Boeing Defense, Space & Security

Global Services & Support

Modification and Sustainment Capability

B-1 Wing Lower Skin Repair and

Structural Life Enhancement
2016 USAF Aircraft Structural Integrity Program Conference
San Antonio, TX
01 December 2016

Mr. Lenny Phillip Mr. Brian Koehl

Boeing, Structural Analysis Engineer USAF, B-1 Structural Engineer, B-1 System Program Office,
AFLCMC/WWDND
Mr. Mark Moss
Boeing, Structural Analysis Engineer Mr. Rodney Harberson
USAF B-1 ASIP Manager, B-1 System Program Office,
Mr. Bob Lee AFLCMC/WWDND
Boeing, B-1 ASIP DADT Analysis Lead

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Special Thanks and Acknowledgements

Global Services & Support | Modification & Sustainment Capability | B-1 Program

 B-1 System Program Office, Tinker AFB, OK

 Boeing Defense, Space and Security, Oklahoma City, OK
 Boeing Engineering Operations & Technology, Huntington Beach, CA
 Fatigue Technology Inc., Seattle, WA

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Overview

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 Background
 Problem
 Inspection Zone
 Initial ASIP Findings
 1st TCTO A/C
 Red Team Actions
 Crack Growth Curve Adjustment
 Phase I Coupon Testing
 Phase II Large Specimen Testing
 Conclusions

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Background – Problem

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 Scheduled ASIP inspection began January 2010

 Unanticipated fatigue damage found on several
aircraft
 Repair Objective:
 Create repair to achieve 2040 service life objective with
the least recurring inspections, repairs, cost and risk
 Repair Development Team: Boeing (prime), Fatigue
Technology (subcontractor)

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Background – Inspection Zone
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 Wing Lower Skin (WLS) Layout

 Material: 2219-T851
 460 Holes per wing
 17 Rib Stations

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Initial ASIP Findings

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 1st A/C of TCTO Inspection (inspected 24 rib stations):

 13,855 Equivalent Flight Hours (EFH)
 Indications found using Bolt Hole Eddy Current:
– ~12% of holes within inspection zone had crack indications
– All crack indications were removed and holes were repaired

 2nd A/C of TCTO Inspection (inspected zones A & B):

 8,482 Equivalent Flight Hours (EFH)
 Indications found using Bolt Hole Eddy Current:
– ~20% of holes within inspected zones had crack indications
– All crack indications were removed and holes were repaired

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Crack Findings on 1st TCTO A/C

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 Indication removed at 31st oversize

 Crack length ~ .242 inch

Crack
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Red Team Actions ~ Year 2010

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 Red Team Members: Chuck Babish, Barry Sturgis

 Actions from Red Team Meeting:
 Conduct specimen testing ASAP to validate inputs
– Baseline test to replicate crack findings, to date, to include density
– Use baseline tests to confirm current NDI results
– Conduct tests to evaluate service life benefit associated with repair
option
– Damage tolerance tests with ~.05” cracks

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Phase I Coupon

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 Designed single hole dogbone coupon

 WLS locations for coupon design
 5/16” Hole Dia Coupon – XRS 410, 40” forward of the rear spar
 1/2” Hole Dia Coupon – XRS 265, 45” forward of the rear spar
 Combination of ribland and farfield skin section
designed to capture the same amount of bending as the
actual wing skin
 Fatigue spectrum was adjusted to capture crack
initiation at the same time as the fleet

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Phase I Coupon Design

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Phase I Coupon Test Matrix

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Coupon type Hole Size Quantity Spectrum Rate(Hz) Location Test Duration
Baseline 5/16" 9 2003 DADTA 5 HB May - Jul 2011
Cx0 5/16" 5 2003 DADTA 5 HB Sep - Oct 2011
FmCx0 5/16" 5 2003 DADTA 5 HB Oct - Nov 2011
Cx0^ 5/16" 5 2003 DADTA 5 HB Dec - Feb 2012
FmCx0^ 5/16" 5 2003 DADTA 5 HB Jan - Feb 2012
Baseline 1/2" 6 2003 DADTA 5 Sea Oct - Nov 2011
Baseline - Wide 5/16" 6 2003 DADTA 5 HB Apr-12
FmCx3^ 5/16" 5 2003 DADTA 5 HB Jun-12
BaCx 5/16" 5 2003 DADTA 5 HB Aug-12
Cx0^ 1/2" 5 2003 DADTA 5 Sea Apr-12
FmCx0^ 1/2" 5 2003 DADTA 5 Sea May-12
Cold Work Abbreviation
Cx Thick Frangible Sleeve Cold Expansion
FmCx ForceMate Bushing Cold Expansion
BaCx Large Crack Cold Expansion
Cx^ Counterbore Cold Expansion
^ Denotes Counterbore was cold expanded
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Phase I Coupon Test –
Life Improvement Results
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• Cx^ included cold expansion

Repair Low to High Comparison Baseline Life for Test Coupons
20.0
of the o-ring counterbore
• Coupons that included cold
18.0 expansion of the counterbore
supported the decision to
16.0
implement cold work on fleet
14.0 A/C
Baseline Life and Life Improvement

12.0

10.0

8.0

6.0

4.0 Test Goal

2.0

Baseline
0.0

Cx FmCx0 Test Coupons

Cx + Cx^ FmCx0 + Cx^
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Phase I Coupon Failure Photos

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2
1

Baseline

2 1

Cold Expanded
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Phase II Specimen

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 Generate Coupon Fatigue Test Data to Support

WLS Damage Tolerance Analysis Using
Specimens More Representative of Skin than
Phase I Coupons
 Standard Cold Work Repair/Mod Hole Configuration
– Establish DT life
– Use DT life to establish inspection interval

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Phase II Specimen Design

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 Phase II testing currently in

progress

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Phase II Specimen Fracture Face

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ORIGIN

WEAR
MARKS
MACHINING
MARKS

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Conclusions

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 Standard cold expansion repair processes

provided large LIFs for 5/16” holes
 Based on initial phase I coupon results, 1/2”
holes will require subsequent inspections to
meet service life goal
 Fleet repair completed in 2016
 Phase II testing is in work and is expected to be
completed in 2018

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Global Services & Support | Modification & Sustainment Capability | B-1 Program

Questions

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Filename.ppt (add in Slide Master) | 19
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