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Wednesday, June 9, 2004 - 2:30 PM
EIF1.3

F-15 Wing Pylon Rib Corrosion Fatigue Detection & Inspection/Repair

R. Murner, V. Tsukernik, D. V. Zilberstein, D. Grundy, JENTEK Sensors, Inc., Waltham, MA; N. J. Goldfine, Jentek Sensors, Inc., Waltham, MA; D. Schlicker, JENTEK Sensors, Inc, Waltham, MA

Several aluminum F-15 Wing Pylon Ribs failed in-service. The root cause has been identified as corrosion fatigue. Based on failure analyses, fatigue cracks initiate primarily at corrosion pits, formed earlier in life of the components. These cracks then propagate under cyclic loading. The critical crack size is quite small, and fractures occurred when crack depth was only slightly greater than 0.01 in. The region of interest is difficult to access, thus a UT inspection from an outside surface has been implemented on the fleet. The UT inspection cannot detect subcritical cracks in all areas of concern due to the geometry limitations. A new inspection has been developed using the MWM®-Array eddy current sensor technology. The MWM-Array has demonstrated capability to inspect the region of interest, both with the bushing (that blocks the area of interest) in place through a very narrow gap and with the bushing removed. UDRI has acted as a third party evaluator, both performing inspections and destructive validation of detection performance. The MWM-Array has demonstrated the capability to detect both small cracks and small pits within the entire region of interest. Once pits and/or cracks are detected, a Condition Based Maintenance action is performed involving removal of the cracks by blending and increasing the radius in the region of concern. This technology is in the process of being transitioned to the fleet.