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By Amos W. Hoggard, Technical Fellow (Retired), Aging Airplane Safety Rule/Widespread Fatigue Damage Program, and
Stephen R. Johnson, Aging Airplane Safety Rule/Widespread Fatigue Damage Program Manager, Chief Structures Engineer
On Jan. 14, 2011, a new FAA rule (14 Code throughout the world. It addresses the operated well past their original design
of Federal Regulations [CFR] 26 Subpart C) imminent future changes to airworthiness objectives in flight cycles or flight hours.
became effective requiring airplane manu limitations, how those changes were Because of the increased difficulty of
facturers to make available service actions developed, and how Boeing will assist identifying all of the necessary service
necessary to preclude the onset of WFD operators with rule compliance. actions and the inability of non-destructive
and to establish operational limits, known inspections to reliably detect small cracks
as limits of validity (LOV), of the mainte associated with the development of a WFD
About wFD
nance program that effectively define an condition, airplane manufacturers, opera
airplane’s usable life. It is important that tors, and regulatory authorities have worked
WFD in an airplane’s structure is defined
operators become familiar with the rule together to address WFD in aging airplanes.
as the simultaneous presence of cracks at
so they can prepare for changes to air The result was the creation of the LOV
multiple locations that are of sufficient size
worthiness limitations that will limit how concept that effectively establishes the life
and density that the structure will no longer
long an airplane may be operated in terms limit on an airplane based on when the
meet required damage tolerance and will
of flight cycles or flight hours. existing fatigue test evidence is no longer
not maintain required residual strength after
This article describes Boeing’s approach sufficient to reliably predict structural
partial structural failure (see fig. 1). The risk
to complying with the new rule and its behavior (see “Sources of fatigue test
of WFD onset increases as airplanes are
impact on operators of Boeing airplanes evidence” on page 6).
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Figure 1: Widespread fatigue damage (WFD)
The cracks on this lap splice are an example of WFD.
Fatigue cracks
Group 1 Airplanes The first group of airplanes affected are those certified prior to 14 CFR 25 Amendment 45.
18 Months 12 Months
Jan. 14, 2011 July 14, 2012, LOV and July 14, 2013
Binding Service Bulletin
Rule Effective Operators incorporate
Schedule
airworthiness limitations
727, 737-100/-200/ containing LOV into their
-300/-400/-500, maintenance programs.
747-100/-200/-300, DC‑8,
DC‑9, MD‑80, DC‑10
Group 2 Airplanes The second group of airplanes affected are those certified between 14 CFR 25 Amendment 45 and 95.
48 Months 12 Months
Jan. 14, 2011 Jan. 14, 2015, LOV and Binding Service Bulletin Schedule Jan. 14, 2016
Group 3 Airplanes The third group includes all airplanes certified to 14 CFR 25 Amendment 96 or greater.
60 Months 12 Months
Jan. 14, 2011 Jan. 14, 2016, LOV and Binding Service Bulletin Schedule Jan. 14, 2017
Manufacturer Action
Operator Action
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Identifying WFD-susceptible structure
The FAA with operators and manufacturers documented 16 examples of airplane structure susceptible to multiple-site damage (MSD)
and/or multiple-element damage (MED).
■■ Longitudinal Skin Joints, Frames, and Tear Straps (MSD/MED)
■■ Circumferential Joints and Stringers (MSD/MED)
■■ Lap Joints with Milled, Chem-milled, or Bonded Radius (MSD)
■■ Fuselage Frames (MED)
■■ Stringer to Frame Attachments (MED)
■■ Shear Clip End Fasteners on Shear Tied Fuselage Frames (MSD/MED)
■■ Aft Pressure Dome Outer Ring and Dome Web Splices (MSD/MED)
■■ Skin Splice at Aft Pressure Bulkhead (MSD) (see fig. 3)
■■ Abrupt Changes in Web or Skin Thickness — Pressurized or Unpressurized Structure (MSD/MED)
■■ Window Surround Structure (MSD/MED)
■■ Over-Wing Fuselage Attachments (MED)
■■ Latches and Hinges of Non-plug Doors (MSD/MED)
■■ Skin at Runout of Large Doubler (MSD) — Fuselage, Wing, or Empennage
■■ Wing or Empennage Chordwise Splices (MSD/MED)
■■ Rib-to-Skin Attachments (MSD/MED)
■■ Typical Wing and Empennage Construction (MSD/MED)
This list is not meant to be inclusive of all structure that might be susceptible on any given airplane model, and it should only be used for general
guidance. It should not be used to exclude any particular structure.
Service bulletin actions to on any given airplane model, and it should Using this information, Boeing has
preclude the onset of WFD up only be used for general guidance. committed to make service bulletin actions
to the LOV
available to the industry to enable operation
up to the LOV (see fig. 4). Specific informa
As part of rule compliance, Boeing is Cost-benefit of specific service
actions tion about each of these bulletins may be
required to identify WFD-susceptible areas
found in the Aging Airplane Program Web
for both the as-delivered structure and any
site on the MyBoeingFleet.com products
structure that required modification by an While the establishment of the LOV will
page under Structures Task Group.
airworthiness directive (AD). Boeing also mandate the retirement of very old air
A similar approach will be used to
must predict which of the identified WFD- planes, the service bulletin actions to
develop the compliance data for Group 2
susceptible areas will develop WFD prior prevent WFD may present even more
and Group 3 airplanes.
