EDWARD KATS & ASSOCIATES 511 South Maria Avenue …1 T. Swift FAA-AIR-90-01 “Repairs to Damage Tolerant Aircraft.”, Structural Integrity of Aging Airplanes, Springer Verlag Berlin

EDWARD KATS & ASSOCIATES 511 South Maria Avenue

Redondo Beach, CA 90277 (310) 344-0081

MODEL: 737-400 DOCUMENT NO.: EAK-15-507-DT REVISION: NC DATE: 11-02-2015

Prepared By: Edward Kats Date: 11-02-2015

Checked By: Ricardo Fernandez Date: 11-02-2015

Approved By: Edward Kats Date: 11-02-2015

DAMAGE TOLERANCE EVALUATION

FUSELAGE ANTENNAS INSTALLATION

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DOCUMENT NO.EAK-15-507-DT

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Damage Tolerance Evaluation Fuselage Antennas Installation

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EDWARD KATS & ASSOCIATES

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i NC ii NC iii NC iv NC

1-68 NC A1-A70 NC

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REVISION RECORD

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APPROVAL

NC Initial Release 11/02/15 E. Kats

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TABLE OF CONTENTS SECTION / TITLE PAGE Title Page ......................................................................................................... - List of Active Pages .................................................................................................. i Revisions Record ...................................................................................................... ii Table of Contents .................................................................................................... iii References .............................................................................................................. iv 1.0 Introduction ....................................................................................................... 1 1.1 Summary of Results ................................................................................. 1 2.0 Antennae Installation ........................................................................................ 2

2.1 Damage Tolerance Evaluation ................................................................. 9 2.1.1 Fastener Load Definition and Durability Analysis ...................... 9

3.0 TCAS Antenna Installation ................................................................................ 10 3.1 Transponder Antenna Installation ............................................................ 24 3.2 GPS Antenna Installation (original skin .................................................... 39

4.0 Residual Strength Evaluation ............................................................................ 58 5.0 Inspection Requirements .................................................................................. 59

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REFERENCES

1 T. Swift FAA-AIR-90-01 “Repairs to Damage Tolerant Aircraft.”, Structural Integrity of Aging Airplanes, Springer Verlag Berlin Heidelberg, 1991

2 EO1668 Cargo Door Surround Skin - Existing Antenna Relocation, Outside STC with Dual GPS Configuration, dated 08/14/2014

3 FAR 25.571 “Federal Aviation Regulations, Part 25 - Airworthiness Standards: Transport Category Airplanes.”

4 WL-TR-94-4054 “Damage Tolerance Design Handbook”

5 D. J. Hagemaier “Maintenance Engineering Plan, Nondestructive Inspection”

6 R. J. Roark &

W. C. Young

“Formulas for Stress and Strain”, Fifth edition

7 D. P. Rooke &

D. J. Cartwright

“Compendium of Stress Intensity Factors”

8 D6-82669 Supplemental Structural Inspection Document Models 737-

300/400/500 Airplanes

9 2799 SUBSTANTIATION OF AEI BOEING 737-300, -400

TRANSPONDER, GPS AND TCAS ANTENNA INSTALLATION, RevC, Dated 4/25/2013

10 R-816, revision J Supplemental Structural Inspection Document For Boeing Model

737-400 Airplane With Cargo Conversion Modification

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1.0 INTRODUCTION This report presents the damage tolerance evaluation of 1. TCAS Antenna Doubler, FS370 between S-2L and S-1 3” Hole w/ external doubler (.080 2024-T3), external mounting plate 2. ATC L-band Antenna Doubler, FS427 between S-2L and S-1 (Ref AMM 34-53-11) 1” Hole w/ external doubler (.080 2024-T3), internal mounting plate. 3. GPS 1 Antenna, FS500D+5.0 between S-2R and S-1, GPS 2 Antenna, FS500D+15.0 between S-1 and S-2L, 2” Hole with external doubler (.081 2024-T3), and internal mounting plate on AEI 737-400 aircraft. Installation of the repair is performed per Engineering Order 1670A (Reference 2). Static Strength of these installations is evaluated under separate cover. Certification basis of 737-400 aircraft is has been brought up to the damage tolerance requirements by virtue of Supplemental Structural Inspection Document (SSID) release. In addition, it is a requirement to perform damage tolerance assessment of the repairs to the pressure shell of the aircraft 1.1 SUMMARY OF RESULTS The results of the damage tolerance evaluation presented in this report show that damage tolerance requirements are met and there are supplemental inspections in addition to existing fuselage inspections.

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2.0 ANTENNAE INSTALLATION Antennae are relocated due to the cargo conversion of the aircraft performed per STC ST01827LA As A part of the main cargo door installation, the existing aircraft skin from FS360 to FS540 and from S-2R to S-22L is repalced with new 0.080 inch thick 2024-T3 Clad skins, installed per AEI drawing AE6203. Antennae had to be relocated as shown below.

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2.1 DAMAGE TOLERANCE EVALUATION 2.1.1 FASTENER LOAD DEFINITION & DURABILITY ANALYSIS

In general, any structural modification or repair to an airframe can substantially degrade

durability and damage tolerance characteristics unless extreme care in design detail is taken. In case there is a doubler installed on the skin, there will be load transfer out of the skin into the doubler due to strain compatibility between the two pieces. The highest fastener loads, induced from the skin into the doubler, typically will occur at the first row of attachments between the skin and a doubler.

This phenomenon can be illustrated as follows: The gross stress in the skin is unchanged in a presence of a doubler, however now bearing

stress in the hole is introduced which will degrade both fatigue life and crack propagation life. The higher the ratio of bearing stress to gross stress is, the lower fatigue life will be. The fastener loads in a doubler to skin attachments are typically determined through a displacement compatibility analysis.

It can be stated that under the same loading a skin-doubler structural configuration with the highest bearing stress to gross stress ratio will be the most critical from the durability and damage tolerance viewpoint. Tom Swift presents results of the compatibility analysis for several types of skin-doubler combinations in his article “Repairs to Damage Tolerant Aircraft” (Reference 1).

bypass stress

bearing stress

gross stress

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3.0 TCAS ANTENNA INSTALLATION

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The TCAS antenna is located on the top just left of the centerline between FS 360.0 and FS 380.0. The external doubler reinforces the 3.00" diameter hole drilled in the fuselage skin for the antenna connector. The doubler is .080 inch thick 2024-T3 clad aluminum. The .036 inch thick fuselage bonded skin was replaced by .080 inch thick 2024-T3 aluminum to accommodate the installation of a cargo door. The Antenna and doubler attach to this new .080 inch thick 2024-T3 skin. The doubler is riveted to the skin with NAS1097AD6 rivets

Stress for this location are obtained from Reference 9

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It needs to be pointed out that limit stress for pressure only (condition 1) includes 1.33 factor that is not required for damage tolerance evaluations. Therefore hoghes stress is for condition 6 (Down Bending + Pressure) in the longitudinal direction Stress = 8909 psi (limt) For this analysis conservatively limit load is utilized for GAG once per flight load Stress = 8.909 ksi, R=0.0 GAG cycle LIMIT = 8.909 ksi .

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CRACK GROWTH ANALYSIS

Critical flaw Location C=0.05 inch

Crack Path

Fuselage skin (0.160 inch)

Rivet hole

Initial Flaw (0.050 inch) Through flaw

Adjacent hole

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The critical location would be at the first row of attachments between fuselage skin and splice doubler. The doubler is attached to the aircraft skin by 0.186 inch diameter aluminum rivets NAS1097AD6 Two stages of crack growth are considered STAGE I Crack growing from the hole and linking with the adjacent hole. The correction for the crack growing toward the adjacent holes is derived from Rooke & Cartwright (Reference 6).

Fastener pitch = 1.00 inches D=0.186 inch First attachment load per 1 ksi gross stress = 21 lbs (skin/doubler configuration) (Ref. 1, Figure 7) (3/16 inch diameter aluminum fastener data). Total first attachment load = (8.909)(21)(1.00) Total first attachment load = 187 lbs Bearing Stress = 187 / (0.186*0.080) Bearing Stress = 12.573 ksi Total crack length possible in Stage I is (1.00-.186) = 0.814 inch

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STAGE II Continuing damage crack growth of initial crack, following linkup. The secondary 0.005 inch flaw will be grown during stage I crack growth and added to the initial crack size of Stage II.

Fastener pitch = 1.00 inches AFGROW 5.01.06.17 crack propagation program is used for crack growth analysis. Crack growth model utilized in this analysis : Non-Interaction Equation/Table : NASGRO Equation Retardation is not used for purposes of this analysis. The stress relieving effects of the stiffeners are ignored in this analysis Results of crack growth analysis for crack growth are presented in appendix A. da/dN data is obtained from the NASGRO material database Fastener spacing is 1.00 inch bypass = ((8.909-12.573(0.186/1.00)) = 6.57 ksi total = (6.57 + 12.573(0.186/1.00)) = 8.909 ksi (AFGROW required parameter) Bearing stress fraction = (12.573)/8.909 = 1.411 bypass stress fraction = (6.57/8.909) = 0.737

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STAGE I Beta correction for the flaw growing toward the adjacent hole (Reference 8, Fig 110)

Crack length c Beta 0.005 1.01 0.10 1.012 0.20 1.04 0.30 1.06 0.40 1.07 0.60 1.10 0.70 1.13 0.814 1.19

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STAGE I Crack growth Crack starts from the 0.05 inch flaw and links up with the adjacent hole at 910600 flights STAGE II Crack growth Crack starts from the total length of 1.46 inch (Half length of 0.73 inch) flaw and becomes unstable at flights At this point it would be considered an overall failure (Conservative, since crack arresting capability of the frames is ignored) Total life = 987341 flights (crack growth)

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Stage I Crack Growth Title: 737 TCAS Antenna Stage I

