1.2.1 Quality
of detail design is fundamental if the craft's envisaged design life
is to be attained. Experience over the past two decades, when structural
concepts were revolutionised and aspects such as speed greatly increased,
clearly indicated that areas of detail design became more prone to
fatigue cracking with the traditional structural arrangements for
details being used at that time.
1.2.2 Service
experience has shown that provided the general concepts of a structural
design are adequate then success or failure in structural terms will
depend on the quality of detail design.
1.2.3 In general,
the problems associated with aspects of detail design are those relating
to fatigue ageing and failure.
1.2.4 Fatigue
is failure under repeated loads. There are three phases in a fatigue
fracture: crack initiation, crack propagation, and fracture. These
phases are not completely separable. The process may be described
as the formation of a crack, because of repeated local plasticity,
its progression until a critical size is reached, where upon the structure
fails. Fatigue accounts for a large percentage of all service failures.
1.2.5 A structural
element can be subjected to various kinds of loading conditions, including
fluctuating stress/strain, fluctuating temperature (thermal stress/strain),
or any of these in a corrosive environment or at elevated temperatures.
Most service failures occur as a result of tensile stresses.
1.2.6 Fatigue
cracks generally initiate at high stress locations such as structural
discontinuities, weld toes, matting in connections, etc. As these
cracks propagate the ultimate load carrying capability of the structure
is reduced until sufficient fatigue damage is accumulated for the
structure to fail at normal working loads. Since fatigue cracks can
be possible points of initiation for catastrophic failures or costly
craft repairs, it is essential that fatigue is given more detailed
consideration in the design of the structure.
1.2.7 Fatigue
ageing of structural components is an accumulative process which is
largely due to the environment and the loads experienced. An important
realisation is that it is inevitable and where stress concentrations
are present in association with significant magnitudes of stress variation
then fatigue cracking will, in general, occur. Factors which influence
performance, in that they affect the magnitude of stress ranges and
provide stress concentrations, are as follows:
-
The loading experienced.
-
The quality of
detail design.
-
The selecting of
the type and grade of material.
-
The standard of
workmanship in the craft construction.
-
Corrosion rates
and magnitudes (metallic structures).
-
Erosion rates and
magnitudes (composite structures).
1.2.8 Since
the fatigue properties of higher tensile strength metallic materials
are, in general, similar to those of the basic grade materials, the
higher allowable stress magnitudes could entail a shorter fatigue
life in standard details. Assuming that the fatigue life is a function
of the stress range to the third power, it is clear that detail design
requires special consideration to reduce the effects of stress concentrations.
If higher tensile strength materials are incorporated and hence higher
stress levels are accepted, then structural details, which would have
been acceptable in mild steel structure manufactured from the basic
grade material, might not be adequate.
1.2.9 The occurrence
of cracking in craft is of prime concern from both a safety and maintenance
point of view. Experience has shown that fatigue cracks in craft structures
are normally of a self limiting nature. However, the existence of
fatigue cracking may, if not repaired, render the structure susceptible
to subsequent brittle or fast fracture. Thus both types of cracks
are significant from a maintenance point of view. Fatigue cracks,
if not repaired, may also initiate catastrophic failure as a consequence
of the more extensive use of structural optimisation leading to a
decrease in the level of structural redundancy.