Corrosion and fatigue life prediction of aircraft typical lap structures based on life envelope
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摘要:
针对飞机在腐蚀环境下服役的寿命预测问题，开展了某型飞机机身壁板搭接结构的腐蚀-疲劳交替试验。基于试验结果和飞机结构寿命包线理论体系，建立了该型飞机机身壁板搭接结构在不同服役地区、不同飞行强度下的寿命包线，并基于寿命包线对其剩余寿命进行了预测。通过开展验证试验，将试验结果与计算结果进行对比，发现预测误差为17.4%。说明结构寿命包线是飞机典型搭接结构寿命预测的有力工具，其预测结果是飞机服役过程中检修周期及寿命管理的一项重要参考依据。
Abstract:The corrosion and fatigue tests of a certain type of aircraft fuselage panel lap structure were conducted alternatively. Based on the test results and the concept of aircraft structure life envelope, the life envelope of the lap joint structure of the fuselage panel in different service areas and under different flight intensities was established. Then, based on this life envelope, the remaining lifetime of the structure was predicted. The prediction error was found to be 17.4% by comparing the experimental results with the calculated results. It is shown that the structural life envelope is a powerful tool for life prediction of aircraft typical lap structures, and its prediction result is an important reference for the maintenance cycle and life management of aircraft in service.
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图 6 某型飞机机身壁板搭接结构的结构寿命包线
Figure 6. Structural life envelope of a fuselage wall panel lap structure for an aircraft type
图 7 某型飞机机身壁板搭接结构在甲、乙、丙、丁4个地区的结构寿命包线
Figure 7. Structural life envelope of certain aircraft fuselage panel overlap structure in areas A, B, C and D
表 1 纯疲劳试验结果
Table 1. Fatigue test results
试验件编号 疲劳寿命/周期 对应飞行小时数/efh 0-1 138 324 17 290.5 0-2 176 771 22 096.4 0-3 195 420 24 427.5 0-4 134 194 16 774.3 
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表 2 腐蚀-疲劳交替试验结果
Table 2. Results of alternating corrosion and fatigue tests
总腐蚀时间/h 试验件编号 疲劳寿命/周期 对应飞行小时数/efh 325 1-1 90 485 11 310.6 1-2 113 470 14 183.8 1-3 128 705 16 088.1 1-4 151 690 18 961.3 975 2-1 110 077 13 759.6 2-2 103 176 12 897.0 2-3 77 767 9 720.9 2-4 73 607 9 200.9 1300 3-1 65 469 8 183.6 3-2 93 485 11 685.6 3-3 94 003 11 750.4 3-4 60 460 7 557.5 1625 4-1 87 463 10 932.9 4-2 75 508 9 438.5 4-3 52 756 6 594.5 4-4 60 634 7 579.3 1950 5-1 68 997 8 622.1 5-2 87 102 10 887.8 5-3 53 866 6 733.3 5-4 48 095 6 011.9
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表 3 不同腐蚀年限下的疲劳寿命与腐蚀影响系数
Table 3. Fatigue life and corrosion impact factor for different corrosion years
试验腐蚀时间/h 等效腐蚀年限/a 对应飞行小时数/efh C(T) 0 0 20 147.2 1.000 0 325 10.00 15 135.9 0.751 3 975 30.00 11 394.6 0.565 6 1 300 40.00 9 794.3 0.486 1 1 625 50.00 8 636.3 0.428 7 1 950 60.00 8 064.4 0.400 3
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表 4 不同地区的结构寿命包线
Table 4. Structural life envelops for different regions
服役
地区防护层
有效期/a对应飞行
小时数/efhC(T)曲线公式 相关系数 甲 6.14 20 147.2 C(T)=1−0.078 4T0.504 0 0.997 乙 4.10 20 147.2 C(T)=1−0.091 3T0.504 0 0.997 丙 3.08 20 147.2 C(T)=1−0.115 4T0.503 8 0.997 丁 2.48 20 147.2 C(T)=1−0.120 2T0.504 3 0.997
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表 5 验证试验加载条件与假设服役历程对应关系
Table 5. Correspondence between validation test loading conditions and assumed service history
服役
地区飞行强度/
（efh·a−1）服役
年数/a试验腐蚀
周期/h试验疲劳
循环数/周期甲 272 5.1 0 11 100 乙 240 0.7 0 1 350 乙 240 2.5 110 4 800 丁 187 4 304 6 000 丙 254 3.2 224 6 500 甲 待求 8 260 疲劳加载至断裂 注：在甲地服役的5.1 a和乙地服役的前0.7 a，防护体系未失效，试验中为纯疲劳加载。
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表 6 模拟结构转场服役/使用的腐蚀-疲劳交替试验结果
Table 6. Results of alternate corrosion and fatigue tests simulating transfer of structure into service/use
试验件编号 疲劳寿命/周期 对应飞行小时数/efh 6-1 72 325 9 040.6 6-2 103 274 12 909.3 6-3 103 843 12 980.4 6-4 66 791 8 348.9
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