Aircraft structures - The aircraft splice joint/connection definition and description

The splice connection is present in all aircraft structure. The aircraft is made of several simple structural members and all this members are connected together by the called splice connection. Therefore this type of connection is the most commonly used in the aircraft. But what is a splice? How can I define a splice and where I will find this connection in the aircraft.

Splice connection is defined as a connection that performs the total load transfer between two structural elements. When we find a structural connection that makes the transfer of 100% of the total load applied, this is a splice connection. The splice connection is different of the doubler reinforcement. This two types of connections are quite different regarding the function and load transfer analysis, future post will define the difference. The aircraft structural splice is made for several reasons and very good reasons. They are:

Manufacturing limitations - the limitation that we have with the techniques and machines in the manufacturing process of structures, requires the application of the splice connection. For example: if we have a fuselage frame, skin or stringer that exceeds the dimensions of my manufacturing process machine. I must divide the structure in several parts that can be made in my manufacturing process machine and then connect the parts with splices. In my manufacturing shop we have a forming machine that produces a 100 inch by 100 inch part like a stringer. But my aircraft needs a 1000 inch stringer, then we must produce 10 simple stringers parts and connect them with splices to give the required 1000 inch stringer. We will have 10 splice connections in the aircraft stringer. The same applies to frames, skin panels, beams, etc...all aircraft structure as splices and need splices.

Fail Safe design philosophy - this structural design philosophy is defined as: the structural load must be transferred by two loading paths, if one of the loading paths fails the other must be capable to safely transfer all the load with no structural failure. If we design for fail safe the structure must be divided in several parts if one fails the others are capable to maintain the structural integrity. This type of design occurs in the stringers, we have several stringers in the fuselage, if one stringer fails the others are capable to transfer all applicable load. The splice connection is the structural option to separate the structures and maintain the structural integrity independent one of the other. As example the wing upper or lower panel can be made of a single panel, but to apply the Fail Safe design generally we separate this panel in 3 or 4 independent panels connected by splice joints. If failure occurs in panel 1, the failure (crack) will not propagate to panel 2 and 3. The total load will be redistributed only to panel 2 and 3 and this two panels must be capable to transfer the load by splice joints. In this case the splice joint is used to maintain the individual structural parts independent one of the others in order that, if cracks occurs in one of them the crack will not propagate to the others, Fail Safe design.

Geometry construction and assembly proposes - sometimes we need to use splice joints because we are required to construct a specific geometry with individual manufactured parts. The structural assembly of the individual parts, up to the main structural components, up to the aircraft itself requires that connection and attachments are needed all over the aircraft. This type of connection are defined as splice joints. As you know the aircraft structural main parts in a large aircraft manufacturing are made in several parts of the world, they are all put together in the final assembly line of the aircraft, all this parts are connected using splice joints. All over the aircraft you will find orbital splices, longitudinal splices, frames splices, stringer splices, wing panel splices, rib splices, spar splices, etc. As you see splice joints/connection are quite common, and very easy to find in the aircraft. For this reason you must understand well the definition, when to use them and the structural behavior of this type of joint. Future load analysis posts of a splice and doubler joint/connection will be available for better understanding the difference.