EDWARD KATS & ASSOCIATES 511 South Maria Avenue … · 2017-06-16 · 1 T. Swift FAA-AIR-90-01 “Repairs to Damage Tolerant Aircraft.”, Structural Integrity of Aging Airplanes,

EDWARD KATS & ASSOCIATES 511 South Maria Avenue

Redondo Beach, CA 90277 (310) 344-0081

MODEL: 737-400 DOCUMENT NO.: EAK-13-201-DT REVISION: NC DATE: 11-21-2013

Prepared By: Edward Kats Date: 11-21-2013

Checked By: Mike Pilarski Date: 11-21-2013

Approved By: Edward Kats Date: 11-21-2013

DAMAGE TOLERANCE EVALUATION

FUSELAGE ANTENNAE INSTALLATION

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Damage Tolerance Evaluation Fuselage Antennae Installation

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EDWARD KATS & ASSOCIATES

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i NC ii NC iii NC iv NC

1-54 NC A1-A81 NC

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REVISION RECORD

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NC Initial Release 11/21/13 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 53-12454-1 Repair Installation .......................................................................... 2

2.1 Damage Tolerance Evaluation ................................................................. 7 2.1.1 Fastener Load Definition and Durability Analysis ...................... 7

3.0 TCAS Antenna Installation ................................................................................ 8 3.1 Transponder Antenna Installation ............................................................ 22 3.2 GPS Antenna Installation ......................................................................... 36

4.0 Residual Stgrength Evaluation .......................................................................... 49 5.0 Inspection Requirements .................................................................................. 50

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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 EO1599 Cargo Door Surround Skin – Existing Antenna Installation

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

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1.0 INTRODUCTION This report presents the damage tolerance evaluation of DM Antenna Technologies N150 Transponder Antenna, Sensor System S67-1575-133 GPS antenna and a Sensor System S72-1735 TCAS Antenna Installation on AEI 737-400 aircraft. Installation of the repair is performed per Engineering Order 1599 (Reference 2). Static Strength of these installations is evaluated under separate cover .(Reference 9) 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 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.

32

PREPARED BY E. Kats

11/21/13 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




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.

33

PREPARED BY E. Kats

11/21/13 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.

34

PREPARED BY E. Kats

11/21/13 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.

35

PREPARED BY E. Kats

11/21/13 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.

36

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


3.2 GPS ANTENNA INSTALLATION

REVISION

NC


PAGE NO.

37

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


The GPS antenna weighs less than a pound and is mounted to the top just left of the centerline with 4, #10-32 screws between FS 500A and FS 500B. The external doubler reinforces the 1.5" diameter hole drilled in the fuselage skin for the antenna connector for the 737-400 aircraft and a 2.0” diameter hole for the 737-300 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

REVISION

NC


PAGE NO.

38

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


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 = 10367 psi (limt) For this analysis conservatively limit load is utilized for GAG once per flight load Stress = 10.367 ksi, R=0.0 GAG cycle

LIMIT = 10.367 ksi .

REVISION

NC


PAGE NO.

39

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.




Crack Path


Rivet hole


Adjacent hole

REVISION

NC


PAGE NO.

40

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.




REVISION

NC


PAGE NO.

41

PREPARED BY E. Kats

11/21/13 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 = ((10.367-14.630(0.186/1.00)) = 7.645 ksi

total = (7.645 + 14.630(0.186/1.00)) = 10.367 ksi (AFGROW required parameter) Bearing stress fraction = (14.630)/10.367 = 1.411 bypass stress fraction = (7.645/10.367) = 0.737

REVISION

NC


PAGE NO.

42

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.




REVISION

NC


PAGE NO.

43

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


REVISION

NC


PAGE NO.

