Quantitative Investigation of Surface and Subsurface Fatigue Cracks Near Rivets in Riveted Joints Using Acoustic, Electron and Optical Microscopy

Abstract

<p>Using scanning acoustic microscopy, optical microscopy and scanning electron microscopy, in conjunction with fractography of fractured surfaces, the crack formation and growth kinetics of subsurface fatigue cracks and surface breaking fatigue cracks near rivets have been characterized in detail in this research. The scanning acoustic microscope was used to quantitatively investigate subsurface fatigue cracks (even when they were very small) at and near countersunk rivets in riveted lap joint specimens that are similar to the riveted lap joints found in the fuselages of many aircraft.</p> <p>It was found that the maximum nominal applied stress influences the fatigue crack initiation and propagation behavior. Eyebrow type cracks develop at lower stresses and centerline cracks develop at higher stresses. At low stress ranges, the fatigue cracks initiate a short distance from the rivet at or near the hidden surface of the chamfered panel. At higher stress amplitudes, the cracks initiate at the blunt knife edge. Residual compressive stresses and fretting are suggested to play more important roles at lower stress ranges. Both types of cracks initiate in a shear mode but transform to tensile, mode I, cracks as they grow. This transition occurs much more rapidly at the higher stress amplitude. At both high and low stresses, the cracks are longer on the fayed surface of the panel than elsewhere.</p> <p>In a comparison of Alclad 2024-T3 and Ale lad 2524-T3, it was found that the high purity aluminum alloy 2524 nucleates cracks at a greater number of cycles than the less pure aluminum alloy 2024. At high stress, crack initiation plays less of a roll and the 2024 alloy has a longer life.</p> <p>The scanning acoustic microscope enabled us to study subsurface fatigue cracks. The understanding gained from the characterization of the subsurface fatigue cracks will help in the modeling of crack initiation and growth in the riveted lap joint and will also aid in the improvement of NDE techniques for the detection of these cracks. This novel technique for examining subsurface cracks will be useful in the study of subsurface cracks in other alloys.</p>