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SECTION 3
LEAFLET 34
FATIGUE
MATERIAL SELECTION
1 INTRODUCTION
1.1
This leaflet provides guidance on the selection of metallic materials for aircraft
structural components where fatigue life and residual strength are major considerations.
Guidance is given on fatigue performance, fracture toughness, resistance to impact and crack
growth behaviour. Special considerations relating to fibre-composite components are
discussed in Leaflet 40. This information was previously issued as Leaflet 201/1.
1.2
Sufficient material must have been tested to demonstrate that the properties used for
design reflect variability both within and between batches, see for example Def Stan 00-932.
Otherwise a programme of testing will be required to establish material behaviour or to
confirm assumed or estimated properties.
2 FATIGUE PERFORMANCE
2.1
Definition. Fatigue performance is a term defining the resistance of a structural
component to the development of cracking under fatigue loading. Under fatigue loading the
design allowable stress levels may be considerably lower than those acceptable for static
design.
2.2
General. The extent to which the intrinsic fatigue performance of a material can be
realised is strongly dependent upon the influence of stress-concentrating features such as
notches, cut-outs and fillet radii, and the extent to which crack initiation is accelerated by the
effects of fretting, such as may occur in joints. Fatigue performance is also affected in varying
degree by material quality, that is the presence in a material of inclusions, residual stresses
and discontinuities introduced by material processing and heat treatment, and the surface
quality, that is the introduction of imperfections into a surface during manufacturing processes
and subsequent surface processes and treatments. Material quality and surface quality are
unlikely to have a controlling effect on fatigue performance unless stress concentration factors
are low and there is no fretting.
2.3
Comparative testing. True comparison of materials for fatigue performance must be
done using coupons representative of component condition (including any significant batch
effects), loading and environment. Where changes are made to the material processing or
manufacturing route, comparative testing must be done under representative conditions to
ensure that fatigue performance has not been adversely affected.
2.4
Surface coatings and surface treatments. Surface layers of different structure or
properties to that of the bulk substrate may significantly affect fatigue performance. For
example, plating, cladding or thickened oxide layers may develop cracks which can then grow
into the substrate. Chemical surface treatments can produce surface pitting leading to reduced
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Dolphin, A.S.
Sharp, R.
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Rating
A
B
C
D
Grain Orientation
T-L and T-S
> 0.088
0.07-0.088
0.056-0.07
< 0.056
> 0.075
0.06-0.075
0.048-0.06
< 0.048
> 0.067
0.053-0.067
0.042-0.053
< 0.042
Values in the table are TYR values (m). L-T values illustrated in Figure 1. Values of TYR are
determined from consideration of scatter in strength and toughness [2].
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