damage - a major concern in Carbon Composites
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– Corrosion – a major concern in ageing aircraft
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• How do we ensure Structural Integrity of Aircraft?
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Challenges, Strategies
– Historical Evolution
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– Strategies as a Designer & as a user
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– Safe-Life, Fail-Safe, Damage Tolerant Design Philosophies
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What is Structural Integrity?
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What is Structural Integrity?
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• Structure remains in-tact (may have local damage, but does
not totally break)
• and fulfils all the functional requirements
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• Does so through entire life time of the aircraft
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• Functional requirements … …
– Carry and sustain loads (STRENGTH)
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–
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Avoid excessive vibrations, deflections or distortions (STIFFNESS)
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– Avoid instabilities (BUCKLING, FLUTTER)
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–
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Provide proper shape (e.g. AEROFOIL)
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–
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Provide proper container shape and volume (e.g. FUEL
STORAGE)
– Others ….
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• Provide Proper RADAR CROSS SECTION (RCS)
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• Multi-functional (SMART) Structures can have other functions as well
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(e.g. Antennae)
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Structural elements
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Structures from Structural elements
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Some Typical Aircraft Structures
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A commercial Transport Aircraft
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https://hendrynoya.wordpress.com/2011/04/17/aircraft-load-part-i/ 9
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Boeing 747 - Classic
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http://www.b747classic.co.uk/gallery
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http://modernairliners.com/airbus-a380/airbus-a380-specs
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LCA - Tejas
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https://forums.bharat-rakshak.com/viewtopic.php?f=3&t=6964&start=3240
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LCA: Tejas
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MULTIROLE
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• Air to Air
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• Air to Ground
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• Air to Sea (naval
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version)
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Facetted structure of F-117 Stealth Fighter
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• Heavy penalties in power requirement
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• High cost of maintenance • Now-a-days, with
the help of
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computer aided
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models and
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calculations, more
streamlined shapes
are possible
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1983 - 2008
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http://defenceforumindia.com/forum/threads/stealth-
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fighters-and-bombers.48973/
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Combat Aircraft : Relative Sizes
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LCA F-16
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F-2A Typhoon F/A-18 F-35
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(Tejas) Rafale F-35A J-10 F-22 E-50
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F-117 ?? J-20 Su-27 SU-47 B-2
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Size
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A-380
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comparison
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LCA
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What can go wrong with
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the structure?
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Why would it fail?
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Why do Structures fail?
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• Several structures have been built… ships, bridges, dams,
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nuclear reactors, rockets, aircraft… etc etc
• On the whole, things work well … but, every now and then….a
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problem shows up leading to structural failure
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• Why do structures fail?
– Negligence : Mistakes or errors in design or fabrication or
operation.. Someone did not follow the set rules.
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– Ignorance : New design or new technology or new
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material applied and used with the confidence that the
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new knowledge was adequate… but unexpected failure.
The set rules were not adequate because of some element
of ignorance.
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• We need to make constant effort to remove ignorance and
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work out better set of rules
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Why aircraft structures fail…
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• Violent manoeuvre induced by the pilot (excessive “g"
force imposed on a wing or tail, etc.), --- Operating
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outside the permitted envelope
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• Violent manoeuvre
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caused by environmental
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There is constant
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conditions (wind gust,
effort to turbulence) --- Un-intentional
operation outside the permitted envelope
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• Pilot-induced
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over-speed,
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ignorance NEGLIGE
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• Improper maintenance or maintenance error,
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• Improper• assembly,
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build tools which
And, last butwill
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the prevent
least, IGNORA
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• Material degradation (fatigue, Corrosion, damage…..)
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negligence
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• Errors in behaviour prediction
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Ensuring Structural Integrity
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• What can go wrong?