Spectrum title: Constant amplitude loading

2020 <‐‐‐ crack geometry code: Single Through Crack at Hole ‐ Standard Solution

Cycles C Length Beta C Sb. Spectrum

Pass Life

0 0.005 3.278313 1 1 0

108000 0.025027 2.170056 1081 1081 108000

167400 0.045033 1.668841 1675 1675 167400

224400 0.065068 1.405154 2245 2245 224400

282100 0.085097 1.212113 2822 2822 282100

339100 0.105108 1.104672 3392 3392 339100

394300 0.125143 1.016084 3944 3944 394300

446300 0.145152 0.96065 4464 4464 446300

494600 0.165166 0.929554 4947 4947 494600

539200 0.18519 0.887378 5393 5393 539200

580400 0.205225 0.86195 5805 5805 580400

618500 0.225245 0.837489 6186 6186 618500

653900 0.245259 0.826378 6540 6540 653900

686900 0.265262 0.806015 6870 6870 686900

717400 0.285262 0.787507 7175 7175 717400

746100 0.305335 0.778943 7462 7462 746100

772800 0.325381 0.769976 7729 7729 772800

797800 0.345386 0.761329 7979 7979 797800

821500 0.365469 0.74536 8216 8216 821500

843800 0.385512 0.738023 8439 8439 843800

864800 0.405533 0.731091 8649 8649 864800

884600 0.42554 0.725167 8847 8847 884600

903300 0.445595 0.71993 9034 9034 903300

920900 0.465629 0.715051 9210 9210 920900

937600 0.48574 0.715051 9377 9377 937600

953400 0.505856 0.710522 9535 9535 953400

968300 0.525928 0.706331 9684 9684 968300

982400 0.546021 0.70277 9825 9825 982400

995700 0.566061 0.699558 9958 9958 995700

1008400 0.586168 0.699558 10085 10085 1008400

1020400 0.606211 0.696686 10205 10205 1020400

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1031800 0.626335 0.696313 10319 10319 1031800

1042500 0.646339 0.696313 10426 10426 1042500

1052600 0.666374 0.697024 10527 10527 1052600

1062200 0.686535 0.697024 10623 10623 1062200

1071200 0.706616 0.69833 10713 10713 1071200

1079700 0.726727 0.70307 10798 10798 1079700

1087600 0.746761 0.70307 10877 10877 1087600

1095000 0.766799 0.710257 10951 10951 1095000

1101900 0.786816 0.710257 11020 11020 1101900

1108400 0.807012 0.718066 11085 11085 1108400

1110600 0.814196 0.718066 11107 11107 1110600

Stage II Crack Growth Title: 737 TCAS Antenna Stage II


2010 <‐‐‐ crack geometry code: Internal Through Crack ‐ Standard Solution


Pass Total Life

0 0.73 1.000789 1 1 910600

5200 0.780307 1.000872 53 53 915800

9800 0.830435 1.000962 99 99 920400

14000 0.88168 1.001063 141 141 924600

17700 0.931921 1.001173 178 178 928300

21100 0.983 1.001433 212 212 931700

24200 1.034325 1.001581 243 243 934800

27000 1.085169 1.001747 271 271 937600

29600 1.136749 1.001747 297 297 940200

32000 1.188611 1.001931 321 321 942600

34200 1.240215 1.002137 343 343 944800

36200 1.290933 1.002357 363 363 946800

38100 1.342882 1.0026 382 382 948700

39900 1.395886 1.002869 400 400 950500

41500 1.446463 1.002869 416 416 952100

43000 1.497163 1.003166 431 431 953600

44400 1.547642 1.003494 445 445 955000

45800 1.601499 1.003494 459 459 956400

47100 1.654855 1.003873 472 472 957700

48300 1.707232 1.004293 484 484 958900

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49400 1.758171 1.004293 495 495 960000

50500 1.812145 1.004757 506 506 961100

51500 1.864096 1.004757 516 516 962100

52500 1.919066 1.005269 526 526 963100

53400 1.97131 1.005269 535 535 964000

54300 2.026484 1.005832 544 544 964900

55100 2.078111 1.006447 552 552 965700

55900 2.132488 1.006447 560 560 966500

56700 2.189724 1.007117 568 568 967300

57400 2.242444 1.007117 575 575 968000

58100 2.297706 1.007898 582 582 968700

58800 2.355886 1.007898 589 589 969400

59400 2.40811 1.007898 595 595 970000

60000 2.462822 1.008749 601 601 970600

60600 2.52008 1.008749 607 607 971200

61200 2.580187 1.009673 613 613 971800

61700 2.632562 1.009673 618 618 972300

62200 2.687147 1.010754 623 623 972800

62700 2.74424 1.010754 628 628 973300

63200 2.803818 1.010754 633 633 973800

63700 2.866291 1.011929 638 638 974300

64100 2.918376 1.011929 642 642 974700

64500 2.97248 1.013191 646 646 975100

64900 3.028872 1.013191 650 650 975500

65300 3.087483 1.013191 654 654 975900

65700 3.148639 1.014676 658 658 976300

66100 3.212518 1.014676 662 662 976700

66500 3.279113 1.016271 666 666 977100

66800 3.331296 1.016271 669 669 977400

67100 3.385223 1.016271 672 672 977700

67400 3.440988 1.016271 675 675 978000

67700 3.498997 1.018162 678 678 978300

68000 3.559237 1.018162 681 681 978600

68300 3.621685 1.018162 684 684 978900

68600 3.686841 1.020189 687 687 979200

68900 3.754704 1.020189 690 690 979500

69200 3.825259 1.022324 693 693 979800

69500 3.899349 1.022324 696 696 980100

69700 3.950463 1.022324 698 698 980300

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69900 4.003029 1.022324 700 700 980500

70100 4.057406 1.024861 702 702 980700

70300 4.113696 1.024861 704 704 980900

70500 4.171695 1.024861 706 706 981100

70700 4.23149 1.027509 708 708 981300

70900 4.293878 1.027509 710 710 981500

71100 4.358303 1.027509 712 712 981700

71300 4.424879 1.027509 714 714 981900

71500 4.494202 1.030676 716 716 982100

71700 4.566455 1.030676 718 718 982300

71900 4.64133 1.030676 720 720 982500

72100 4.718988 1.034534 722 722 982700

72300 4.800987 1.034534 724 724 982900

72500 4.886258 1.034534 726 726 983100

72700 4.975024 1.03859 728 728 983300

72900 5.069226 1.03859 730 730 983500

73100 5.167607 1.03859 732 732 983700

73200 5.218464 1.03859 733 733 983800

73300 5.270491 1.043595 734 734 983900

73400 5.324943 1.043595 735 735 984000

73500 5.380723 1.043595 736 736 984100

73600 5.437887 1.043595 737 737 984200

73700 5.496494 1.043595 738 738 984300

73800 5.55661 1.048787 739 739 984400

73900 5.619781 1.048787 740 740 984500

74000 5.684686 1.048787 741 741 984600

74100 5.751412 1.048787 742 742 984700

74200 5.820047 1.048787 743 743 984800

74300 5.890689 1.055294 744 744 984900

74400 5.965684 1.055294 745 745 985000

74500 6.043055 1.055294 746 746 985100

74600 6.122939 1.055294 747 747 985200

74700 6.205482 1.061883 748 748 985300

74800 6.29357 1.061883 749 749 985400

74900 6.384866 1.061883 750 750 985500

75000 6.479587 1.061883 751 751 985600

75100 6.577969 1.070281 752 752 985700

75200 6.684576 1.070281 753 753 985800

75300 6.795802 1.070281 754 754 985900

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75400 6.912021 1.078397 755 755 986000

75500 7.038746 1.078397 756 756 986100

75600 7.171941 1.078397 757 757 986200

75700 7.312241 1.088891 758 758 986300

75800 7.468775 1.088891 759 759 986400

75900 7.635178 1.088891 760 760 986500

76000 7.812694 1.103277 761 761 986600

76100 8.018662 1.103277 762 762 986700

76200 8.24205 1.11683 763 763 986800

76300 8.506348 1.11683 764 764 986900

76400 8.800479 1.136292 765 765 987000

76500 9.177075 1.136292 766 766 987100

76600 9.62057 1.169114 767 767 987200

76669 10.10825 1.191365 767 767 987269

76700 10.46958 1.191365 768 768 987300

76735 10.99536 1.238035 768 768 987335

76741 11.56773 1.273146 768 768 987341

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3.1 TRANSPONDER ANTENNA INSTALLATION

External Doubler (2024-T3, t = .080")

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The Transponder antenna weighs 4 oz and is mounted to the top just left of the centerline with 4, #10-32 screws between FS 420.0 and FS 440.0. The external doubler reinforces the 1.00" diameter hole drilled in the fuselage skin for the antenna connector. The doubler is .080 inch thick 2024-T3 clad aluminum. The doubler is riveted to the skin with NAS1097AD6 rivets. Stress for this location are obtained from Reference 9.

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It needs to be pointed out that limit stress for pressure only (condition 1) includes 1.33 factor that is not required for damage tolerance evaluations. Therefore hoghes stress is for condition 6 (Down Bending + Pressure) in the longitudinal direction Stress = 9315 psi (limt) For this analysis conservatively limit load is utilized for GAG once per flight load Stress = 9.315 ksi, R=0.0 GAG cycle

LIMIT = 9.315 ksi .

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Crack Path


Rivet hole


Adjacent hole

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Fastener pitch = 1.00 inches AFGROW 5.01.06.17 crack propagation program is used for crack growth analysis. Crack growth model utilized in this analysis : Non-Interaction Equation/Table : NASGRO Equation Retardation is not used for purposes of this analysis. The stress relieving effects of the stiffeners are ignored in this analysis Results of crack growth analysis for crack growth are presented in appendix A. da/dN data is obtained from the NASGRO material database Fastener spacing is 1.00 inch

bypass = ((9.315-13.146(0.186/1.00)) = 6.869 ksi

total = (6.869 + 13.146(0.186/1.00)) = 9.315 ksi (AFGROW required parameter) Bearing stress fraction = (13.146)/9.315 = 1.411 bypass stress fraction = (6.869/9.315) = 0.737

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STAGE I Crack growth Crack starts from the 0.05 inch flaw and links up with the adjacent hole at 776900 flights STAGE II Crack growth Crack starts from the total length of 1.47 inch (Half length of 0.735 inch) flaw and becomes unstable at flights At this point it would be considered an overall failure (Conservative, since crack arresting capability of the frames is ignored) Total life = 840871 flights (crack growth)

REVISION

NC


PAGE NO.

