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An integrated approach to local ultrasonic monitoring of fastener hole fatigue cracks

Published online by Cambridge University Press:  03 February 2016

A. C. Cobb ,
J. E. Michaels  and
T. E. Michaels
A. C. Cobb
Affiliation:
Southwest Research Institute, San Antonio, Texas, USA
J. E. Michaels
Affiliation:
[email protected], School of Electrical and Computer Engineering, Georgia Institute of Technology, Atlanta, Georgia, USA
T. E. Michaels
Affiliation:
[email protected], School of Electrical and Computer Engineering, Georgia Institute of Technology, Atlanta, Georgia, USA
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Abstract

Ultrasonic nondestructive evaluation methods are routinely used to detect and size fatigue cracks near fastener holes in aircraft structures as a part of scheduled maintenance. In contrast, statistical crack propagation models provide an estimate of the expected fatigue life assuming a known crack size and future fatigue loadings. Here an integrated approach for in situ diagnosis and prognosis of fastener hole fatigue cracks is proposed and implemented that incorporates both ultrasonic monitoring and crack growth laws. The sensing method is an ultrasonic angle beam technique, and cracks are automatically detected from the ultrasonic response. An extended Kalman filter is applied to combine ultrasonically estimated crack sizes with a crack growth law, effectively using the time history of the ultrasonic results rather than only the most recent measurement. A natural extension of this method is fatigue life prognosis. Results from fatigue tests on 7075-T651 aluminium coupons show improved crack size estimates as compared to those obtained from ultrasonic measurements alone, and also demonstrate the capability of predicting the remaining life. This approach for fatigue crack detection, sizing and prognosis is an example of a general strategy for in situ monitoring of structural damage whereby improved results are achieved from the integration of noisy measurements with imperfect crack growth models.

Type
Research Article
Information
The Aeronautical Journal , Volume 113 , Issue 1150: Flight structures fundamental research in the United States of America: A Special Issue – PART II , December 2009 , pp. 775 - 788
Copyright
Copyright © Royal Aeronautical Society 2009 

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