H. R. Zonker, G. H. Bray, R. J. Bucci, H. T. Wang, Alcoa, Inc., Alcoa Center, PA; L. Haylock, Alcoa Fastening Systems, Torrance, CA
Mechanically fastened joints are one of the most common joint manufacturing processes used by airframers and are often considered a fatigue critical detail in aerospace structures. To enable weight reduction while allowing aluminum structures to operate at increased stress levels, improvements in joint fatigue must be realized. Many options exist and are being developed related to aluminum alloys, fastening systems and fatigue enhancement processes, which can have a positive impact on joint fatigue life. From an aluminum perspective, alloys are being developed which have improved or equivalent joint fatigue resistance, in combination with superior strength and damage tolerance. Fastening systems continue to emerge which offer improved residual clamping for fatigue critical applications. Additionally, alternative blind fastening options are being developed, which facilitate automation while improving residual clamping forces in the joint. Processing alternatives also exist and are being developed which can potentially improve joint fatigue by inducing favorable residual stress fields or by modifying faying surfaces to increase resistance to fretting and crack initiation. This presentation will discuss results of recent evaluations conducted using low load and high load transfer joint fatigue specimens and review future direction of this work.