33

PREPARED BY E. Kats

11/02/15 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


Stage I Crack Growth Title: 737 Transponder Antenna Stage I




Pass Life

0 0.005 3.278313 1 1 0

90100 0.025002 2.166665 902 902 90100

140100 0.04502 1.664313 1402 1402 140100

188100 0.065055 1.401263 1882 1882 188100

236600 0.085091 1.20856 2367 2367 236600

284600 0.105108 1.101489 2847 2847 284600

331000 0.125149 1.013459 3311 3311 331000

374800 0.145164 0.958558 3749 3749 374800

415600 0.165195 0.927569 4157 4157 415600

453100 0.185212 0.885617 4532 4532 453100

487900 0.205267 0.860274 4880 4880 487900

520100 0.225322 0.835958 5202 5202 520100

550100 0.245359 0.824956 5502 5502 550100

578000 0.265417 0.804647 5781 5781 578000

603800 0.285422 0.795229 6039 6039 603800

628000 0.305476 0.777716 6281 6281 628000

650600 0.325519 0.768725 6507 6507 650600

671800 0.345555 0.76015 6719 6719 671800

691800 0.365638 0.751971 6919 6919 691800

710700 0.385731 0.736961 7108 7108 710700

728500 0.405776 0.730174 7286 7286 728500

745300 0.42583 0.72435 7454 7454 745300

761100 0.445848 0.719145 7612 7612 761100

776100 0.465965 0.719145 7762 7762 776100

790200 0.485994 0.714314 7903 7903 790200

803600 0.506147 0.709844 8037 8037 803600

816200 0.526194 0.705753 8163 8163 816200

828100 0.546213 0.702265 8282 8282 828100

839400 0.566261 0.702265 8395 8395 839400

850200 0.58643 0.699099 8503 8503 850200

860400 0.606543 0.696271 8605 8605 860400

870100 0.626703 0.696271 8702 8702 870100

REVISION

NC


PAGE NO.

34

PREPARED BY E. Kats

11/02/15 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


879200 0.646778 0.696391 8793 8793 879200

887800 0.666897 0.697197 8879 8879 887800

895900 0.686979 0.697197 8960 8960 895900

903600 0.707233 0.698569 9037 9037 903600

910900 0.727518 0.704173 9110 9110 910900

917600 0.747685 0.704173 9177 9177 917600

923900 0.767753 0.711453 9240 9240 923900

929800 0.788083 0.711453 9299 9299 929800

935300 0.808187 0.719376 9354 9354 935300

936900 0.814389 0.719376 9370 9370 936900

Stage II Crack Growth Title: 737 Transponder Antenna Stage II


2010 <‐‐‐ crack geometry code: Internal Through Crack ‐ Standard Solution


Pass Total Life

0 0.735 1.0008 1 1 776900

4400 0.785801 1.000884 45 45 781300

8300 0.836561 1.000978 84 84 785200

11800 0.887564 1.001079 119 119 788700

14900 0.937805 1.001192 150 150 791800

17700 0.987953 1.001318 178 178 794600

20300 1.039214 1.001458 204 204 797200

22700 1.091153 1.001614 228 228 799600

24900 1.143234 1.001781 250 250 801800

26900 1.194812 1.001965 270 270 803800

28700 1.245139 1.002167 288 288 805600

30400 1.296498 1.002401 305 305 807300

32000 1.348651 1.002661 321 321 808900

33500 1.401314 1.002661 336 336 810400

34900 1.454151 1.002948 350 350 811800

36200 1.506752 1.003265 363 363 813100

37400 1.558657 1.003613 375 375 814300

38500 1.609393 1.003613 386 386 815400

39600 1.663425 1.003994 397 397 816500

40600 1.715694 1.003994 407 407 817500

41600 1.7713 1.00441 417 417 818500

42500 1.824431 1.004893 426 426 819400

REVISION

NC


PAGE NO.

35

PREPARED BY E. Kats

11/02/15 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


43400 1.880818 1.004893 435 435 820300

44200 1.933907 1.005421 443 443 821100

45000 1.990049 1.005421 451 451 821900

45700 2.041929 1.005995 458 458 822600

46400 2.096556 1.005995 465 465 823300

47100 2.154235 1.006666 472 472 824000

47700 2.206254 1.006666 478 478 824600

48300 2.260915 1.007395 484 484 825200

48900 2.318376 1.007395 490 490 825800

49400 2.368615 1.008181 495 495 826300

49900 2.42113 1.008181 500 500 826800

50400 2.476061 1.009103 505 505 827300

50900 2.533712 1.009103 510 510 827800

51400 2.594119 1.010097 515 515 828300

51800 2.644775 1.010097 519 519 828700

52200 2.697466 1.010097 523 523 829100

52600 2.752444 1.011155 527 527 829500

53000 2.809867 1.011155 531 531 829900

53400 2.869782 1.012396 535 535 830300

53800 2.932684 1.012396 539 539 830700

54200 2.998478 1.012396 543 543 831100

54500 3.050037 1.013711 546 546 831400

54800 3.103554 1.013711 549 549 831700

55100 3.15905 1.013711 552 552 832000

55400 3.216894 1.015262 555 555 832300

55700 3.277116 1.015262 558 558 832600

56000 3.339741 1.016892 561 561 832900

56300 3.405376 1.016892 564 564 833200

56600 3.473786 1.016892 567 567 833500

56900 3.545359 1.018825 570 570 833800

57200 3.620545 1.018825 573 573 834100

57400 3.672587 1.018825 575 575 834300

57600 3.726484 1.020835 577 577 834500

57800 3.782344 1.020835 579 579 834700

58000 3.840038 1.020835 581 581 834900

58200 3.899665 1.023229 583 583 835100

58400 3.961975 1.023229 585 585 835300

58600 4.026492 1.023229 587 587 835500

58800 4.09335 1.023229 589 589 835700

REVISION

NC


PAGE NO.

36

PREPARED BY E. Kats

11/02/15 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


59000 4.163132 1.026127 591 591 835900

59200 4.236049 1.026127 593 593 836100

59400 4.311855 1.026127 595 595 836300

59600 4.391276 1.029147 597 597 836500

59800 4.474599 1.029147 599 599 836700

60000 4.561566 1.029147 601 601 836900

60200 4.653211 1.032833 603 603 837100

60400 4.749955 1.032833 605 605 837300

60500 4.800081 1.032833 606 606 837400

60600 4.851441 1.0366 607 607 837500

60700 4.904988 1.0366 608 608 837600

60800 4.959927 1.0366 609 609 837700

60900 5.016322 1.0366 610 610 837800

61000 5.074239 1.0366 611 611 837900

61100 5.13375 1.041235 612 612 838000

61200 5.196248 1.041235 613 613 838100

61300 5.260583 1.041235 614 614 838200

61400 5.32685 1.041235 615 615 838300

61500 5.395151 1.045815 616 616 838400

61600 5.467123 1.045815 617 617 838500

61700 5.541469 1.045815 618 618 838600

61800 5.618329 1.045815 619 619 838700

61900 5.697858 1.051478 620 620 838800

62000 5.782482 1.051478 621 621 838900

62100 5.87031 1.051478 622 622 839000

62200 5.961564 1.051478 623 623 839100

62300 6.056488 1.058707 624 624 839200

62400 6.158937 1.058707 625 625 839300

62500 6.265982 1.058707 626 626 839400

62600 6.378011 1.06569 627 627 839500

62700 6.499689 1.06569 628 628 839600

62800 6.627775 1.06569 629 629 839700

62900 6.762918 1.074704 630 630 839800

63000 6.912819 1.074704 631 631 839900

63100 7.072407 1.074704 632 632 840000

63200 7.242925 1.087011 633 633 840100

63300 7.438865 1.087011 634 634 840200

63400 7.65157 1.098485 635 635 840300

63500 7.900369 1.098485 636 636 840400

REVISION

NC


PAGE NO.

37

PREPARED BY E. Kats

11/02/15 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


63600 8.177061 1.114703 637 637 840500

63700 8.523175 1.114703 638 638 840600

63800 8.927815 1.141042 639 639 840700

63875 9.377425 1.158814 639 639 840775

63900 9.603247 1.158814 640 640 840800

63947 10.09259 1.190616 640 640 840847

63968 10.59887 1.216108 640 640 840868

63971 11.28335 1.25516 640 640 840871

REVISION

NC


PAGE NO.

38

PREPARED BY E. Kats

11/02/15 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


3.2 GPS ANTENNA INSTALLATION (GPS 1 & 2)

Installations are the same performed in different fuselage bays.

REVISION

NC


PAGE NO.

39

PREPARED BY E. Kats

11/02/15 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


REVISION

NC


PAGE NO.

40

PREPARED BY E. Kats

11/02/15 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


The GPS antenna weighs less than a pound and is mounted to the top just right and left of the centerline with 4, #10-32 screws. The external doubler reinforces the 2.0" diameter hole drilled in the fuselage skin for the antenna connector for the 737-400 aircraft. The doubler is .080 inch thick 2024-T3 clad aluminum. The doubler is riveted to the skin with NAS1097AD6 rivets. Stress for this location are obtained from Reference 9 (Element 11033 and 11034)

GPS 1 & 2 antennae Location

REVISION

NC


PAGE NO.

