DC-10 composite vertical stabilizer ground test program

A review of the structural configuration and ground test program is presented. Particular emphasis is placed on the testing of a full-scale stub box test subcomponent and full span ground test unit. The stub box subcomponent was tested in an environmental chamber under ambient, cold/wet, and hot/wet conditions. The test program included design limit static loads, fatigue spectrum loading to approximately two service lifetimes (with and without damage), design limit damage tolerance tests, and a final residual strength test to a structural failure. The first full-scale ground test unit was tested under ambient conditions. The test unit was to have undergone static, fatigue, and damage tolerance tests but a premature structural failure occurred at design limit load during the third limit load test. A failure theory was developed which explains the similarity in types of failure and the large load discrepancy at failure between the two test articles. The theory attributes both failures to high stress concentrations at the edge of the lower rear spar access opening. A second full-scale ground test unit has been modified to incorporate the various changes resulting from the premature failure. The article has been assembled and is active in the test program.