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Bolt Hole Corrosion and Fatigue Damage Repair in Hybrid Vertical Lift Structure

Jude Restis, Matthew Kokaly, Michael Dubberly, Dale Manning, PartWorks

https://doi.org/10.4050/F-0079-2023-18171

Abstract:
Cold expansion has been successfully used in aerospace structures, including vertical lift airframes to repair and prevent fatigue damage for more than 50 years. In 2022 PartWorks described an innovative program that would be performed for the United States Air Force using a new process, that included cold expansion, to repair corroded fastener holes (U.S. Patent 11,255,371). This paper will focus on the test results of that development and demonstration program for the United States Air Force (Air Force Research Lab/AFRL) for repairs to bolt holes on aerospace structures with metal/carbon-fiber composite skins. Locations in aerospace structures that combine composites and metallic for vertical lift or fixed wing have demonstrated greater levels of corrosion when compared to all-metal structural skin due to galvanic corrosion between metal and carbon fiber composites. Existing repair methods for these metal/carbon fiber composite skin bolt hole/fastener sites often involve extensive removal of corrosion, non-standard or oversized holes, and extensive modeling/validation to prove repair effectiveness. Existing repairs can also lead to premature structural component replacement. This project evaluated a new repair method that uses cold expansion with thin wall bushings and/or a rivetless nut plate (RNP) to restore fatigue life to the metal bolt hole if damage is missed or potentially without having to remove all the damage/corrosion.


Bolt Hole Corrosion and Fatigue Damage Repair in Hybrid Vertical Lift Structure

  • Presented at Forum 79
  • 9 pages
  • SKU # : F-0079-2023-18171
  • Structures and Materials

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Bolt Hole Corrosion and Fatigue Damage Repair in Hybrid Vertical Lift Structure

Authors / Details:
Jude Restis, Matthew Kokaly, Michael Dubberly, Dale Manning, PartWorks