41

PREPARED BY E. Kats

11/02/15 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


AEI 737‐400 Converted Freighter

Fuselage Skin Panel Stresses, Bet. S‐2L to S‐2R

OUTPUT SET 1 ‐ Pressure Only 17.3 psi

Elem PRINCIPAL STRESSES (ZERO SHEAR)

ID FIBRE DIST NORMAL‐X NORMAL‐Y SHEAR‐XY ANGLE MAJOR MINOR VON MISES

40 BOT ‐0.09 5002 5777 5467 47.03 10870 ‐92 10916

TOP 0.09 4648 5553 5572 47.32 10691 ‐490 10944

71 BOT ‐0.09 9764 9269 ‐5073 ‐43.60 14595 4438 12959

TOP 0.09 9271 8665 ‐5309 ‐43.37 14285 3650 12855

10622 BOT ‐0.02 25802 14455 635 3.19 25837 14420 22426

TOP 0.02 25639 14168 616 3.07 25672 14135 22271

10623 BOT ‐0.02 16741 11049 433 4.33 16774 11016 14762

TOP 0.02 16660 10797 371 3.60 16683 10774 14651

10628 BOT ‐0.02 26744 15098 ‐1107 ‐5.38 26849 14994 23305

TOP 0.02 26628 15023 ‐1201 ‐5.85 26751 14900 23217

10629 BOT ‐0.02 21863 13148 ‐2299 ‐13.91 22433 12579 19475

TOP 0.02 21851 13032 ‐2347 ‐14.01 22437 12446 19470

11031 BOT ‐0.02 26045 15740 ‐751 ‐4.15 26100 15685 22756

TOP 0.02 26020 15698 ‐762 ‐4.20 26076 15642 22732

11032 BOT ‐0.02 25935 16841 ‐878 ‐5.46 26019 16757 22843

TOP 0.02 25908 16791 ‐889 ‐5.52 25994 16705 22814

11033 BOT ‐0.02 26584 18108 ‐987 ‐6.55 26697 17995 23583

TOP 0.02 26575 18072 ‐982 ‐6.50 26687 17960 23568

11034 BOT ‐0.02 26583 19167 ‐822 ‐6.25 26673 19077 23802

TOP 0.02 26593 19131 ‐813 ‐6.15 26681 19043 23800

11035 BOT ‐0.02 26844 20067 ‐113 ‐0.96 26846 20065 24179

TOP 0.02 26892 20096 ‐116 ‐0.98 26894 20094 24221

11105 BOT ‐0.02 26459 14774 ‐75 ‐0.37 26460 14774 22967

TOP 0.02 26461 14859 ‐120 ‐0.59 26462 14858 22975

11106 BOT ‐0.02 27310 16267 ‐1211 ‐6.19 27442 16136 23887

TOP 0.02 27361 16428 ‐1244 ‐6.41 27500 16288 23951

11107 BOT ‐0.02 24604 17531 ‐1646 ‐12.48 24968 17167 22124

TOP 0.02 24646 17729 ‐1691 ‐13.03 25037 17338 22212

11108 BOT ‐0.02 24408 19598 ‐1492 ‐15.90 24833 19173 22542

TOP 0.02 24536 19882 ‐1526 ‐16.63 24991 19427 22726

11109 BOT ‐0.02 22874 20914 ‐887 ‐21.08 23216 20572 22013

TOP 0.02 23012 21135 ‐900 ‐21.90 23373 20773 22188

70642 BOT ‐0.04 4777 8623 2194 65.62 9618 3782 8393

TOP 0.04 4675 8267 2187 64.70 9301 3640 8118

70643 BOT ‐0.04 11478 5899 ‐3411 ‐25.36 13095 4282 11564

TOP 0.04 11489 5817 ‐3434 ‐25.22 13106 4200 11592

70644 BOT ‐0.09 9287 10384 ‐1662 ‐54.13 11586 8085 10292

TOP 0.09 9052 9984 ‐2146 ‐51.13 11715 7322 10250

70657 BOT ‐0.04 8280 8187 ‐1143 ‐43.83 9378 7089 8468

TOP 0.04 7963 7628 ‐1189 ‐40.99 8996 6596 8068

70658 BOT ‐0.04 7009 7571 ‐3340 ‐47.40 10642 3938 9319

TOP 0.04 6461 7027 ‐3327 ‐47.43 10083 3405 8884

70659 BOT ‐0.04 7300 8254 ‐5360 ‐47.54 13158 2396 12139

TOP 0.04 7099 7960 ‐5434 ‐47.26 12980 2079 12076

70660 BOT ‐0.09 4507 8768 ‐3089 ‐62.30 10390 2885 9290

TOP 0.09 4160 8578 ‐3195 ‐62.33 10254 2485 9265

70661 BOT ‐0.09 4110 6044 5755 49.77 10913 ‐759 11312

TOP 0.09 4024 6150 5865 50.14 11047 ‐874 11509

70686 BOT ‐0.04 13486 10025 ‐2491 ‐27.61 14789 8722 12876

TOP 0.04 13305 9608 ‐2634 ‐27.47 14674 8238 12740

70687 BOT ‐0.04 12085 10388 ‐3876 ‐38.83 15204 7269 13172

TOP 0.04 11703 9684 ‐3885 ‐37.72 14707 6679 12755

70688 BOT ‐0.04 10765 12776 ‐4998 ‐50.69 16869 6672 14715

TOP 0.04 10593 12237 ‐4778 ‐49.88 16263 6567 14171

70689 BOT ‐0.04 7068 11633 ‐4109 ‐59.53 14051 4651 12398

TOP 0.04 6817 11418 ‐3875 ‐60.35 13624 4611 12002

70690 BOT ‐0.04 6799 9145 5012 51.59 13119 2824 11959

TOP 0.04 6553 9058 5055 51.96 13014 2597 11929

Note: NORMAL‐X ‐ Hoop Stress (psi)

NORMAL‐Y ‐ Axial Stress (psi)

SHEAR‐XY ‐ Shear Stress (psi)

ELEMENT STRESSES

REVISION

NC


PAGE NO.

42

PREPARED BY E. Kats

11/02/15 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


AEI 737‐400 Converted Freighter

Fuselage Skin Panel Stresses, Bet. S‐2L to S‐2R

OUTPUT SET 2 ‐ Down Bending

Elem PRINCIPAL STRESSES (ZERO SHEAR)

ID FIBRE DIST NORMAL‐X NORMAL‐Y SHEAR‐XY ANGLE MAJOR MINOR VON MISES

40 BOT ‐0.09 ‐1476 4213 3354 65.15 5766 ‐3029 7738

TOP 0.09 ‐1614 4360 3718 64.39 6142 ‐3396 8374

71 BOT ‐0.09 2159 7662 ‐4939 ‐59.56 10564 ‐743 10954

TOP 0.09 2294 8246 ‐5079 ‐60.18 11156 ‐617 11477

10622 BOT ‐0.02 1021 14222 943 85.93 14289 954 13837

TOP 0.02 966 14212 938 85.97 14279 900 13851

10623 BOT ‐0.02 2106 13879 ‐1085 ‐84.78 13978 2007 13090

TOP 0.02 2082 13892 ‐1088 ‐84.78 13992 1983 13113

10628 BOT ‐0.02 1292 14579 3143 77.34 15285 586 15000

TOP 0.02 1223 14573 3157 77.34 15282 514 15032

10629 BOT ‐0.02 1807 15648 ‐1074 ‐85.59 15731 1724 14944

TOP 0.02 1775 15670 ‐1071 ‐85.62 15752 1693 14978

11031 BOT ‐0.02 1175 18857 160 89.48 18859 1174 18300

TOP 0.02 1085 18837 173 89.44 18839 1083 18321

11032 BOT ‐0.02 1146 20252 ‐648 ‐88.06 20274 1124 19736

TOP 0.02 1061 20242 ‐637 ‐88.10 20263 1040 19763

11033 BOT ‐0.02 1022 21456 ‐1059 ‐87.04 21510 967 21044

TOP 0.02 959 21453 ‐1050 ‐87.07 21506 906 21068

11034 BOT ‐0.02 1057 22221 ‐922 ‐87.51 22261 1017 21770

TOP 0.02 1023 22221 ‐918 ‐87.53 22260 983 21785

11035 BOT ‐0.02 1203 22256 ‐546 ‐88.51 22270 1189 21700

TOP 0.02 1200 22273 ‐553 ‐88.50 22288 1185 21719

11105 BOT ‐0.02 1121 16475 519 88.07 16493 1103 15970

TOP 0.02 1035 16454 530 88.03 16472 1017 15988

11106 BOT ‐0.02 1354 18680 ‐1481 ‐85.15 18805 1228 18222

TOP 0.02 1279 18659 ‐1477 ‐85.18 18784 1154 18234

11107 BOT ‐0.02 1761 21522 ‐1892 ‐84.58 21702 1582 20956

TOP 0.02 1705 21523 ‐1893 ‐84.59 21702 1526 20981

11108 BOT ‐0.02 1950 22966 ‐1496 ‐85.95 23072 1844 22207

TOP 0.02 1943 23005 ‐1498 ‐85.95 23111 1837 22250

11109 BOT ‐0.02 1720 22873 ‐1011 ‐87.27 22922 1672 22133

TOP 0.02 1750 22909 ‐1007 ‐87.28 22957 1702 22155

70642 BOT ‐0.04 9740 1330 3014 17.81 10709 361 10532

TOP 0.04 9852 1309 3028 17.67 10816 345 10648

70643 BOT ‐0.04 2755 9465 ‐3213 ‐68.12 10755 1465 10103

TOP 0.04 2798 9607 ‐3241 ‐68.20 10903 1502 10235

70644 BOT ‐0.09 2333 9658 ‐5326 ‐62.26 12460 ‐468 12700

TOP 0.09 2401 10052 ‐5565 ‐62.25 12980 ‐526 13251

70657 BOT ‐0.04 1399 12708 ‐1829 ‐81.04 12997 1111 12479

TOP 0.04 1338 12791 ‐1823 ‐81.17 13074 1055 12580

70658 BOT ‐0.04 1246 12132 ‐3121 ‐75.08 12963 414 12761

TOP 0.04 1203 12260 ‐3114 ‐75.31 13076 386 12888

70659 BOT ‐0.04 837 11167 ‐3027 ‐74.81 11988 15 11980

TOP 0.04 848 11295 ‐3061 ‐74.82 12125 17 12117

70660 BOT ‐0.09 ‐356 8900 ‐594 ‐86.34 8938 ‐394 9142

TOP 0.09 ‐230 9197 ‐576 ‐86.51 9232 ‐265 9367

70661 BOT ‐0.09 262 4972 3342 62.59 6705 ‐1472 7550

TOP 0.09 349 5203 3537 62.23 7066 ‐1514 7932

70686 BOT ‐0.04 733 13672 ‐1449 ‐83.69 13833 572 13555

TOP 0.04 644 13662 ‐1471 ‐83.63 13826 480 13592

70687 BOT ‐0.04 187 13336 ‐1689 ‐82.80 13550 ‐26 13563

TOP 0.04 86 13248 ‐1706 ‐82.73 13465 ‐132 13532

70688 BOT ‐0.04 ‐71 14270 ‐1395 ‐84.50 14405 ‐205 14509

TOP 0.04 ‐60 14285 ‐1363 ‐84.62 14414 ‐189 14509

70689 BOT ‐0.04 ‐417 11338 ‐767 ‐86.28 11388 ‐467 11629

TOP 0.04 ‐338 11475 ‐725 ‐86.50 11519 ‐383 11715

70690 BOT ‐0.04 134 7412 3116 69.72 8564 ‐1018 9115

TOP 0.04 233 7526 3147 69.60 8696 ‐937 9200

Note: NORMAL‐X ‐ Hoop Stress (psi)

NORMAL‐Y ‐ Axial Stress (psi)

SHEAR‐XY ‐ Shear Stress (psi)

ELEMENT STRESSES

REVISION

NC


PAGE NO.

