F-22 Full Scale

Durability Test & Evaluation

Pete Caruso, Tom Brussat, and Wendy Hynes
Lockheed Martin Aeronautics Company

2006 USAF ASIP Conference

San Antonio, Texas
28-30 November 2006
Unclassified Lockheed Martin Aeronautics Company
 Overview

¾ Applied Test Loads

¾ Full Scale Test Evaluation Challenges
¾ Test Reaction Load Error
¾ Test Spectrum Update
¾ Coarse Grain Titanium
¾ Crack Growth Correlation
¾ Test Teardown Summary
¾ Summary/Conclusions

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 Applied Test Loads
¾ 2.67 Lifetimes of 2.78M Cycles
1% Landing
2% Other
3% Braking

6%
Sp
ee
db
ra
ke
14% Taxi/Turns
40% Air-to-Air

34% Buffet

Flight
FlightManeuvers
Maneuversand
andBuffet
BuffetLoads
LoadsDominate
Dominatethe
theTest
TestSpectrum
Spectrum
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 Test Reaction Load Error

¾ 196 RAMS Balanced at 7 Reaction Points

¾ Imbalance Loads Detected
¾ Wear or Friction
¾ RAM Load Errors

Reaction Point

Balance Point

New
NewMethod
MethodRequired
Requiredfor
forLoad
LoadError
ErrorEvaluation
Evaluation
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 Test Spectrum Update

¾ Pre-test Start Spectrum Adjustments

¾ Post-Start Spectrum Update
¾ Pre-Production AFT Boom Experienced Early Cracking

Critical Analysis
Locations

Aft Boom

New
NewMethod
MethodRequired
Requiredfor
forSpectrum
SpectrumUpdates
Updates
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 Reaction Load Error and Spectrum Update
- Recovery Plan

¾ Unit Load Cases Applied to Test Article FEM

¾ 1050 Unit Cases for 11 A/V Configurations, Pressures, and
Reaction Loads

¾ Internal Loads Spectra With Actual Test Loads

Reaction Error, ΔRn= (Rn – Bth,n)

Internal Load = σth + σn,T*ΔRn/Tn = σth + σn,T*(Rn – Bth,n)/Tn

P1 P2 P3 . . P
. 196 S1 S2 S3. . . S196 F1

= f +

R1 R2 R7 B1 B2 B7 T1 T2 T7

Stress
StressSpectra
SpectraIncludes
IncludesSources
Sourcesof
ofError
ErrorLoads
Loads
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 Test Accelerated

¾ 2nd and 3d Lifetime Test Spectrum Updated

¾ Horizontal Tail Buffet Cycles Removed (25% of End-Points)
¾ Events Containing Both Vertical and Horizontal Buffet is Unchanged

1st Lifetime Spectrum 2nd and 3d Lifetime – After Update

VERTICAL TAIL

No Change
HORIZONTAL
TAIL

Cycles
Removed

Test
TestLife
Lifeof
ofPre-Production
Pre-ProductionAFT
AFTBoom
BoomImproved
Improved7%-291%
7%-291%
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 Coarse Grain Titanium
3.175 mm
(.125 in)

¾ Ti 6Al-4V BA
¾ Poor fracture surface marking

Limited
LimitedObservations
Observationsof
ofCrack
CrackGrowth
GrowthRate
Rate
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 Coarse Grain Titanium
- Recovery Plan

¾ Additional Strain Gages During Cycling

¾ Quantitative Fractography (as feasible)
¾ 75 Crack Indications Examined
¾ Spectrum Crack Growth Tests
Center Crack Specimen

Crack
CrackModels
Modelshave
haveImproved
Improved
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 Crack Growth Correlation

¾ Crack Correlation Procedure

¾ Crack Initiation + Crack Growth
¾ EIFS Developed

Anomaly Anomaly

.01 inch
or EIFS EIFS

Crack Crack Test Hours

Initiation Growth

Single
Singlepoint
pointdata
datarequires
requiresconservative
conservativecorrelation
correlationanalysis
analysis
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 Frame 2 Crack Discovery

¾ Strain Departure Detected

¾ Crack Located

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 Frame 2 Crack Location

Up

Aft

Crack

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 Frame 2 Stress Spectra
Stress Exceedances (1/10th Lifetime)
100000
--- Test Design
--- Command
10000
Exceedances --- Actual
1000

100

10

1
-0.4 -0.2 0 0.2 0.4 0.6 0.8 1 1.2
Normalized Stress

Stress Time History Command

Actual
Frame 2 Stress Level

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 EIFS (in) Crack Correlation Results

Correlated Stress:
149.5 ksi

Life (Hrs)

Redesign Eliminated
this Shortfall in
Production A/C CI + CG Life (Hrs)

Durability
DurabilityAnalysis
AnalysisUpdated
Updated
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 Test Teardown Report

¾ NDI Scope

¾ 37 New
Discrepancies
Documented

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 Total Test Discrepancies

2% Disbond 2% Dummy
Structure
3% Wear / Fretting

10%
Loos
e Fas
tener
40%
12%
Broken Fastener Surface or Edge

15%
Fastener Hole 16%
or Lug Bushing or
Bearing Migration

Majority
Majorityof
ofTest
TestAnomalies
AnomaliesWere
WereSurface
SurfaceCracks
Cracksor
orBushing
BushingMigration
Migration
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 Surface or Edge
Discrepancies

Up

Inbd

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 Surface or Edge
Discrepancies

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 Bushing or Bearing
Migration

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 Test Discrepancy Summary

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 Summary/Conclusions

¾ F-22 Successfully Completed the Full Scale Durability Test

Program
¾ Test Unit Loads Method Applied
¾ Reaction Error Loads, Test Spectrum Update, and Crack Correlation
¾ Corrective Action Policies
¾ Conservative Crack Correlation Analysis
¾ Proactively Implemented Repairs and Redesigns for Test
Demonstrated Lives < 2 LT
¾ In-service Inspections for Correlated Crack Growth Lives < 2 LT
¾ Continuing Development Testing to Relieve Inspection Burden
¾ Developing an Air Vehicle Crack & Anomaly Database

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