Review of requirements for the durability and damage tolerance certification of additively manufactured aircraft structural parts and AM repairs

Sudip Kundu, Rhys Jones, Daren Peng, Neil Matthews, Alankar Alankar, Singh R.K. Raman, Pu Huang

Research output: Contribution to journalArticleResearchpeer-review

2 Citations (Scopus)

Abstract

The USAF requirements for the durability and damage tolerance certification for additively manufactured (AM) aircraft structural parts, which are detailed in Structures Bulletin EZ-19-01, raise a number of new and, as yet, unanswered questions. The present paper attempts to address three questions: How to perform a fracture mechanics-based analysis of crack growth in an AM part so as to account for the residual stresses, how to perform a fracture mechanics-based durability analysis of a cold spray repair so as to account for both the induced residual stresses and the presence of multiple co-located cracks, and how to perform a fracture mechanics-based durability analysis of an AM part so as to account for the presence of multiple collocated surface braking cracks. In this context, the present paper reveals the potential of the Hartman-Schijve variant of the NASGRO crack growth equation to accurately predict the growth of each of the individual (collocated) cracks that arose in a cold spray-repaired specimen and in a specimen from a crack that nucleated and grew from a rough surface.

Original languageEnglish
Article number1341
Number of pages28
JournalMaterials
Volume13
Issue number6
DOIs
Publication statusPublished - 1 Mar 2020

Keywords

  • Additive manufacturing
  • Cold spray
  • Friction stir welding
  • Laser shock peening
  • Multiple collocated cracks
  • Residual stress

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