43

PREPARED BY E. Kats

11/02/15 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


REVISION

NC


PAGE NO.

44

PREPARED BY E. Kats

11/02/15 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


REVISION

NC


PAGE NO.

45

PREPARED BY E. Kats

11/02/15 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


Pressure case Operational pressure is 7.85 psi Taking stress levels from element 11034 Longitudinal stress level = (7.85/17.3)(19167) = 8697 psi Hoop stress level = (7.85/17.3)( 26593) = 12067 psi Down Bending case (2.5 G limit) Taking 1.5 G conservatively as GAG stress level Longitudinal stress level = (1.5/2.5)(22221) = 13332 psi Hoop stress level = (1.5/2.5)(1057) = 484 psi Typical GAG load case is (1P+1.5G)(longitudinal direction) σ = (8697+ 13332) = 22029 psi (longitudinal load case) Typical GAG load case (1.15P +1.0 G)(Hoop direction) σ = (12087*1.15+484) = 14384 psi (longitudinal load case) σ = 22.029 ksi (longitudinal load case)

LIMIT = (8697+22221) = 30.918 ksi

REVISION

NC


PAGE NO.

46

PREPARED BY E. Kats

11/02/15 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


For this analysis (1.5G +1.0P)is utilized for GAG once per flight load Stress = 22.029 ksi, R=0.0 GAG cycle

LIMIT = 30.918 ksi Skin thickness is 0.040 inch

REVISION

NC


PAGE NO.

47

PREPARED BY E. Kats

11/02/15 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.




Crack Path


Rivet hole


Adjacent hole

REVISION

NC


PAGE NO.

48

PREPARED BY E. Kats

11/02/15 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.




REVISION

NC


PAGE NO.

49

PREPARED BY E. Kats

11/02/15 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



Fastener pitch = 1.00 inches AFGROW 5.01.06.17 crack propagation program is used for crack growth analysis. Crack growth model utilized in this analysis : Non-Interaction Equation/Table : NASGRO Equation Retardation is not used for purposes of this analysis. The stress relieving effects of the stiffeners are ignored in this analysis Results of crack growth analysis for crack growth are presented in appendix A. da/dN data is obtained from the NASGRO material database Fastener spacing is 1.00 inch

bypass = ((22.029-41.452(0.186/1.00)) = 14.319 ksi

total = (14.319 + 41.452(0.186/1.00)) = 22.029 ksi (AFGROW required parameter) Bearing stress fraction = 41.452)/22.029 = 1.882 bypass stress fraction = (14.319/22.029) = 0.65

REVISION

NC


PAGE NO.

50

PREPARED BY E. Kats

11/02/15 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.




REVISION

NC


PAGE NO.

51

PREPARED BY E. Kats

11/02/15 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


REVISION

NC


PAGE NO.

52

PREPARED BY E. Kats

11/02/15 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


STAGE I Crack growth Crack starts from the 0.05 inch flaw and links up with the adjacent hole at 32500 flights STAGE II Crack growth Not used At this point it would be considered an overall failure (Conservative, since crack arresting capability of the frames is ignored) Total life = 32500 flights (crack growth)

REVISION

NC


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Stage I Crack Growth Title: 737 GPS Antenna Stage I 500D location




Pass Life

0 0.05 1.717043 1 1 0

800 0.061036 1.568872 9 9 800

1600 0.072082 1.41812 17 17 1600

2400 0.08268 1.338474 25 25 2400

3200 0.093183 1.248782 33 33 3200

4000 0.103453 1.182051 41 41 4000

4800 0.113771 1.120921 49 49 4800

5600 0.124113 1.090701 57 57 5600

6400 0.134434 1.036946 65 65 6400

7200 0.144897 1.009545 73 73 7200

8000 0.155573 0.964306 81 81 8000

8800 0.166288 0.943989 89 89 8800

9600 0.177344 0.923079 97 97 9600

10400 0.188718 0.904766 105 105 10400

11100 0.198963 0.887648 112 112 11100

11800 0.209492 0.871375 119 119 11800

12500 0.220304 0.855656 126 126 12500

13200 0.231408 0.840905 133 133 13200

13900 0.242881 0.82503 140 140 13900

14500 0.253025 0.810185 146 146 14500

15100 0.26336 0.810185 152 152 15100

15700 0.27391 0.796277 158 158 15700

16300 0.284811 0.78377 164 164 16300

16900 0.296084 0.772189 170 170 16900

17500 0.307647 0.772189 176 176 17500

18100 0.319493 0.760573 182 182 18100

18600 0.329693 0.749177 187 187 18600

19100 0.340143 0.749177 192 192 19100

19600 0.35075 0.738395 197 197 19600

20100 0.361748 0.728234 202 202 20100

20600 0.37292 0.728234 207 207 20600

21100 0.384406 0.718761 212 212 21100

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21600 0.396326 0.718761 217 217 21600

22100 0.408419 0.708638 222 222 22100

22500 0.41849 0.708638 226 226 22500

22900 0.428665 0.699798 230 230 22900

23300 0.439184 0.699798 234 234 23300

23700 0.449956 0.691631 238 238 23700

24100 0.46098 0.691631 242 242 24100

24500 0.472401 0.683933 246 246 24500

24900 0.483985 0.683933 250 250 24900

25300 0.496113 0.676687 254 254 25300

25700 0.508317 0.676687 258 258 25700

26100 0.521099 0.671047 262 262 26100

26500 0.534075 0.671047 266 266 26500

26800 0.544214 0.671047 269 269 26800

27100 0.554511 0.665719 272 272 27100

27400 0.565073 0.665719 275 275 27400

27700 0.576022 0.660703 278 278 27700

28000 0.587055 0.660703 281 281 28000

28300 0.598494 0.660703 284 284 28300

28600 0.610269 0.656579 287 287 28600

28900 0.622295 0.656579 290 290 28900

29200 0.63478 0.656579 293 293 29200

29500 0.647695 0.655497 296 296 29500

29800 0.66109 0.655497 299 299 29800

30100 0.675024 0.654895 302 302 30100

30400 0.689478 0.654895 305 305 30400

30700 0.704536 0.654895 308 308 30700

30900 0.714965 0.656088 310 310 30900

31100 0.725733 0.656088 312 312 31100

31300 0.736816 0.656088 314 314 31300

31500 0.74823 0.661489 316 316 31500

31700 0.760371 0.661489 318 318 31700

31900 0.772897 0.661489 320 320 31900

32100 0.785829 0.667269 322 322 32100

32300 0.799651 0.667269 324 324 32300

32500 0.813952 0.667269 326 326 32500

32600 0.821291 0.667269 327 327 32600

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Stage II Crack Growth NOT USED

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REF. DWG. NO.


4.0 RESIDUAL STRENGTH EVALUATION For the pressurized cabins of aircraft certificated to Amendment 96, FAR 25.571 requires that the residual strength evaluation must show that the remaining structure is able to withstand loads corresponding to the following conditions: (i) The normal operating differential pressure combined with the expected external aerodynamic pressures applied simultaneously with the flight loading conditions specified in paragraphs (b)(1) through (4) of FAR 25.571, if they have significant effect. (ii) The expected external aerodynamic pressures in 1 g flight combined with a cabin differential pressure equal to 1.15 times the normal operating differential pressure without any other load. Condition (i) typically takes precedence for modifications located on the top of the fuselage, since the tensile fuselage bending stresses are significant. Condition (ii) takes precedence for modifications located on the bottom of the fuselage since the fuselage bending stresses are compressive. The critical crack lengths for the modification are calculated for the fastener holes. The apparent fracture toughness, Kf, of 0.050" thick clad 2024-T3 material, 153 ksiin, was taken from the material database of the Federal Aviation Administration's RAPID v2.1 aircraft repair design and analysis program. The database provides fracture toughness data for a sheet thickness ranging from 0.010" to 0.090". The most critical installation is GPS antenna and it is used for residual strength evaluation Fresidual =( KIC)/((beta)(3.14*c)) 0.5

GPS ANTENNA 1 & 2 INSTALLATION) At 32500 flights crack half length reaches 0.814 inch Fresidual =(153)/{(0.667)(3.14*0.814)} 0.5

Fresidual =143 ksi LIMIT = 30.918 ksi (Axial direction, principal)

LIMIT < Fresidual Therefore it can be stated that crack growth life of this detail is conservatively assumed to be 32500 Flight cycles.

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REF. DWG. NO.


5.0 INSPECTION REQUIREMENTS

The crack growth was calculated using iterative techniques. The critical location initial flaw was assumed to be a 0.05" through crack at the edge of a circular hole, growing perpendicular to the applied load. The threshold inspection interval is defined as the number of aircraft landings permitted from the time of installation before the first inspection must be conducted. The recurring inspection interval is defined as the number of landings allowed between subsequent inspections.

