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structure with poor damage containment feature at the most.
• Bonded FML-reinforcement is normally optimal for SLP frames,
regarding:
1. Safety -> larger critical crack length, reducing risk of MED.
2. Weight -> Higher Allowable Stresses for DT
3. Cost -> Less inspection with lower inspection level
Matthijs Plokker / Derk Daverschot - ICAF 2009 20/05/2009 Page 17
© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.
Implementation - Design & Material
• The FML-Strap is bonded to the inner frame flange in an area which is
fatigue design-driven.
• The upper end run-out is not a fatigue-driven location.
Run-out
Glare2A
•Thickness ratio inner flange to
FML strap is 1:2
•Glass-Fibres are unidirectional
in hoop direction (GLARE2A)
•Strap Lay-up according to
A380 Principles
Loft
web
inner flange
outer flange
Matthijs Plokker / Derk Daverschot - ICAF 2009 20/05/2009 Page 18
© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.
Implementation - Design & Material
• Anti-peeling fastener
Not load transfering rivet
Reducing net-section
Introduces fatigue sensible locations
Request based on CS23.573(a) (although applicable to smaller
aircraft and subparagraphe for composite material)
Bonded strap
with anti-peeling
fasteners
Matthijs Plokker / Derk Daverschot - ICAF 2009 20/05/2009 Page 19
© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.
Implementation - Design & Material
CS23.573 (a) (5)
„(5) For any bonded joint, the failure of which would result in catastrophic loss of
the aeroplane, the limit load capacity must be substantiated by one of the
following methods:-
(i) The maximum disbonds of each bonded joint consistent with the capability to
withstand the loads in subparagraph (a)(3) must be determined by analysis,
test, or both. Disbonds of each bonded joint greater than this must be
prevented by design features; or
(ii) Proof testing must be conducted on each production article that will apply the
critical limit design load to each critical bonded joint; or
(iii) Repeatable and reliable nondestructive inspection techniques must be
established that ensure the strength of each joint.“
(i) -> Possible
(ii) -> Not practical/economical
(iii) -> Not feasible
Matthijs Plokker / Derk Daverschot - ICAF 2009 20/05/2009 Page 20
© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.
Implementation - Production Process
1) Production of FML-panel 2) FML-straps milled out of panel
5) FML-strap bonded to frame
3) Frame pretreated with CAA 4) Frame primed with BR127
Distortion due to delta in CTE
First assemblies acceptable, some frames
have to be shimmed on shell level assy.
Matthijs Plokker / Derk Daverschot - ICAF 2009 20/05/2009 Page 21
© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.
Implementation - Production Process
Matthijs Plokker / Derk Daverschot - ICAF 2009 20/05/2009 Page 22
© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.
Implementation - Quality Assurance
Inspection during manufacturing:
Step 1: Manufacturing of FML-strap laminate
Inspection of the laminate by ultrasonic through transmission in squirter technique
Step 2: Bonding of FML-strap to Aluminium frame
Inspection of bond line by manual ultrasonic through transmission technique
Matthijs Plokker / Derk Daverschot - ICAF 2009 20/05/2009 Page 23
© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.
Implementation - Quality Assurance
Principle of the ultrasonic through transmission method – single channel mode
water beam
Water jet
water supply
receiver transducer
Squirter technique
x
z
• Basic principle: ultrasonic through transmission method in squirter technique
• Both side accessibility of the inspected part required
• Complete and reproducible documentation of test data
• Display mode: C-scan (top-view)
Matthijs Plokker / Derk Daverschot - ICAF 2009 20/05/2009 Page 24
© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.
Implementation - Quality Assurance
Principle of the ultrasonic through transmission method – single channel mode
• Information on location and size of defect provided
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