to when the LOV is reached and provide significant costs to the airline. Service
service bulletin actions to prevent that bulletin actions include inspection, modifi
development (see fig. 3). These service cation, or both and must be accomplished Addressing WFD as an operator
actions would be in the form of service prior to utilization thresholds specified in
bulletins that would require inspection, modi the associated AD. Boeing will provide the FAA with updated
fication, or both. The FAA will issue an AD Similar to the requirements of LOV, oper airworthiness limitations containing the LOV
to make these service bulletins mandatory. ators may not operate airplanes that are for each airplane model in accordance with
To assist the industry in defining areas past AD thresholds without complying with the compliance dates in figure 2. Following
that might be susceptible to WFD, the FAA, the AD-mandated inspection and modifi approval of the airworthiness limitations by
with the assistance of operators and air cation requirements. The service bulletin the FAA, Boeing will make them available
plane manufacturers, identified 16 generic actions for Boeing airplanes were devel to operators on MyBoeingFleet.com. Oper
structural areas susceptible to developing oped with the assistance of the Structures ators will need to acquire the documents
WFD (see “Identifying WFD-susceptible Task Group (STG), which consists of (per 14 CFR 91.403) and update their main
structure” on this page). All of these areas Boeing, operators, and the FAA. The STG tenance programs and have those programs
are explained in the FAA Advisory Circular was asked to evaluate each proposed approved by their FAA principal maintenance
120-104. This list is not meant to be inclu service bulletin action and ensure it was inspector by the dates specified in 14 CFR
sive of all structure that might be susceptible of value to the industry. 121.1115 or 129.115 (see fig. 2).
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Figure 3: Example of structure susceptible to WFD
This skin splice at an aft pressure bulkhead is one area of airplane structure determined by the FAA to be susceptible to WFD.
1 Forward
Fatigue Cracks 3
4
727 2 0 0
737 5 3 2
747 5 3 7
DC-8 1 2 0
DC-9 2 1 0
DC-10 1 0 1
MD-80 1 0 0`
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Figure 5: LOV for Group 1 Boeing airplane models
737 -100/-200/‑200 Cargo Line No. 1–291 34,000 34,000 D6-38278- CMR
747 -100, -200, -300, Special Performance 35,000 135,000 D6-13747- CMR
Figure 6: Anticipated LOV for Group 2 and Group 3 Boeing airplane models
These anticipated values are based on preliminary engineering calculations and are subject to final revision before final submission to the FAA. These LOV
values are substantially beyond the original design service objectives embodied in the design of the airplanes. These are anticipated values only and are
subject to revision. This information was part of Boeing multi-operator message 10-0783-01B, dated Dec. 19, 2010.
Anticipated LOV
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Boeing strongly recommends that airplanes above their
LOV be immediately and permanently removed from service.
However, Boeing will continue existing support policies for
these airplanes up to the date when operators are required
to comply with the operational rule.
For example, Boeing provided the compliance date of July 14, 2013. Because recently introduced an Aging Airplane Pro
compliance documents to the FAA on the existence of WFD in the structure can gram Web site on the MyBoeingFleet.com
July 13, 2012, for the 727, 737-100/-200/ not be reliably detected by maintenance products page. This Web site is updated
-300/-400/-500, 747-100/-200/-300, DC-8, inspections beyond the LOV, Boeing on a regular basis and contains links to the
DC-9, DC-10, and MD-80. Subsequently, strongly recommends that airplanes above current versions of all service letters and
the FAA approved LOV values for Boeing’s their LOV be immediately and permanently multi-operator messages, as well as FAA
Group 1 airplanes (see fig. 5). Updates removed from service. However, Boeing will rules and advisory circulars. It also provides
to the airworthiness limitations are now continue existing support policies for these directions for obtaining documents required
available on MyBoeingFleet.com. Operators airplanes up to the date when operators are for operator compliance.
of Group 1 airplane models have until required to comply with the operational rule. Information concerning upcoming STG
July 14, 2013, to integrate the LOV into With the exception of certain military meetings and Boeing seminars on topics
their maintenance programs and develop derivatives, including commercially certified of general interest is also available on
a plan to stop operation of these airplanes airplanes in military service, Boeing will not the Web site.
when they reach the LOV. Boeing has also provide support to airplanes beyond LOV
developed anticipated LOVs for the Group after the date when operational compliance
Summary
2 and Group 3 airplanes (see fig. 6). is required. This includes operations within
In the near future, Boeing will begin the United States under any operational
Concern about WFD increases as airplanes
publishing the service bulletin actions rules (not limited to Federal Aviation Regula
operate beyond their original design objec
required to preclude WFD for Group 1 tions Parts 121 and 129), as well as airplanes
tives. Manufacturers, operators, and the
airplanes. These Boeing service bulletins operated outside of FAA jurisdiction. This
FAA have worked together to address
will be identified by a statement in the also includes the 707/720 model, which
WFD by defining service bulletin actions
background section of the bulletin. The has an FAA-defined LOV.
necessary to preclude the onset of WFD up
FAA will mandate each of these bulletins This policy will go into effect as of the
to the LOV specified in the airworthiness
in due course. If an airplane is above a respective operational rule compliance dates
limitations. Operators will need to comply
specific threshold in the bulletin, Boeing specified in 14 CFR 121.1115 or 129.115.
with the LOV specified in the airworthiness
recommends performing the service
limitations as early as July 2013 and to
bulletin actions as instructed.
Resources for operators comply with future ADs.
For more information, please contact
Boeing support of airplanes Boeing has several means to keep agingairplaneprograms@boeing.com.
beyond LOV operators informed of the latest information
concerning WFD rule compliance. When
Boeing estimates that approximately significant information becomes available,
25 Group 1 airplanes will exceed their Boeing will publish a multi-operator mes
FAA-approved LOV by the initial operational sage or a service letter. Boeing also has
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