– Normal Wear & Tear
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– Abuse – Usage beyond Intended conditions
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– Accidental Damage
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• How to handle - Need a strategy
– Design Strategy
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– Operational Strategy
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• Stake holders
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– OEMs (Design, Manufacture)
– Operators (Airlines, Airforces, …)
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MROs (Maintenance, Repairs)
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Regulatory Bodies
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Causes of Structural Degradation, Deterioration
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(Perm. Deform)
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Erosion
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Impact
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Corrosion
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❖ Environment induced
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…&
others?
❖ Mech Load induced
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❖ External events
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FATIGUE
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Historical perspective …
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• Industrial revolution in 19th century: several
machineries developed & built. Many of them --
Steam engines, locomotives, pumps, etc -- had
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sudden failures after a period of successful run…..
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And that too without any visual evidence of plastic
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deformation. And no evidence of overload.
• 1837: Wilhelm Albert (studying failure of mining
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chains) published an article establishing a
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correlation between applied loads and durability.
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• 1839: Jean-Victor Poncelet, designer of cast iron
axles for mill wheels, officially used the term
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"fatigue" for the first time in a book on Mechanics
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• 1842:
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Versailles rail accident: 8 May 1842
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August
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(1819-
1914)
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• Problem with axles. Metal fatigue was poorly understood at the
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time. The immensity of the accident initiated a systematic
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research into the problem. … in Europe as a whole.
• Work by Edwards, Rankine and others described the fatigue
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process
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• 1856–1870, August Wöhler : Pioneering work on fatigue,
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Wöhler (and others) ~1870
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• Systematic measurement of loads on axles. Importance
of arriving at proper service loads for design.
• Design of fatigue testing m/cs, creating test procedures
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• Extensive data generation, cyclic stress vs life
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• Amplitude of cyclic loads as the main factor
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• Recommended tests & procedure for notched configs.
• Noted scatter in fatigue lives, brought in concept of
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finite life on account of fatigue
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• Suggested origin of fatigue as crack initiation &
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propagation
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• Created standard design procedures for design (sizing,
detailing) of rotating components for fatigue.
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• In fact, S-N Curve is referred to as Wohler Curve by
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What is fatigue?
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Fatigue is …
• a process in which damage accumulates due to
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repetitive loads which may be well below yield
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stress or static strength
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• a fracture phenomenon occurring after a large
number of load cycles where a single load of the
same magnitude will do no harm
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• a form of failure that occurs in structures
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subjected to dynamic and fluctuating stresses.
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Under these circumstances it is possible for
failure to occur at a stress level considerably
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lower than the tensile or yield strength for a
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static load.
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Stress – Life (S-N) Curve
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Fatigue: Cyclic low loads lead to failure!
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❖By the time Wright
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known phenomenon
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machineries. ….Not much
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loads on structures.
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❖Also, STEEL dominated the
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material. …And steel had a
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Early aircraft: Strut and wire-braced structures
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Wright Flyer
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1917
Sopwith
Camel
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• All structures: Rectangular
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Hawker
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frames, prevented from
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shearing or collapsing by
diagonally stretched wire.
• Use of Bamboo, Spruce Wood
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• Initial use of metal (~1930), just
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Semi-monocoque Structures
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• Room for passengers? … Experience from Boat building…”…bent
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wooden frames & double or triple skins, …with a clear varnished
finish…”
• First applied to fuselage… and then to wing as well.
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• Sheet metal technology could be effectively utilised
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• Outer skin not only defines aerodynamic profile, but also carries
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Early years of aircraft structural integrity
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• Mostly strength based design with factor of
safety
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– Strength test on components
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– Early material, wood, had excellent fatigue
resistance
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– Not much was known about “fatigue loads”
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Sep 23, 1900: Wilbur Wright writing to his father
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I am constructing my machine to sustain about five times my weight
and am testing every piece. I think there is no possible chance of its
breaking in the air. If it is broken, it will be by awkward landing. My
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Strength Test of an Aircraft (Early years)
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We will look at some more landmark events in the next class!
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Questions?
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