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    A380 WING RIB Feet Cracking

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    gygjhkjnl
    There were two types of cracks found in the A380 wing ribs. Type 1 cracks were intergranular fractures in the 7449 material of the rib feet driven by build stresses during assembly. Type 2 cracks were fatigue driven fractures located at rib manholes that were caused by the difference in thermal expansion between the composite rib webs and aluminum alloy rib feet, generating out-of-plane deformations and overstressing. Solutions included temporary repairs by replacing cracked rib sections and a final fix by replacing all hybrid ribs with metallic ribs and adding stiffeners to address the thermal issues.

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    A380 WING RIB Feet Cracking

    Uploaded by

    gygjhkjnl
    1K views9 pages
    There were two types of cracks found in the A380 wing ribs. Type 1 cracks were intergranular fractures in the 7449 material of the rib feet driven by build stresses during assembly. Type 2 cracks were fatigue driven fractures located at rib manholes that were caused by the difference in thermal expansion between the composite rib webs and aluminum alloy rib feet, generating out-of-plane deformations and overstressing. Solutions included temporary repairs by replacing cracked rib sections and a final fix by replacing all hybrid ribs with metallic ribs and adding stiffeners to address the thermal issues.

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    RIB Feet Cracking

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    There were two types of cracks found in the A380 wing ribs. Type 1 cracks were intergranular fractures in the 7449 material of the rib feet driven by build stresses during assembly. Type 2 cracks were fatigue driven fractures located at rib manholes that were caused by the difference in thermal expansion between the composite rib webs and aluminum alloy rib feet, generating out-of-plane deformations and overstressing. Solutions included temporary repairs by replacing cracked rib sections and a final fix by replacing all hybrid ribs with metallic ribs and adding stiffeners to address the thermal issues.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    1K views9 pages

    A380 WING RIB Feet Cracking

    Uploaded by

    gygjhkjnl
    There were two types of cracks found in the A380 wing ribs. Type 1 cracks were intergranular fractures in the 7449 material of the rib feet driven by build stresses during assembly. Type 2 cracks were fatigue driven fractures located at rib manholes that were caused by the difference in thermal expansion between the composite rib webs and aluminum alloy rib feet, generating out-of-plane deformations and overstressing. Solutions included temporary repairs by replacing cracked rib sections and a final fix by replacing all hybrid ribs with metallic ribs and adding stiffeners to address the thermal issues.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 9

    A380 WING RIB BOOM

    CRACK ROOT CAUSES


    &
    CHANGES
    MENU

    EXIT
    1

    GENERAL
    A380 has 3 main types of rib:
    Metallic 7449, Metallic 7010,
    Composite Rib Web with metallic 7449 rib feet
    Cracking found primarily on hybrid composite/metallic rib booms and some all metallic ribs.
    All affected metallic structure made out of 7449

    3 main types of Ribs, Metallic 7449, 7010, Hybrid (CFRP web +


    metallic 7449 foot boom),
    Cracking : mainly on hybrid ribs booms + metallic 7449 rib .
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    2

    TYPE OF CRACKS FOUND


    Two types of cracks identified.

    TYPE 1 CRACKS

    INTERGRANULAR FRACTURE
    (quasi-static failure)

    FATIGUE DRIVEN FRACTURE

    Reported: End September 2011

    Reported: End January 2012

    MEDIUM TERM SIGNIFICANCE

    TYPE 2 CRACKS

    SHORT TERM SIGNIFICANCE

    Two types of cracks identified with different mechanisms and


    significance. Type 1 cracks starting from rib foot/stringer/skin
    fasteners holes. Type 2 cracks located in the rib foot vertical web.
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    3

    TYPE 1 CRACKS
    INTERGRANULAR FRACTURE
    (quasi-static failure)

    All findings are on ribs/rib feet made from 7449 material.


    The majority (77%) are on the top skin
    The majority (over 90%) are on hybrid booms
    Cracks are driven by:
    . A high installed build stress loading generating static overload failure once combined
    with a certain level of operational loading,
    . 7449 material properties in the S-L direction.

    Type 1 cracks origin:


    essentially to material properties (7449) , combined with stresses
    generated during assembly (interference fit installation to wing
    skin/stringer).
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    4

    TYPE 2 CRACKS
    FATIGUE DRIVEN FRACTURE

    The majority of cracks appear on ribs 24,26 & 29 between stringer 17 and 25. A smaller number
    appear on rib 25 in the same area.

    Strong correlation between crack findings and rib manhole locations in ribs.

    Some detail features on rib feet act as stress concentrators.

    Following inspection results, the majority of crack appears at ribs


    24 to 29 mainly at manhole areas.
    Two origins have been identified: gaps at rib installation and out of
    plane deformation due to thermal loading.
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    5

    TYPE 2 CRACKS

    Root Causes Thermal effects on Hybrid ribs

    The thermal effects have been established throughout the whole wing:
    Hybrid Ribs

    CFRP
    rib
    web

    Aluminum Alloy
    Rib Feet / skin/stgr

    Difference in Thermal
    Expansion Coefficient
    Out of Plane Deformations
    Over stresses in Rib Foot
    Cracking
    (type 2)

    The difference in thermal expansion coefficient in between CFRP


    rib web and aluminum alloy rib foot generates out of plane
    deformations. This results in an over stressing of the rib foot leading
    to type 2 cracks.
    MENU

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    6

    TYPE 2 CRACKS

    Root Causes Thermal effects on Hybrid ribs

    The thermal effects on hybrid ribs explain why the Type 2 cracks
    are mainly concentrated under the manhole in the rib.

    MENU

    EXIT
    7

    SOLUTIONS
    TEMPORARY FIX

    FINAL FIX

    AD (Airworthiness Directive)
    Standard Repair

    Start end 2012

    Replace center section of Rib


    Boom for ribs 24, 25, 26, 27, 29.

    Replace all Rib booms


    Upper/Lower for Hybrid
    Ribs (23 ribs per wing)

    Repair boom sections made


    from 7010 material.

    SERIAL SOLUTION
    Hybrid ribs
    changed to Metallic

    New Metallic Rib 24

    Replace metallic Ribs 48, 49

    Manage a gap of +/- 0.2mm.


    Hybrid Rib 24
    Interference fit fasteners

    Install additional CFRP


    Stiffeners at Rib web
    (manholes)

    7449 Metallic Ribs


    changed to 7010

    TEXT

    MENU

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    8

    MENU

    General
    Type of cracks found
    Type 1 cracks
    Type 2 cracks
    Solutions

    EXIT
    9

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