44

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

45

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


Stage I Crack Growth Title: 737 GPS Antenna Stage I




Pass Life

0 0.005 3.278313 1 1 0

59100 0.025009 2.159986 592 592 59100

92300 0.045019 1.655746 924 924 92300

124200 0.065026 1.392703 1243 1243 124200

156400 0.08507 1.22992 1565 1565 156400

188300 0.105091 1.095139 1884 1884 188300

219200 0.125121 1.027928 2193 2193 219200

248400 0.145184 0.970922 2485 2485 248400

275600 0.165239 0.923402 2757 2757 275600

300700 0.185317 0.895087 3008 3008 300700

323900 0.205385 0.869129 3240 3240 323900

345500 0.225477 0.844201 3456 3456 345500

365600 0.24555 0.821805 3657 3657 365600

384200 0.265592 0.801757 3843 3843 384200

401600 0.285649 0.792456 4017 4017 401600

417700 0.305651 0.783629 4178 4178 417700

432900 0.325685 0.766018 4330 4330 432900

447200 0.345769 0.75756 4473 4473 447200

460700 0.365922 0.749509 4608 4608 460700

473400 0.386034 0.741929 4735 4735 473400

485400 0.406155 0.734759 4855 4855 485400

496700 0.426217 0.728272 4968 4968 496700

507400 0.446355 0.722653 5075 5075 507400

517500 0.466509 0.717577 5176 5176 517500

527000 0.48659 0.71287 5271 5271 527000

536000 0.50673 0.708482 5361 5361 536000

544500 0.52685 0.70457 5446 5446 544500

552600 0.547054 0.70457 5527 5527 552600

560300 0.567316 0.701196 5604 5604 560300

567500 0.58733 0.698142 5676 5676 567500

574400 0.607573 0.696123 5745 5745 574400

580900 0.627623 0.696123 5810 5810 580900

587100 0.647934 0.6966 5872 5872 587100

REVISION

NC


PAGE NO.

46

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


592900 0.668079 0.6966 5930 5930 592900

598400 0.688368 0.697611 5985 5985 598400

603600 0.708677 0.699666 6037 6037 603600

608500 0.729014 0.699666 6086 6086 608500

613100 0.749461 0.706564 6132 6132 613100

617400 0.769931 0.706564 6175 6175 617400

621400 0.790441 0.714127 6215 6215 621400

625100 0.810598 0.714127 6252 6252 625100

625800 0.814518 0.714127 6259 6259 625800

Stage II Crack Growth Title: 737 GPS Antenna Stage II




Pass Total Life

0 0.73 1.000789 1 1 515800

3000 0.780812 1.000871 31 31 518800

5700 0.832501 1.000965 58 58 521500

8100 0.884106 1.001068 82 82 523900

10200 0.934429 1.001183 103 103 526000

12100 0.984826 1.001308 122 122 527900

13900 1.037531 1.001596 140 140 529700

15500 1.089069 1.001596 156 156 531300

17000 1.142003 1.00177 171 171 532800

18300 1.192011 1.00196 184 184 534100

19500 1.242038 1.002167 196 196 535300

20700 1.296264 1.002406 208 208 536500

21800 1.350138 1.002667 219 219 537600

22800 1.403021 1.002667 229 229 538600

23700 1.454189 1.002948 238 238 539500

24600 1.509125 1.003274 247 247 540400

25400 1.561478 1.003626 255 255 541200

26200 1.617559 1.003626 263 263 542000

26900 1.669995 1.004 270 270 542700

27600 1.725897 1.004435 277 277 543400

28200 1.776909 1.004435 283 283 544000

28800 1.831009 1.004894 289 289 544600

REVISION

NC


PAGE NO.

