Rosebank Engineering Australia

Bayswater, Australia

Rosebank Engineering Australia

Bayswater, Australia
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Jones R.,Monash University | Molent L.,Defence Science and Technology Organisation, Australia | Barter S.,Defence Science and Technology Organisation, Australia | Matthews N.,Rosebank Engineering Australia | Tamboli D.,Monash University
International Journal of Fatigue | Year: 2014

The paper presents the results of experimental studies into the application of supersonic particle deposition (SPD) for repairing and enhancing the airworthiness and integrity of aging aircraft structures. Presented are the results of coupon tests on the application of SPD doublers to mechanically fastened joints and to simulated corrosion damage tested under constant amplitude fatigue loads. These successful tests are then supported by an application to an F/A-18 Hornet wing attachment centre barrel laboratory test article. © 2014 Elsevier Ltd. All rights reserved.

Jones R.,Monash University | Matthews N.,Rosebank Engineering Australia | Green R.,Rosebank Engineering Australia | Peng D.,Monash University
Engineering Fracture Mechanics | Year: 2015

•Previous studies have been limited to constant amplitude laboratory tests.•This paper is the first to study SPD on structures under representative flight load spectra.•This study suggests that SPD has the potential to address corrosion damage in operational aircraft. Previous constant amplitude laboratory tests have shown that supersonic particle deposition (SPD) can be used, as an alternative to mechanically fastened doublers, to enhance the structural integrity of aircraft structures. This paper compliments these findings via a numerical study into the potential for SPD scarf repairs to repair simulated corrosion in thin aircraft structural components. The results of this study, when taken in concert with the results of prior applications to full scale fatigue tests and laboratory tests, suggest that a SPD scarf repair to simulated corrosion damage subjected to load spectra representative of helicopters, fighter, maritime, and transport aircraft has the potential to give lives that are compare favourably with either the original design objectives or the stated operational life of the aircraft. © 2014 Elsevier Ltd.

Jones R.,Monash University | Peng D.,Monash University | Singh Raman R.K.,Monash University | Huang P.,Monash University | And 2 more authors.
JOM | Year: 2015

This paper focuses on problems associated with aircraft sustainment-related issues and illustrates how cracks, that grow from small naturally occurring material and manufacturing discontinuities in operational aircraft, behave. It also explains how, in accordance with the US Damage Tolerant Design Handbook, the size of the initiating flaw is mandated, e.g. a 1.27-mm-deep semi-circular surface crack for a crack emanating from a cut out in a thick structure, a 3.175-mm-deep semi-circular surface crack in thick structure, etc. It is subsequently shown that, for cracks in (two) full-scale aircraft tests that arose from either small manufacturing defects or etch pits, the use of da/dN versus ∆K data obtained from ASTM E647 tests on long cracks to determine the number of cycles to failure from the mandated initial crack size can lead to the life being significantly under-estimated and therefore to an unnecessarily significant increase in the number of inspections, and, hence, a significant cost burden and an unnecessary reduction in aircraft availability. In contrast it is shown that, for the examples analysed, the use of the Hartman–Schijve crack growth equation representation of the small crack da/dN versus ∆K data results in computed crack depth versus flight loads histories that are in good agreement with measured data. It is also shown that, for the examples considered, crack growth from corrosion pits and the associated scatter can also be captured by the Hartman–Schijve crack growth equation. © 2015 The Minerals, Metals & Materials Society

Matthews N.,Rosebank Engineering Australia | Jones R.,Monash University | Sih G.C.,Lehigh University
Science China: Physics, Mechanics and Astronomy | Year: 2014

Aircraft metal components and structures are susceptible to environmental degradation throughout their original design life and in many cases their extended lives. This paper summarizes the results of an experimental program to evaluate the ability of Supersonic Particle Deposition (SPD), also known as cold spray, to extend the limit of validity (LOV) of aircraft structural components and to restore the structural integrity of corroded panels. In this study [LU1]the potential for the SPD to seal the mechanically fastened joints and for this seal to remain intact even in the presence of multi-site damage (MSD) has been evaluated. By sealing the joint the onset of corrosion damage in the joint can be significantly retarded, possibly even eliminated, thereby dramatically extending the LOV of mechanically fastened joints. The study also shows that SPD can dramatically increase the damage tolerance of badly corroded wing skins. © 2013 Science China Press and Springer-Verlag Berlin Heidelberg.

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