Analytical and experimental investigation of aircraft metal structures reinforced with filamentary composites. Phase 2: Structural fatigue, thermal cycling, creep, and residual strength

Specimens representative of metal aircraft structural components reinforced with boron filamentary composites were manufactured and tested under cyclic loading, cyclic temperature, or continuously applied loading to evaluate some of the factors that affect structural integrity under cyclic conditions. Bonded, stepped joints were used throughout to provide composite-to-metal transition regions at load introduction points. Honeycomb panels with titanium or aluminum faces reinforced with unidirectional boron composite were fatigue tested at constant amplitude under completely reversed loading. Results indicated that the matrix material was the most fatigue-sensitive part of the design, with debonding initiating in the stepped joints. However, comparisons with equal weight all-metal specimens show a 10 to 50 times improved fatigue life. Fatigue crack propagation and residual strength were studied for several different stiffened panel concepts, and were found to vary considerably depending on the configuration. Composite-reinforced metal specimens were also subjected to creep and thermal cycling tests. Thermal cycling of stepped joint tensile specimens resulted in a ten percent decrease in residual strength after 4000 cycles.