Aircraft Sustainment and Repair - 1st Edition - ISBN: 9780081005408

Aircraft Sustainment and Repair

1st Edition

Editors: Rhys Jones A.A. Baker Neil Matthews V K Champagne
Paperback ISBN: 9780081005408
Imprint: Butterworth-Heinemann
Published Date: 15th December 2017
Page Count: 900
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Aircraft Sustainment and Repair is a one-stop-shop for practitioners and researchers in the field of aircraft sustainment, adhesively bonded aircraft joints, bonded composites repairs, and the application of cold spray to military and civil aircraft. Outlining the state-of-the-art in aircraft sustainment, this book covers the use of quantitative fractography to determine the in-service crack length versus flight hours curve, the effect of intergranular cracking on structural integrity and the structural significance of corrosion. The book additionally illustrates the potential of composite repairs and SPD applications to metallic airframes.

Key Features

  • Covers corrosion damage assessment and management in aircraft structures
  • Includes a key chapter on U.S. developments in the emerging field of supersonic particle deposition (SPD)
  • Shows how to design and assess the potential benefits of both bonded composite repairs and SPD repairs to metallic aircraft structures to meet the damage tolerance requirements inherent in FAA ac 20-107b and the U.S. Joint Services


Materials and aerospace scientists and engineers; practitioners in airworthiness, fatigue and fracture, adhesive bonding, maintenance and aircraft certification, fleet management; Researchers in the fields of cold spray, surface treatments and structural integrity

Table of Contents

1. Introduction and overview
2. Fatigue requirements for aircraft structures
3. Typical fatigue-initiating discontinuities in metallic aircraft structures
4. Practical computational fracture mechanics for aircraft structural integrity
5. Crack growth from naturally occurring material discontinuities
6. Adhesively bonded repair/reinforcement of metallic airframe components: materials, processes, design and proposed through-life management
7. Surface treatment and repair bonding
8. Analysis, design and assessment of composite repairs to operational aircraft
9. Repair of multi-site damage in civil transport aircraft - an example of the damage tolerant design of composite repairs
10. The F111C wing pivot fitting repair and implications for the design/assessment of bonded joints and composite repairs
11. Development and validation of bonded composite doubler repairs for commercial aircraft
12. Computing the growth of naturally-occuring disbonds in adhesively-bonded joints
13. Delamination growth in polymer-matrix fibre composites and the use of fracture mechanics data for material characterisation and life prediction
14. Introduction to supersonic particle deposition
15. Additive metal technologies for aerospace sustainment
16. Applications of SPD to enhance the structural integrity of corroded airframes
17. Application of SPD to enhance the structural integrity of fuseage skins and centre barells
18. Multiplicative manufacturing and aircraft sustainment


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About the Editor

Rhys Jones

Rhys Jones is Professor of Mechanical Engineering at Monash University where he is also Head of the RAAF Directorate General Technical Airworthiness Funded Centre of Expertise in Structural Mechanics. With over 350 fully refereed publications, several books and an H-index of 35 Professor Jones has made significant contributions to the fields of: aircraft structural integrity, fatigue life extension, thermo-elastic stress analysis; fatigue assessment and fracture mechanics; computational mechanics; aging structures; repair technology; Supersonic Particle Deposition (SPD) and composite materials. Professor Jones is internationally acknowledged, together with Dr. Alan Baker, as having played a pioneering role in the development of advanced composites to extend the operational life of Military and Civilian aircraft , , i.e. F111, Mirage III0, B-52, 747, 767, 727 and (Airbus) A-340, and played a leading role in transferring this technology to the US as part of the US Federal Aviation Administration’s (FAA) Aging Aircraft Program . This technology has subsequently been adopted in Australia, Europe and in the USA and has been applied to a large crossection of military aircraft. In 2008 his work on thermoelasicity was chosen by the Australian Chief Defence Scientist as one of the top ten (Australian) Defence Science papers in the period 1907-2007 . As a result of his standing in the field of Fatigue and Fracture and his pioneering work on the use of cold spray to ensure continued airworthiness Professor Jones is a member of the joint Australian Naval Aircraft System Project Office-Directorate General Technical Airworthiness working group formed to transfer Supersonic Particle Deposition Technology to Australian military aircraft.

Affiliations and Expertise

Mechanical Engineering Department, Monash University, Victoria, Australia

A.A. Baker

Dr Alan Baker is Research Consultant in Advanced Composite Structures - Australia and Emeritus Research Leader Aerospace Composite Structures, in Air Vehicles Division, DSTO. He is Australian member of the International Editorial Boards of the Journals Composites Part A Applied Science and Manufacturing, Applied Composites and International Journal of Adhesion and Adhesives. He has edited and contributed to several books, chapters in books and many scientific papers on composites and composite repair technology. He co-edited and extensively contributed to the highly popular book: “Composite Materials for Aircraft Structures”, published by the American Society for Aeronautics and Astronautics (AIAA) and Advances in Bonded Composite Repairs for Metallic Aircraft Structure, published by Elsevier.

Dr. Baker has over 40 years experience in advanced composites including 10 years in the Rolls Royce UK Advanced Research Laboratory; he is particularly recognised for pioneering work on bonded composite repair of metallic aircraft components for which he has received several awards, including the 1990 Ministers Award for Achievement in Defence Science, the 1999 Royal Aeronautical Society (Australia) Hargraves Award and the 1999 Royal Aeronautical Society (UK) Specialist Gold Medal. This repair technology has saved ADF many hundreds of millions of dollars and is being widely exploited world-wide.

Affiliations and Expertise

Defence Science and Technology Organisation, Air Vehicles Division, Victoria, Australia

Neil Matthews

Neil Matthews is the Vice President of Operations at Rosebank Engineering, a RUAG company, and holds a Master of Aircraft Design from Cranfield University in the U.K Neil has been involved in Military Aircraft Engineering support for the nearly 40 years both as a serving Air Force Officer and then in the commercial military aviation industry. Much of this involvement has been in the Structural integrity sustainment of ageing aerospace platforms. Neil has been pioneering the use of Supersonic Particle Deposition (SPD) also known as Cold Spray since 2004 and has been working closely with both Australian and International Research and Academic institutions to have the Cold Spray technology adopted for a range of applications including corrosion protection, wear protection and restoration of dimensionally discrepant parts. More recently Neil has undertaken collaborative research which has shown that SPD offers significant potential for the restoration and enhance of structural integrity. Neil has co-authored Journal papers and has been an invited speaker on this technology both In Australia and internationally on a number of occasions.

Affiliations and Expertise

Rosebank Engineering

V K Champagne

Victor K. Champagne is the Technical Team Leader of the Advanced Materials and Processes Group within the Weapons and Materials Research Directorate of the US Army Research Laboratory. He is internationally known for his research on the cold spray process.

Affiliations and Expertise

US Army Research Laboratory, USA