Effect of Load Spectra and Stress Magnitude on Crack Growth Behavior Variability from Typical Manufacturing Defects

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Abstract
DSTO conducted a comprehensive series of fatigue coupon tests as part of the fatigue life substantiation of the RAAF F/A-18 Hornet. The study employed five spectra which were applied to flat aluminium alloy 7050-T7451 coupons to determine the effects of manufacturing discontinuities and stress magnitude on the fatigue nucleation and crack growth behavior. Crack growth behavior was established using optical microscopy and scanning electron fractography, measuring crack sizes greater than approximately 0.05 mm. This paper reports the fraction of life to failure as well as the probability of occurrence of a crack with a defined size.

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