47

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


29400 1.888535 1.004894 295 295 545200

29900 1.939348 1.00543 300 300 545700

30400 1.993002 1.00543 305 305 546200

30900 2.049805 1.005992 310 310 546700

31400 2.109974 1.006648 315 315 547200

31800 2.160864 1.006648 319 319 547600

32200 2.214292 1.006648 323 323 548000

32600 2.270597 1.007421 327 327 548400

33000 2.329936 1.007421 331 331 548800

33400 2.392684 1.008232 335 335 549200

33800 2.459049 1.008232 339 339 549600

34100 2.511502 1.009189 342 342 549900

34400 2.56639 1.009189 345 345 550200

34700 2.623903 1.010178 348 348 550500

35000 2.684329 1.010178 351 351 550800

35300 2.747736 1.011348 354 354 551100

35600 2.814699 1.011348 357 357 551400

35900 2.885196 1.012532 360 360 551700

36200 2.959917 1.012532 363 363 552000

36400 3.012064 1.012532 365 365 552200

36600 3.066377 1.013929 367 367 552400

36800 3.123004 1.013929 369 369 552600

37000 3.181932 1.013929 371 371 552800

37200 3.243542 1.0156 373 373 553000

37400 3.308037 1.0156 375 375 553200

37600 3.3754 1.017263 377 377 553400

37800 3.446364 1.017263 379 379 553600

38000 3.520705 1.017263 381 381 553800

38200 3.599045 1.019247 383 383 554000

38400 3.68175 1.019247 385 385 554200

38600 3.768851 1.021651 387 387 554400

38800 3.861763 1.021651 389 389 554600

39000 3.960067 1.023979 391 391 554800

39100 4.011955 1.023979 392 392 554900

39200 4.065441 1.023979 393 393 555000

39300 4.120609 1.023979 394 394 555100

39400 4.177552 1.026786 395 395 555200

39500 4.237138 1.026786 396 396 555300

39600 4.298764 1.026786 397 397 555400

REVISION

NC


PAGE NO.

48

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


39700 4.362553 1.026786 398 398 555500

39800 4.428639 1.030242 399 399 555600

39900 4.498298 1.030242 400 400 555700

40000 4.570657 1.030242 401 401 555800

40100 4.645904 1.030242 402 402 555900

40200 4.724248 1.034615 403 403 556000

40300 4.807667 1.034615 404 404 556100

40400 4.894842 1.034615 405 405 556200

40500 4.986082 1.038771 406 406 556300

40600 5.083734 1.038771 407 407 556400

40700 5.186422 1.038771 408 408 556500

40800 5.294635 1.04402 409 409 556600

40900 5.412054 1.04402 410 410 556700

41000 5.536628 1.04402 411 411 556800

41100 5.669198 1.050925 412 412 556900

41200 5.816099 1.050925 413 413 557000

41300 5.974092 1.056995 414 414 557100

41400 6.150738 1.056995 415 415 557200

41500 6.343465 1.064916 416 416 557300

41600 6.565452 1.064916 417 417 557400

41700 6.813312 1.07594 418 418 557500

41800 7.11424 1.07594 419 419 557600

41900 7.465446 1.093141 420 420 557700

41978 7.839854 1.1041 420 420 557778

42000 7.983591 1.1041 421 421 557800

42056 8.383763 1.121566 421 421 557856

42094 8.813225 1.136762 421 421 557894

42100 8.938051 1.136762 422 422 557900

42119 9.395838 1.159576 422 422 557919

42122 9.997675 1.186125 422 422 557922

REVISION

NC


PAGE NO.

49

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


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

At 557922 flights crack half length reaches 9.998 inch Fresidual =(153)/{(1.186)(3.14*9.9976)} 0.5

Fresidual =23.024 ksi LIMIT = 10.367 ksi (Axial direction, principal)

LIMIT < Fresidual Therefore it can be stated that crack growth life of this detail is conservatively assumed to be 557922 landings.

REVISION

NC


PAGE NO.

50

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


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) antenna installations, since it has the shortest life.

Crack growth life is long

Detailed visual Inspection is utilized.

HFEC 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

Therefore, following inspections are utilized

Inspection threshold = 30,000 landings

Repeat interval = 20,000 landings

Inspection Method is detailed visual

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

REVISION

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PAGE NO.

51

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


Inspection requirements are for 737 antenna relocation installations

Inspection Intervals

(Landings) Detectable

Crack Threshold Recurring Length (in) TCAS Antenna 30000 20000 1.00 Transponder Antenna 30000 20000 1.00 GPS antenna 30000 20000 1.00

INSPECTION PROGRAM Perform additional inspection of the repair 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, 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

REVISION

NC


PAGE NO.

52

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


TCAS ANTENNA INSPECTION AREA & METHOD

Detailed Visual Inspection Area

REVISION

NC


PAGE NO.

53

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


TRANSPONDER ANTENNA

INSPECTION AREA & METHOD


REVISION

NC


PAGE NO.

54

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


GPS ANTENNA

INSPECTION AREA & METHOD


REVISION

NC


PAGE NO.

A1

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


APPENDIX A REFERENCE MATERIAL

REVISION

NC


PAGE NO.

A2

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


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

REVISION

NC


PAGE NO.

A3

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


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

REVISION

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PAGE NO.

A4

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


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

REVISION

NC


PAGE NO.