GPS antenna analysis is utilized for all three (3) Door surround doubler antenna installations, since it has the shortest life.

Crack growth life is long

Detailed visual Inspection is utilized.

Detailed visual inspection detectable flaw size = 1.00 inch (Reference 5)

Crack is detectable following link-up

Life from the point of crack link-up (for GPS Antenna) is 42122 flight cycles

GPS antenna location installed on the original fuselage skin

Doublers are installed externally and internally and critical crack length is relatively short. Therefore, NDI inspections are required.

High Frequency Eddy Current Inspection is utilized.

HFEC inspection detectable flaw size = 0.300 inch (conservative)

Crack reaches detectable size at 17500 flight cycles

N threshold =12000 landings (Supported by crack growth analysis)(Since installation)

This is conservative, since following inspectionwas performed during antenna installation. Accomplish HFEC inspection at all existing fastener holes common to the subject area per 737NDT Manual, Part 6, 51-00-00, Procedure 16 (0.03inch notch) to verify crack free structure

Repeat inspection is calculated as total crack growth life with number flights when crack becomes detectable subtracted and then divided by a scatter factor.

Inspection interval = (32500-17500)/2 = 7500 flight-cycles (Supported by crack growth)

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REF. DWG. NO.


Upper skin splice is inspected under requirements of F-31(Reference 10)

Addition of extra fasteners rows will reduce bearing stress level in the first row of attachments betwwen the existing skin and splice. Therefore, existion inspections are sufficient

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REF. DWG. NO.


REVISION

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REF. DWG. NO.


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REF. DWG. NO.


Therefore, following inspections are utilized for the antenna locations on the door surround doubler

Inspection threshold = 30,000 flight cycles

Repeat interval = 20,000 flight cycles

Inspection Method is detailed visual

Different inspections are utilized for the GPS antenna location on the original fusealge skin

Inspection threshold = 12,000 flight cycles

Repeat interval = 7,500 flight cycles

Inspection Method is HFEC

Note: Antenna has to be removed for inspection

Note: Inspections have to be performed by the qualified NDI specialist

Note: Inspection requirements have to be added to the aircraft ICA’s ALI portion

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REF. DWG. NO.


Inspection requirements are for 737 antenna relocation installations

Inspection Intervals (Landings)

Detectable Crack

DOOR SURROUND DOUBLER INSTALLATIONS

Threshold Recurring Length (in) Detailed visual

TCAS Antenna 30000 20000 1.00 Transponder Antenna 30000 20000 1.00 ORIGINAL SKIN INSTALLATION

HFEC

GPS antenna 1 & 2 12000 7500 0.3 INSPECTION PROGRAM Perform additional inspection of the antenna installations INSPECTION METHOD

Inspect fuselage skin in the antenna installation area, doubler fastener holes, anrenna penetration hole and antenna attachment holes area, using detailed visual inspection techniques or HFEC inspection technique, according to the intervals outlined in the table above. For the fastener holes, the inspector should look for cracks on the surfaces of the skin and doubler around the fastener holes.

MAINTENANCE MANUAL SUPPLEMENT GUIDELINES A maintenance manual supplement should be created that describes in detail the locations to be examined and the inspection procedure to be followed. The inspection intervals contained within the maintenance manual supplement may be aligned with the existing aircraft maintenance program, provided the following conditions are met: (1) The maintenance check for the aircraft occurs before the threshold inspection interval indicated by the analysis in this report. (2) Subsequent maintenance checks for the aircraft occur before the recurring inspection interval indicated by the analysis in this report. If the maintenance checks for the aircraft exceed the threshold or recurring inspection intervals specified in this report, then the inspection intervals specified within this report apply. Inspection area is presented on the next page

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TCAS ANTENNA INSPECTION AREA & METHOD

Detailed Visual Inspection Area

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REF. DWG. NO.


TRANSPONDER ANTENNA

INSPECTION AREA & METHOD

Detailed Visual Inspection Area

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REF. DWG. NO.


GPS ANTENNA 1 &2

INSPECTION AREA & METHOD

HFEC Inspection Area. Additionally inspection fuselage skin Chem-milled step area around the periphery of skin bay with antenna installation

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APPENDIX A REFERENCE MATERIAL

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REF. DWG. NO.


TCAS ANTENNA CRACK GROWTH PHASE I

AFGROW 5.1.6.17 **English Units [ Length(in), Stress(Ksi), Temperature(F) ] Crack Growth Model and Spectrum Information Title: 737 TCAS Antenna Stage I Load: Axial Stress Fraction: 0.737, Bending Stress Fraction: 0, Bearing Stress Fraction: 1.411 Crack Model: 2020 - Single Through Crack at Hole - Standard Solution Initial surface crack length (c): 0.0050 Thickness : 0.080 Width : 20.000 Hole Diameter: 0.156 Young's Modulus =10600 Poisson's Ratio =0.33 Coeff. of Thermal Expan. =1.29e-005 No crack growth retardation is being considered Determine Stress State automatically (2 = Plane stress, 6 = Plane strain) The stress intensity factors are being modified for a non-uniform stress field as follows: C Stress Beta Correction --------------------------------------- 0.0050000 1.0000 1.010000 0.1000000 1.0000 1.012000 0.2000000 1.0000 1.040000 0.3000000 1.0000 1.060000 0.4000000 1.0000 1.070000 0.6000000 1.0000 1.100000 0.7000000 1.0000 1.130000 0.8140000 1.0000 1.190000 No K-Solution Filters The Forman-Newman-de Koning- Henriksen (NASGRO) crack growth relation is being used For Reff < 0.0, Delta K = Kmax

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REF. DWG. NO.


Material: 1000-9000 series aluminum, 2024-T3 Al, [ Clad; plt & sht; L-T ] Plane strain fracture toughness: 33 Plane stress fracture toughness: 66 Effective fracture toughness for surface/elliptically shaped crack: 46 Fit parameters (KC versus Thickness Equation): Ak= 1, Bk=1 Yield stress: 53 Lower 'R' value boundary: -0.3 Upper 'R' value boundary: 0.7 Exponents in NASGRO Equation: n=3.284, p=0.5, q=1 Paris crack growth rate constant: 8.29e-009 Threshold stress intensity factor range at R = 0: 2.9 Threshold coefficient: 1.5 Plane stress/strain constraint factor: 1.5 Ratio of the maximum applied stress to the flow stress: 0.3 Failure is based on the current load in the applied spectrum Vroman integration at 5% crack length **Spectrum Information Constant amplitude loading Spectrum multiplication factor: 8.909 SPL: 0 The spectrum will be repeated up to 999999 times Total Cycles: 100 Levels: 1 Subspectra: 1 Max Value: 1 Min Value: 0 No Spectrum Filters Critical Crack Length is Based on the Maximum Spectrum Stress Critical crack size in 'C' direction=9.15333, Stress State=2 (Based on Kmax criteria) Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.005 3.2783 3.2783 0.0000 0.0000 3.6605e+000 6.5711e-008 Max stress = 8.909000 R = 0.00 0 Cycles Constant amp.: 1 Pass: 1 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.025027 2.1701 2.1701 0.0000 0.0000 5.4210e+000 3.0813e-007

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REF. DWG. NO.


Max stress = 8.909000 R = 0.00 108000 Cycles Constant amp.: 1081 Pass: 1081 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.045033 1.6688 1.6688 0.0000 0.0000 5.5922e+000 3.4557e-007 Max stress = 8.909000 R = 0.00 167400 Cycles Constant amp.: 1675 Pass: 1675 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.065068 1.4052 1.4052 0.0000 0.0000 5.6600e+000 3.6123e-007 Max stress = 8.909000 R = 0.00 224400 Cycles Constant amp.: 2245 Pass: 2245 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.085097 1.2121 1.2121 0.0000 0.0000 5.5835e+000 3.4209e-007 Max stress = 8.909000 R = 0.00 282100 Cycles Constant amp.: 2822 Pass: 2822 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.10511 1.1047 1.1047 0.0000 0.0000 5.6553e+000 3.5927e-007 Max stress = 8.909000 R = 0.00 339100 Cycles Constant amp.: 3392 Pass: 3392 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.12514 1.0161 1.0161 0.0000 0.0000 5.6759e+000 3.6419e-007 Max stress = 8.909000 R = 0.00 394300 Cycles Constant amp.: 3944 Pass: 3944 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.14515 0.9606 0.9606 0.0000 0.0000 5.7794e+000 3.9051e-007 Max stress = 8.909000 R = 0.00 446300 Cycles Constant amp.: 4464 Pass: 4464 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN

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C 0.16517 0.9296 0.9296 0.0000 0.0000 5.9654e+000 4.4125e-007 Max stress = 8.909000 R = 0.00 494600 Cycles Constant amp.: 4947 Pass: 4947 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.18519 0.8874 0.8874 0.0000 0.0000 6.0301e+000 4.5984e-007 Max stress = 8.909000 R = 0.00 539200 Cycles Constant amp.: 5393 Pass: 5393 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.20523 0.8620 0.8620 0.0000 0.0000 6.1660e+000 5.0080e-007 Max stress = 8.909000 R = 0.00 580400 Cycles Constant amp.: 5805 Pass: 5805 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.22524 0.8375 0.8375 0.0000 0.0000 6.2764e+000 5.3588e-007 Max stress = 8.909000 R = 0.00 618500 Cycles Constant amp.: 6186 Pass: 6186 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.24526 0.8264 0.8264 0.0000 0.0000 6.4624e+000 5.9884e-007 Max stress = 8.909000 R = 0.00 653900 Cycles Constant amp.: 6540 Pass: 6540 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.26526 0.8060 0.8060 0.0000 0.0000 6.5552e+000 6.3205e-007 Max stress = 8.909000 R = 0.00 686900 Cycles Constant amp.: 6870 Pass: 6870 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.28526 0.7875 0.7875 0.0000 0.0000 6.6417e+000 6.6417e-007 Max stress = 8.909000 R = 0.00 717400 Cycles Constant amp.: 7175 Pass: 7175

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REF. DWG. NO.


Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.30533 0.7789 0.7789 0.0000 0.0000 6.7967e+000 7.2456e-007 Max stress = 8.909000 R = 0.00 746100 Cycles Constant amp.: 7462 Pass: 7462 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.32538 0.7700 0.7700 0.0000 0.0000 6.9355e+000 7.8182e-007 Max stress = 8.909000 R = 0.00 772800 Cycles Constant amp.: 7729 Pass: 7729 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.34539 0.7613 0.7613 0.0000 0.0000 7.0653e+000 8.3815e-007 Max stress = 8.909000 R = 0.00 797800 Cycles Constant amp.: 7979 Pass: 7979 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.36547 0.7454 0.7454 0.0000 0.0000 7.1153e+000 8.6060e-007 Max stress = 8.909000 R = 0.00 821500 Cycles Constant amp.: 8216 Pass: 8216 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.38551 0.7380 0.7380 0.0000 0.0000 7.2359e+000 9.1646e-007 Max stress = 8.909000 R = 0.00 843800 Cycles Constant amp.: 8439 Pass: 8439 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.40553 0.7311 0.7311 0.0000 0.0000 7.3517e+000 9.7246e-007 Max stress = 8.909000 R = 0.00 864800 Cycles Constant amp.: 8649 Pass: 8649 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.42554 0.7252 0.7252 0.0000 0.0000 7.4699e+000 1.0320e-006 Max stress = 8.909000 R = 0.00

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884600 Cycles Constant amp.: 8847 Pass: 8847 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.44559 0.7199 0.7199 0.0000 0.0000 7.5886e+000 1.0945e-006 Max stress = 8.909000 R = 0.00 903300 Cycles Constant amp.: 9034 Pass: 9034 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.46563 0.7151 0.7151 0.0000 0.0000 7.7048e+000 1.1581e-006 Max stress = 8.909000 R = 0.00 920900 Cycles Constant amp.: 9210 Pass: 9210 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.48574 0.7151 0.7151 0.0000 0.0000 7.8694e+000 1.2527e-006 Max stress = 8.909000 R = 0.00 937600 Cycles Constant amp.: 9377 Pass: 9377 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.50586 0.7105 0.7105 0.0000 0.0000 7.9799e+000 1.3191e-006 Max stress = 8.909000 R = 0.00 953400 Cycles Constant amp.: 9535 Pass: 9535 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.52593 0.7063 0.7063 0.0000 0.0000 8.0886e+000 1.3870e-006 Max stress = 8.909000 R = 0.00 968300 Cycles Constant amp.: 9684 Pass: 9684 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.54602 0.7028 0.7028 0.0000 0.0000 8.2002e+000 1.4590e-006 Max stress = 8.909000 R = 0.00 982400 Cycles Constant amp.: 9825 Pass: 9825 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.56606 0.6996 0.6996 0.0000 0.0000 8.3111e+000 1.5334e-006

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Stress State in 'C' direction (PSC): 6 Crack length exceeded stop value - run time : 0 hour(s) 0 minute(s) 0 second(s)

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TCAS ANTENNA

CRACK GROWTH PHASEII

AFGROW 5.1.6.17 **English Units [ Length(in), Stress(Ksi), Temperature(F) ] Crack Growth Model and Spectrum Information Title: 737 TCAS Antenna Stage II Load: Axial Stress Fraction: 1, Bending Stress Fraction: 0, Bearing Stress Fraction: 0 Crack Model: 2010 - Internal Through Crack - Standard Solution Initial surface crack length (c): 0.7300 Thickness : 0.080 Width : 40.000 Young's Modulus =10600 Poisson's Ratio =0.33 Coeff. of Thermal Expan. =1.29e-005 No crack growth retardation is being considered Determine Stress State automatically (2 = Plane stress, 6 = Plane strain) No K-Solution Filters The Forman-Newman-de Koning- Henriksen (NASGRO) crack growth relation is being used For Reff < 0.0, Delta K = Kmax Material: 1000-9000 series aluminum, 2024-T3 Al, [ Clad; plt & sht; L-T ] Plane strain fracture toughness: 33 Plane stress fracture toughness: 66 Effective fracture toughness for surface/elliptically shaped crack: 46 Fit parameters (KC versus Thickness Equation): Ak= 1, Bk=1 Yield stress: 53 Lower 'R' value boundary: -0.3 Upper 'R' value boundary: 0.7 Exponents in NASGRO Equation: n=3.284, p=0.5, q=1 Paris crack growth rate constant: 8.29e-009 Threshold stress intensity factor range at R = 0: 2.9 Threshold coefficient: 1.5 Plane stress/strain constraint factor: 1.5

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Ratio of the maximum applied stress to the flow stress: 0.3 Failure is based on the current load in the applied spectrum Vroman integration at 5% crack length **Spectrum Information Constant amplitude loading Spectrum multiplication factor: 8.909 SPL: 0 The spectrum will be repeated up to 999999 times Total Cycles: 100 Levels: 1 Subspectra: 1 Max Value: 1 Min Value: 0 No Spectrum Filters Critical Crack Length is Based on the Maximum Spectrum Stress Critical crack size in 'C' direction=11.1898, Stress State=2 (Based on Kmax criteria) Critical crack size in 'C' direction=15.9137, Stress State=2 (Based on Net Section Yield criteria) Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.73 1.0008 1.0008 0.0000 0.0000 1.3502e+001 9.1086e-006 Max stress = 8.909000 R = 0.00 0 Cycles Constant amp.: 1 Pass: 1 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.78031 1.0009 1.0009 0.0000 0.0000 1.3961e+001 1.0300e-005 Max stress = 8.909000 R = 0.00 5200 Cycles Constant amp.: 53 Pass: 53 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.83043 1.0010 1.0010 0.0000 0.0000 1.4404e+001 1.1557e-005 Max stress = 8.909000 R = 0.00 9800 Cycles Constant amp.: 99 Pass: 99 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN

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C 10.108 1.1914 1.1914 0.0000 0.0000 5.9812e+001 1.1656e-002 Max stress = 8.909000 R = 0.00 76669 Cycles Constant amp.: 767 Pass: 767 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 10.47 1.1914 1.1914 0.0000 0.0000 6.0871e+001 1.5022e-002 Max stress = 8.909000 R = 0.00 76700 Cycles Constant amp.: 768 Pass: 768 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 10.995 1.2380 1.2380 0.0000 0.0000 6.4825e+001 9.5395e-002 Max stress = 8.909000 R = 0.00 76735 Cycles Constant amp.: 768 Pass: 768 *********Fracture based on ' Kmax' Criteria (current maximum stress) Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 11.568 1.2731 1.2731 0.0000 0.0000 6.8376e+001 1.0000e-001 Max stress = 8.909000 R = 0.00 76741 Cycles Constant amp.: 768 Pass: 768 Stress State in 'C' direction (PSC): 2 Fracture has occurred - run time : 0 hour(s) 0 minute(s) 1 second(s)

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TRANSPONDER ANTENNA CRACK GROWTH PHASE I

AFGROW 5.1.6.17 **English Units [ Length(in), Stress(Ksi), Temperature(F) ] Crack Growth Model and Spectrum Information Title: 737 Transponder Antenna Stage I Load: Axial Stress Fraction: 0.737, Bending Stress Fraction: 0, Bearing Stress Fraction: 1.411 Crack Model: 2020 - Single Through Crack at Hole - Standard Solution Initial surface crack length (c): 0.0050 Thickness : 0.080 Width : 20.000 Hole Diameter: 0.156 Young's Modulus =10600 Poisson's Ratio =0.33 Coeff. of Thermal Expan. =1.29e-005 No crack growth retardation is being considered Determine Stress State automatically (2 = Plane stress, 6 = Plane strain) The stress intensity factors are being modified for a non-uniform stress field as follows: C Stress Beta Correction --------------------------------------- 0.0050000 1.0000 1.010000 0.1000000 1.0000 1.012000 0.2000000 1.0000 1.040000 0.3000000 1.0000 1.060000 0.4000000 1.0000 1.070000 0.6000000 1.0000 1.100000 0.7000000 1.0000 1.130000 0.8140000 1.0000 1.190000 No K-Solution Filters The Forman-Newman-de Koning- Henriksen (NASGRO) crack growth relation is being used For Reff < 0.0, Delta K = Kmax Material: 1000-9000 series aluminum, 2024-T3 Al, [ Clad; plt & sht; L-T ]

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Plane strain fracture toughness: 33 Plane stress fracture toughness: 66 Effective fracture toughness for surface/elliptically shaped crack: 46 Fit parameters (KC versus Thickness Equation): Ak= 1, Bk=1 Yield stress: 53 Lower 'R' value boundary: -0.3 Upper 'R' value boundary: 0.7 Exponents in NASGRO Equation: n=3.284, p=0.5, q=1 Paris crack growth rate constant: 8.29e-009 Threshold stress intensity factor range at R = 0: 2.9 Threshold coefficient: 1.5 Plane stress/strain constraint factor: 1.5 Ratio of the maximum applied stress to the flow stress: 0.3 Failure is based on the current load in the applied spectrum Vroman integration at 5% crack length **Spectrum Information Constant amplitude loading Spectrum multiplication factor: 9.315 SPL: 0 The spectrum will be repeated up to 999999 times Total Cycles: 100 Levels: 1 Subspectra: 1 Max Value: 1 Min Value: 0 No Spectrum Filters Critical Crack Length is Based on the Maximum Spectrum Stress Critical crack size in 'C' direction=9.07886, Stress State=2 (Based on Kmax criteria) Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.005 3.2783 3.2783 0.0000 0.0000 3.8273e+000 7.9968e-008 Max stress = 9.315000 R = 0.00 0 Cycles Constant amp.: 1 Pass: 1 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.025002 2.1667 2.1667 0.0000 0.0000 5.6564e+000 3.6358e-007 Max stress = 9.315000 R = 0.00 90100 Cycles Constant amp.: 902 Pass: 902

