Fatigue And Fracture Mechanics Of High Risk Parts

In the preliminary stage of designing new structural hardware that must perform a given mission in a fluctuating load environment, there are several factors the designers should consider. Trade studies for different design configurations should be performed and, based on strength and weight considerations, among others, an optimum configuration selected. The selected design must be able to withstand the environment in question without failure. Therefore, a comprehen sive structural analysis that consists of static, dynamic, fatigue, and fracture is necessary to ensure the integrity of the structure. During the past few decades, fracture mechanics has become a necessary discipline for the solution of many structural problems. These problems include the prevention of failures resulting from preexisting cracks in the parent material, welds or that develop under cyclic loading environment during the life of the structure. The importance of fatigue and fracture in nuclear, pressure vessel, aircraft, and aerospace structural hardware cannot be overemphasized where safety is of utmost concern. This book is written for the designer and strength analyst, as well as for the material and process engineer who is concerned with the integrity of the structural hardware under load-varying environments in which fatigue and frac ture must be given special attention. The book is a result of years of both acade mic and industrial experiences that the principal author and co-authors have accumulated through their work with aircraft and aerospace structures.

Thematerialsusedinmanufacturingtheaerospace,aircraft,automobile,andnuclear parts have inherent aws that may grow under uctuating load environments during the operational phase of the structural hardware. The design philosophy, material selection, analysis approach, testing, quality control, inspection, and manufacturing are key elements that can contribute to failure prevention and assure a trouble-free structure. To have a robust structure, it must be designed to withstand the envir- mental load throughout its service life, even when the structure has pre-existing aws or when a part of the structure has already failed. If the design philosophy of the structure is based on the fail-safe requirements, or multiple load path design, partial failure of a structural component due to crack propagation is localized and safely contained or arrested. For that reason, proper inspection technique must be scheduled for reusable parts to detect the amount and rate of crack growth, and the possible need for repairing or replacement of the part. An example of a fail-sa- designed structure with crack-arrest feature, common to all aircraft structural parts, is the skin-stiffened design con guration. However, in other cases, the design p- losophy has safe-life or single load path feature, where analysts must demonstrate that parts have adequate life during their service operation and the possibility of catastrophic failure is remote. For example, all pressurized vessels that have single load path feature are classi ed as high-risk parts. During their service operation, these tanks may develop cracks, which will grow gradually in a stable manner.

In the preliminary stage of designing new structural hardware to perform a given mission in a fluctuating load environment, there are several factors that the designer should consider. Trade studies for different design configurations should be performed and, based on strength and weight considerations, among others, an optimum configuration selected. The selected design must withstand the environment in question without failure. Therefore, a comprehensive structural analysis that consists of static, dynamic, fatigue, and fracture is necessary to ensure the integrity of the structure. Engineers must also consider the feasibility of fabricating the structural hardware in the material selection process. During the past few decades, fracture mechanics has become a necessary discipline for the solution of many structural problems in which the survivability of structure containing pre-existing flaws is of great interest. These problems include structural failures resulting from cracks that are inherent in the material, or defects that are introduced in the part due to improper handling or rough machining, that must be assessed through fracture mechanics concepts.

What can be added to the fracture mechanics of metal fatigue that has not already been said since the 1900s? From the view point of the material and structure engineer, there are many aspects of failure by fatigue that are in need of attention, particularly when the size and time of the working components are changed by orders of magnitude from those considered by st traditional means. The 21 century marks an era of technology transition where structures are made larger and devices are made smaller, rendering the method of destructive testing unpractical. While health monitoring entered the field of science and engineering, the practitioners are discovering that the correlation between the signal and the location of interest depends on a priori knowledge of where failure may initiate. This information is not easy to find because the integrity of the physical system will change with time. Required is software that can self-adjust in time according to the monitored data. In this connection, effective application of health monitoring can use a predictive model of fatigue crack growth. Earlier fatigue crack growth models assumed functional dependence on the maximum stress and the size of the pre-existing crack or defect. Various possibilities were examined in the hope that the data could be grouped such that linear interpolation would apply.