A5

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


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

REVISION

NC


PAGE NO.

A6

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


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

REVISION

NC


PAGE NO.

A7

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


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

REVISION

NC


PAGE NO.

A8

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

A9

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

A10

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


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

REVISION

NC


PAGE NO.

A11

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


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

REVISION

NC


PAGE NO.

A12

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


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

REVISION

NC


PAGE NO.

A13

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

A14

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

A15

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

A16

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

A17

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

A18

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

A19

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

A20

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

A21

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

A22

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

A23

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

A24

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

A25

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

A26

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

A27

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

A28

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

A29

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


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)

REVISION

NC


PAGE NO.

A30

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


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 ]

REVISION

NC


PAGE NO.

A31

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


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

REVISION

NC


PAGE NO.

A32

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


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

REVISION

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PAGE NO.

A33

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11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

A34

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11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

A35

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

A36

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.



REVISION

NC


PAGE NO.

A37

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


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

REVISION

NC


PAGE NO.

A38

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


SUBJECT:


REF. DWG. NO.


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

REVISION

NC


PAGE NO.

A39

PREPARED BY E. Kats

11/21/13 DATE

CHECKED BY


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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

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 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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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: 10.367 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=8.8688, 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 4.2595e+000 1.2541e-007 Max stress = 10.367000 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 0.025009 2.1600 2.1600 0.0000 0.0000 6.2767e+000 5.4178e-007

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Stress State in 'C' direction (PSC): 5.76927 Crack length exceeded stop value - run time : 0 hour(s) 0 minute(s) 0 second(s)

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GPS 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 GPS 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: 10.367 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=9.5135, Stress State=2 (Based on Kmax criteria) Critical crack size in 'C' direction=15.2731, 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 1.5712e+001 1.5943e-005 Max stress = 10.367000 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 0.78081 1.0009 1.0009 0.0000 0.0000 1.6251e+001 1.8071e-005 Max stress = 10.367000 R = 0.00 3000 Cycles Constant amp.: 31 Pass: 31 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 0.8325 1.0010 1.0010 0.0000 0.0000 1.6782e+001 2.0370e-005 Max stress = 10.367000 R = 0.00 5700 Cycles Constant amp.: 58 Pass: 58 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN

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C 7.8399 1.1041 1.1041 0.0000 0.0000 5.6806e+001 6.5335e-003 Max stress = 10.367000 R = 0.00 41978 Cycles Constant amp.: 420 Pass: 420 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 7.9836 1.1041 1.1041 0.0000 0.0000 5.7324e+001 7.1459e-003 Max stress = 10.367000 R = 0.00 42000 Cycles Constant amp.: 421 Pass: 421 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 8.3838 1.1216 1.1216 0.0000 0.0000 5.9672e+001 1.1302e-002 Max stress = 10.367000 R = 0.00 42056 Cycles Constant amp.: 421 Pass: 421 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 8.8132 1.1368 1.1368 0.0000 0.0000 6.2010e+001 2.0804e-002 Max stress = 10.367000 R = 0.00 42094 Cycles Constant amp.: 421 Pass: 421 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 8.9381 1.1368 1.1368 0.0000 0.0000 6.2448e+001 2.4094e-002 Max stress = 10.367000 R = 0.00 42100 Cycles Constant amp.: 422 Pass: 422 Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 9.3958 1.1596 1.1596 0.0000 0.0000 6.5312e+001 2.0061e-001 Max stress = 10.367000 R = 0.00 42119 Cycles Constant amp.: 422 Pass: 422 *********Fracture based on ' Kmax' Criteria (current maximum stress) Crack size Beta Tension Beta Compression R(k) R(final) Delta-K D( )/DN C 9.9977 1.1861 1.1861 0.0000 0.0000 6.8914e+001 1.0000e-001 Max stress = 10.367000 R = 0.00 42122 Cycles Constant amp.: 422 Pass: 422

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Stress State in 'C' direction (PSC): 2 Fracture has occurred - run time : 0 hour(s) 0 minute(s) 1 second(s)

Documents

EDWARD KATS & ASSOCIATES 511 South Maria Avenue … · 2017-06-16 · 1 T. Swift FAA-AIR-90-01 “Repairs to Damage Tolerant Aircraft.”, Structural Integrity of Aging Airplanes,