<p>The failure of the forward wing spar terminal fitting in a Boeing B-17 highlights how intrusive inspection practices can influence the long-term fatigue behavior of mechanically fastened joints. This study investigates the possible contribution of inspection-induced wear, specifically repeated fastener removals required by successive mandatory inspections, to a fracture of the lower forward wing spar terminal fitting. Using classical load transfer methods, and a finite element model based on original production drawings, the effects of accumulated bolt hole clearance on load sharing and local stress concentration were evaluated. Results show that modest increases in hole diameter, consistent with decades of maintenance activity, can raise the local stress concentration factor (K<sub>t</sub>), reducing average fatigue life by several orders of magnitude under representative cyclic stresses. Classical analytical predictions correlate well with finite element trends, demonstrating that simplified calculation methods provide sufficient fidelity for assessing inspection program effects. Comparison of these findings with inspection requirements indicates that repetitive fastener removal and associated wear occurred at the most structurally critical location. The study emphasizes the need to account for inspection-induced degradation in long-term maintenance planning and discusses possible approaches for mitigating cumulative wear in aging bolted assemblies.</p>

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Inspection-Induced Fatigue in a Bolted Joint: Lessons from the Boeing B-17 Spar Terminal Fitting

  • Scott A. Fohrman P.E.,
  • Mark E. Barkey,
  • Narendra Kumar Gadwal,
  • Hunter Zilmer

摘要

The failure of the forward wing spar terminal fitting in a Boeing B-17 highlights how intrusive inspection practices can influence the long-term fatigue behavior of mechanically fastened joints. This study investigates the possible contribution of inspection-induced wear, specifically repeated fastener removals required by successive mandatory inspections, to a fracture of the lower forward wing spar terminal fitting. Using classical load transfer methods, and a finite element model based on original production drawings, the effects of accumulated bolt hole clearance on load sharing and local stress concentration were evaluated. Results show that modest increases in hole diameter, consistent with decades of maintenance activity, can raise the local stress concentration factor (Kt), reducing average fatigue life by several orders of magnitude under representative cyclic stresses. Classical analytical predictions correlate well with finite element trends, demonstrating that simplified calculation methods provide sufficient fidelity for assessing inspection program effects. Comparison of these findings with inspection requirements indicates that repetitive fastener removal and associated wear occurred at the most structurally critical location. The study emphasizes the need to account for inspection-induced degradation in long-term maintenance planning and discusses possible approaches for mitigating cumulative wear in aging bolted assemblies.