Damage Tolerance of a Stiffened Composite Panel with an Access Cutout under Fatigue Loading and Validation Using FEM Analysis and Digital Image Correlation

Aircraft structures must be capable of performing their function throughout their design life while meeting safety objectives. Such structures may contain defects and/or damages that can occur for several reasons. Therefore, aircraft structures are inspected regularly and repaired if necessary. The concept of combining an inspection plan with knowledge of damage threats, damage growth rates, and residual strength is referred to as “damage-tolerant design” in the field of aircraft design. In the present study, we fabricated a composite panel with a cutout (which is generally found in the bottom skin of the wing) using a resin infusion process and studied the damage tolerance of a co-cured skin-stringer composite panel. The composite panel was subjected to low-velocity impact damage, and the extent of damage was studied based on non-destructive inspection techniques such as ultrasonic inspection. Fixtures were designed and fabricated to load the composite panel under static and fatigue loads. Finally, the panel was tested under tensile and fatigue loads (mini TWIST). Deformations and strains obtained from FE simulations were compared and verified against test data. Results show that the impact damages considered in this study did not alter the load path in the composite panel. Damage did not occur under the application of one block (10% life) of spectrum fatigue loads. The damage tolerance of the stiffened skin composite panel was demonstrated through test and analysis.