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Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.04502 1.6643 1.6643 0.0000 0.0000 5.8303e+000 4.0623e-007 Max stress = 9.315000 R = 0.00 140100 Cycles Constant amp.: 1402 Pass: 1402 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.065055 1.4013 1.4013 0.0000 0.0000 5.9009e+000 4.2452e-007 Max stress = 9.315000 R = 0.00 188100 Cycles Constant amp.: 1882 Pass: 1882 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.085091 1.2086 1.2086 0.0000 0.0000 5.8206e+000 4.0213e-007 Max stress = 9.315000 R = 0.00 236600 Cycles Constant amp.: 2367 Pass: 2367 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.10511 1.1015 1.1015 0.0000 0.0000 5.8960e+000 4.2229e-007 Max stress = 9.315000 R = 0.00 284600 Cycles Constant amp.: 2847 Pass: 2847 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.12515 1.0135 1.0135 0.0000 0.0000 5.9194e+000 4.2857e-007 Max stress = 9.315000 R = 0.00 331000 Cycles Constant amp.: 3311 Pass: 3311 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.14516 0.9586 0.9586 0.0000 0.0000 6.0298e+000 4.6001e-007 Max stress = 9.315000 R = 0.00 374800 Cycles Constant amp.: 3749 Pass: 3749 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.1652 0.9276 0.9276 0.0000 0.0000 6.2245e+000 5.1942e-007

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Max stress = 9.315000 R = 0.00 903600 Cycles Constant amp.: 9037 Pass: 9037 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.72752 0.7042 0.7042 0.0000 0.0000 9.9165e+000 2.9366e-006 Max stress = 9.315000 R = 0.00 910900 Cycles Constant amp.: 9110 Pass: 9110 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.74769 0.7042 0.7042 0.0000 0.0000 1.0053e+001 3.0875e-006 Max stress = 9.315000 R = 0.00 917600 Cycles Constant amp.: 9177 Pass: 9177 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.76775 0.7115 0.7115 0.0000 0.0000 1.0292e+001 3.3656e-006 Max stress = 9.315000 R = 0.00 923900 Cycles Constant amp.: 9240 Pass: 9240 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.78808 0.7115 0.7115 0.0000 0.0000 1.0428e+001 3.5307e-006 Max stress = 9.315000 R = 0.00 929800 Cycles Constant amp.: 9299 Pass: 9299 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.80819 0.7194 0.7194 0.0000 0.0000 1.0677e+001 3.8506e-006 Max stress = 9.315000 R = 0.00 935300 Cycles Constant amp.: 9354 Pass: 9354 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.81439 0.7194 0.7194 0.0000 0.0000 1.0718e+001 3.9049e-006 Max stress = 9.315000 R = 0.00 936900 Cycles Constant amp.: 9370 Pass: 9370 Stress State in 'C' direction (PSC): 5.93829

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Crack length exceeded stop value - run time : 0 hour(s) 0 minute(s) 1 second(s)

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TRANSPONDER ANTENNA CRACK GROWTH PHASE II

AFGROW 5.1.6.17 **English Units [ Length(in), Stress(Ksi), Temperature(F) ] Crack Growth Model and Spectrum Information Title: 737 Transponder Antenna Stage II Load: Axial Stress Fraction: 1, Bending Stress Fraction: 0, Bearing Stress Fraction: 0 Crack Model: 2010 - Internal Through Crack - Standard Solution Initial surface crack length (c): 0.7350 Thickness : 0.080 Width : 40.000 Young's Modulus =10600 Poisson's Ratio =0.33 Coeff. of Thermal Expan. =1.29e-005 No crack growth retardation is being considered Determine Stress State automatically (2 = Plane stress, 6 = Plane strain) No K-Solution Filters The Forman-Newman-de Koning- Henriksen (NASGRO) crack growth relation is being used For Reff < 0.0, Delta K = Kmax Material: 1000-9000 series aluminum, 2024-T3 Al, [ Clad; plt & sht; L-T ] Plane strain fracture toughness: 33 Plane stress fracture toughness: 66 Effective fracture toughness for surface/elliptically shaped crack: 46 Fit parameters (KC versus Thickness Equation): Ak= 1, Bk=1 Yield stress: 53 Lower 'R' value boundary: -0.3 Upper 'R' value boundary: 0.7 Exponents in NASGRO Equation: n=3.284, p=0.5, q=1 Paris crack growth rate constant: 8.29e-009 Threshold stress intensity factor range at R = 0: 2.9 Threshold coefficient: 1.5 Plane stress/strain constraint factor: 1.5 Ratio of the maximum applied stress to the flow stress: 0.3

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Failure is based on the current load in the applied spectrum Vroman integration at 5% crack length **Spectrum Information Constant amplitude loading Spectrum multiplication factor: 9.315 SPL: 0 The spectrum will be repeated up to 999999 times Total Cycles: 100 Levels: 1 Subspectra: 1 Max Value: 1 Min Value: 0 No Spectrum Filters Critical Crack Length is Based on the Maximum Spectrum Stress Critical crack size in 'C' direction=10.7048, Stress State=2 (Based on Kmax criteria) Critical crack size in 'C' direction=15.7346, Stress State=2 (Based on Net Section Yield criteria) Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.735 1.0008 1.0008 0.0000 0.0000 1.4166e+001 1.0869e-005 Max stress = 9.315000 R = 0.00 0 Cycles Constant amp.: 1 Pass: 1 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.7858 1.0009 1.0009 0.0000 0.0000 1.4649e+001 1.2300e-005 Max stress = 9.315000 R = 0.00 4400 Cycles Constant amp.: 45 Pass: 45 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.83656 1.0010 1.0010 0.0000 0.0000 1.5116e+001 1.3813e-005 Max stress = 9.315000 R = 0.00 8300 Cycles Constant amp.: 84 Pass: 84 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN

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Max stress = 9.315000 R = 0.00 63900 Cycles Constant amp.: 640 Pass: 640 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 10.093 1.1906 1.1906 0.0000 0.0000 6.2450e+001 2.4109e-002 Max stress = 9.315000 R = 0.00 63947 Cycles Constant amp.: 640 Pass: 640 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 10.599 1.2161 1.2161 0.0000 0.0000 6.5367e+001 2.2816e-001 Max stress = 9.315000 R = 0.00 63968 Cycles Constant amp.: 640 Pass: 640 *********Fracture based on ' Kmax' Criteria (current maximum stress) Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 11.283 1.2552 1.2552 0.0000 0.0000 6.9611e+001 1.0000e-001 Max stress = 9.315000 R = 0.00 63971 Cycles Constant amp.: 640 Pass: 640 Stress State in 'C' direction (PSC): 2 Fracture has occurred - run time : 0 hour(s) 0 minute(s) 1 second(s)

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GPS ANTENNA 1 & 2

CRACK GROWTH PHASE I

AFGROW 5.1.6.17 **English Units [ Length(in), Stress(Ksi), Temperature(F) ] Crack Growth Model and Spectrum Information Title: 737 GPS Antenna Stage I 500D location Load: Axial Stress Fraction: 0.65, Bending Stress Fraction: 0, Bearing Stress Fraction: 1.882 Crack Model: 2020 - Single Through Crack at Hole - Standard Solution Initial surface crack length (c): 0.0500 Thickness : 0.040 Width : 20.000 Hole Diameter: 0.186 Young's Modulus =10600 Poisson's Ratio =0.33 Coeff. of Thermal Expan. =1.29e-005 No crack growth retardation is being considered Determine Stress State automatically (2 = Plane stress, 6 = Plane strain) The stress intensity factors are being modified for a non-uniform stress field as follows: C Stress Beta Correction --------------------------------------- 0.0050000 1.0000 1.010000 0.1000000 1.0000 1.012000 0.2000000 1.0000 1.040000 0.3000000 1.0000 1.060000 0.4000000 1.0000 1.070000 0.6000000 1.0000 1.100000 0.7000000 1.0000 1.130000 0.8140000 1.0000 1.190000 No K-Solution Filters The Forman-Newman-de Koning- Henriksen (NASGRO) crack growth relation is being used

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For Reff < 0.0, Delta K = Kmax Material: 1000-9000 series aluminum, 2024-T3 Al, [ Clad; plt & sht; L-T ] Plane strain fracture toughness: 33 Plane stress fracture toughness: 66 Effective fracture toughness for surface/elliptically shaped crack: 46 Fit parameters (KC versus Thickness Equation): Ak= 1, Bk=1 Yield stress: 53 Lower 'R' value boundary: -0.3 Upper 'R' value boundary: 0.7 Exponents in NASGRO Equation: n=3.284, p=0.5, q=1 Paris crack growth rate constant: 8.29e-009 Threshold stress intensity factor range at R = 0: 2.9 Threshold coefficient: 1.5 Plane stress/strain constraint factor: 1.5 Ratio of the maximum applied stress to the flow stress: 0.3 Failure is based on the current load in the applied spectrum Vroman integration at 5% crack length **Spectrum Information Constant amplitude loading Spectrum multiplication factor: 22.029 SPL: 0 The spectrum will be repeated up to 999999 times Total Cycles: 100 Levels: 1 Subspectra: 1 Max Value: 1 Min Value: 0 No Spectrum Filters Critical Crack Length is Based on the Maximum Spectrum Stress Critical crack size in 'C' direction=5.95814, Stress State=2 (Based on Kmax criteria) Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.05 1.7170 1.7170 0.0000 0.0000 1.4991e+001 1.3409e-005 Max stress = 22.029000 R = 0.00 0 Cycles Constant amp.: 1 Pass: 1 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.061036 1.5689 1.5689 0.0000 0.0000 1.5134e+001 1.3882e-005

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Stress State in 'C' direction (PSC): 2 Crack length exceeded stop value - run time : 0 hour(s) 0 minute(s) 1 second(s)

Documents

EDWARD KATS & ASSOCIATES 511 South Maria Avenue …1 T. Swift FAA-AIR-90-01 “Repairs to Damage Tolerant Aircraft.”, Structural Integrity of Aging Airplanes, Springer Verlag Berlin