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During full body fatigue testing, an aircraft wing spar initiated a crack from a rivet hole and crack growth data was obtained unique to the test spectrum loading. Fatigue testing of the 7050-T73511 spar material was used to obtain crack growth rate data and variable amplitude fatigue crack growth tests were performed on specimens fabricated from the spar material. Calculated results were in excellent agreement with these experimental results. A layered analysis of the adhesively bonded spar showed that the stress intensity in the lower cap was approximately constant, independent of crack length. When the constant stress intensity is used in a variable amplitude fatigue crack growth analysis, there is good correlation between the predicted and observed crack growth rates.

The NASA Airframe Structural Integrity Program is a multi-disciplinary program to develop analysis methodology, a fracture data base, and improved methods of NDE detection of disbonds and cracks. As part of this program, analysis tools to predict crack growth rates and fracture propagation in shell structures are being developed. This paper describes a finite element model of crack growth in layered structures, such as lap splice joints. The model is developed using separate two-dimensional meshes of individual layers which can overlap in space. These layers can be connected with either rivet elements or by adhesive elements. Cracks can be modeled in any layer, with automatic remeshing during crack growth. Using the model, an investigation was made of the effect of rivet interference on fatigue crack growth from a loaded rivet hole. It was found that the interference reduced the stress intensity factor range significantly, resulting in slower crack growth.