FATIGUE, FRACTURE MECHANICS & DAMAGE TOLERANCE

COURSE OUTLINE

1. 150 YEARS OF FATIGUE MISHAPS & Counting! 1 hour
   Structural Failure Modes: Creep, Fatigue, Corrosion, Wear, Fretting. Why "High-Strength" Materials Are weak In Fatigue
2. CRACK INITIATION AND PROPAGATION: DESIGN STRATEGIES TO COMBAT FATIGUE 2 hours
   What is a FAILURE? USAF-Navy-FAA-NASA Guidelines, Case Study: Cracking In F-16 Fighters: US Navy & USAF Safety Factor Fantasies -- The Chippewa Effect, Infant Mortality. F-111 Crash: Dawn of FAIL-SAFE Policy Crack Arrest and Multiple Load Paths Case Study: Sioux City 1989 DC-10 Crash
3. FRACTOGRAPHY 1 hour
   Beach Marks, Striations, Demo of Parts Failed by Fatigue
4. CRACK INITIATION PROBLEMS 2 hours
   S-N CURVES, Endurance Limit and Fatigue Strength Surface & Size effects, STRESS CONCENTRATION Data, Load Streamlines Analogy, Classroom Exercises in Crack Initiation
5. MEAN STRESS EFFECTS 1 hour
   GOODMAN & HAIGH Diagrams, Design Charts, Problems
6. LOW-CYCLE FATIGUE 2 hours
   Neuber Notch Strain Analysis, Example Problems Data For Aerospace Materials
7. MINER'S MYTH 1 hour
   Limited Applicability of Cumulative Damage, Dangers in Over-Reliance, Other Methods, Sample Data
8. FRACTURE MECHANICS 5 hours
   DA Vinci & Griffith Experiments
   The Stress Intensity Factor
   Fracture Toughness -- Thickness & Directionality Effects
   Residual Strength Paris, Forman, & Walker Equations
   Example Crack Growth Calculations
   The Principle of Superposition, Compounding, Beta Factors
   Exercises using Stress Intensity Factor Handbook
   The Surface Crack
   Cracked Lugs, Stiffeners
   Variable Amplitude Loading; Retardation
   Willenborg, Wheeler, and Closure Models
   Dynamic Fracture; Adhesives
   Multiaxial Loadings -- Mixed Mode Crack Problems
9. CRACKING AT STRUCTURAL HOLES 2 hours
   Loaded Holes Solution Methods
   Stop-Drill Technical Data
   Demo: StopCrack, ForceMate, & Coldworking of Holes
10. DAMAGE TOLERANCE 2 hours
    Slow Crack Growth Structure
    Multiple Load Path Structure
    Continuing Damage & Multi-Site Damage
    FAA FAR 25.571 and 1529
    USAF MIL-A-83444 & MIL-A-87221A
    Demo: Fatigue-Fuse & Krak-Gage
    ASIP - Aircraft Structural Integrity Pgm.
    Individual Aircraft Tracking -- IATP
11. COMPOSITES 2 hours
12. BEARINGS, SHAFTS, SPRINGS, RIVETS 1 hour
13. NDE 1 hour
    Important Inspection Methods -- Applicability, Reliability, Probability of Detection, Ultra Imaging, MagRubber, Eddy Scan
14. PRESSURE VESSELS 1 hour
    ASME Boiler Code, Leak Before Break, Cases: Comet, Aloha Convertible-in-the-sky!
15. LOAD SPECTRUM DEVELOPMENT 1 hour
    Sequence Effects, Truncation, Clipping, Retardation
16. CRACK GROWTH COMPUTER PROGRAMS 1 hour
    CRACKS, ENDURE, FLAGRO, MODGRO, LUGGRO, FATLIF
17. AGING AIRCRAFT ISSUES 1 hour
    FAA, Airlines, Navy, USAF Guidelines, Retrofits
18. SHORT CRACKS 1 hour
19. CORROSION FATIGUE 2 hours
    Case Study: A Landing Gear Failure
20. FRETTING FATIGUE 1 hour
    Case Study: A Helicopter Lug Failure
21. STRESS CORROSION CRACKING 2 hours
    Case Study: SCC of an Improperly Repaired Aircraft Structure
22. WELDS-BREEDING GROUND FOR CRACKS 2 hours
    Porosity, Residual Stress, Reinforcement, Beta Factors,
    Hot Cracking, S-N & da/dN Data
23. HELPFUL TREATMENTS & PROCESSES 1 hour
    Examples of Bad Design & Improvements, Residual Stress, Demo: Rollscan, Stresscan, Barkhausen Noise, SHOT-PEENING Advantages & Limitations, SHOT PEENING Manual
24. CRACKED PARTS REPAIR PROCEDURES 1 hour
    Videos On Boron/Epoxy Repair, Case Study -- Boeing 747 Japan Airlines Crash, 1985
25. FATIGUE, CRACK GROWTH & DTA TESTS 1 hour
    Specimen, Coupon, Component, & Full-Scale Tests
    ASTM Test Methods E399 & E647, Test Machines
26. OPTIONALS (enter # in your Registration Form)
    1. Bearings --- Pitting & Spalling Fatigue
    2. Sonic Fatigue
    3. Creep & Thermal Fatigue, Radiation
    4. Weibull Parameters for Reliability
    5. Fatigue in Helicopters
    6. Fatigue of Polymers