Elsevier S & T

Composite Structures: Safety Management

Backman, Dr. Bjorn F.

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Table of contents

Composite Structures: Safety Managementiii
Copyright Pageiv
Contentsv
Prefacexii
PART I: Safety Management Analysis1
Chapter 1 Introduction3
1.1 Elements of structural safety4
1.2 Interaction between elements7
1.2.1 Manufacturing and safety8
1.2.2 Safety and maintenance12
1.2.3 Safety and operation14
1.2.4 Safety and regulations17
1.3 Effects on safety and the influence of residual strength24
1.3.1 Safety and integrity25
1.4 Conclusions30
Chapter 2 Structural Integrity and Safety Threats32
2.1 Integrity and manufacturing33
2.1.1 Property reductions34
2.1.2 Increase above limit load45
2.1.3 Spurious and/or unreported damage45
2.2 Integrity and maintenance46
2.3 Integrity and operation47
2.4 Integrity and requirements48
2.5 Integrity summary49
2.6 Conclusions51
2.7 The process quality of the elements of safety52
Chapter 3 Elements of Safety and Design Data53
3.1 Mishaps in manufacturing54
3.1.1 Reduced structural properties54
3.1.2 Added internal loads58
3.1.3 Reduced damage resistance, increased damage growth rate and reduced damage tolerance59
3.1.4 Reduced fatigue resistance60
3.2 Quality assurance61
3.3 Quality control62
3.4 Errors in maintenance64
3.4.1 Scheduled maintenance64
3.4.2 Major inspections65
3.4.3 Repairs66
3.5 Failures in operation67
3.5.1 Exceeding limit loads67
3.5.2 Operational violations of the environmental envelope69
3.5.3 Avoidance of environmental extremes71
3.5.4 Ground damage – occurrence and reporting71
3.6 Requirement transgressions73
3.6.1 Government regulations73
3.6.2 Design criteria76
3.7 Effects of different elements of safety76
3.7.1 Design and actions76
3.7.2 Manufacturing mishaps and actions76
3.7.3 Maintenance defects and action77
3.7.4 Operational defects and actions77
3.7.5 Requirements element78
3.8 Conclusions78
Chapter 4 Effects on the Probability of a Safe State79
4.1 Manufacturing and processing discrepancies80
4.1.1 Property reduction81
4.2 Mechanical flaws and damage84
4.2.1 Location of defects84
4.3 'Added' spurious internal loads85
4.4 Summary of effects86
4.5 Installation and assembly problems87
4.6 Maintenance defects87
4.7 Operational mishaps88
4.8 Requirement formulation88
4.9 Monitoring, interpretation, reporting and updating91
4.10 Conclusions92
Chapter 5 Process Defects Affecting Quality of Structures93
5.1 Defects of Manufacturing95
5.1.1 Structural properties affected by manufacturing95
5.1.2 Internal overloads due to manufacturing97
5.2 Defects in maintenance98
5.2.1 Defects affecting structural integrity98
5.3 Operational Defects99
5.3.1 Reduced structural properties due to defects in operation100
5.4 Defects in requirements formulation100
5.4.1 Regulation targets for composites104
5.5 Targets for monitoring105
5.6 Conclusions107
Chapter 6 Design Criteria Development108
6.1 Foundation of safety-based criteria108
6.2 Fail-safety, structural design and safe manufacturing111
6.3 Reduced structural properties and unsafe manufacturing113
6.4 Conclusions115
Chapter 7 Scenarios and Structural Integrity116
7.1 Critical scenarios117
7.2 Conclusions120
Chapter 8 Safety and Structural Integrity121
8.1 Ultimate integrity, the basic cornerstone121
8.2 Process quality and monitoring121
8.3 Defect targets and relations123
8.3.1 Defects in the design process123
8.4 Purpose and approach to structural integrity and process quality131
8.4.1 Analysis of numerical results131
8.4.2 Unsafe state – large damage132
8.4.3 Process defects – influence from all defects originating from elements of safety134
8.4.4 Structural safety135
8.4.5 Safety control136
8.5 Conclusions137
Chapter 9 Structural Service Monitoring138
9.1 Monitoring process examples139
9.2 Priority targets for monitoring141
9.3 Structural defects142
9.3.1 Reduced structural properties143
9.3.2 Spurious internal design loads146
9.4 Conclusions148
Chapter 10 Structural Integrity, Safety and Design149
10.1 Structural safety and criteria149
10.1.1 Damage growth and criteria151
10.1.2 Mechanical damage and criteria152
10.1.3 Criticality and criteria155
10.2 Conclusions158
Chapter 11 Design Mission, Criticality and Integrity159
11.1 Damage tolerance integrity and criticality159
11.2 Criticality and process defects162
11.3 Criticality and repair processes166
11.4 Criticality and damage tolerance related processes167
11.5 Mechanical damage threats168
11.6 Conclusions169
Chapter 12 Risk and Uncertainty170
12.1 Markers for monitoring action172
12.2 Situations after scheduled inspections173
12.3 Widespread defects173
12.4 Initial damage regions and process definitions174
12.5 Conclusions175
Chapter 13 Elements of Safety and their Characteristics176
13.1 Element of structural design176
13.2 Element of manufacturing177
13.3 Element of maintenance178
13.4 Element of requirements formulation179
13.5 Safety targets181
13.6 Conclusions182
Chapter 14 Generalized Safe States183
14.1 Fail-safe integrity185
14.2 Description of integrity186
14.3 Safety management strategy189
14.4 Uncertainty and monitoring190
14.5 Conclusions192
Chapter 15 Scenarios and Safety193
15.1 Manufacturing process defects193
15.1.1 Widespread defects195
15.1.2 Increase in growth rates and reduction in damage resistance196
15.2 Increase in internal loads due to manufacturing defects197
15.3 Maintenance defects198
15.4 Defects in operation198
15.5 Defects in requirements formulation199
15.6 Conclusions201
Chapter 16 Design Mission and Philosophy202
16.1 Maneuver critical designs202
16.2 Gust critical structure204
16.3 Widespread defects205
16.4 Structural integrity and composites205
16.5 Safety strategy and objectives208
16.6 Design data and integrity208
16.7 Conclusions209
Chapter 17 Strategy and Objectives for Design210
17.1 Ultimate integrity210
17.2 State of damage for ultimate conditions211
17.3 Fail-safe integrity212
17.4 Discrete source damage integrity214
17.5 Conclusions215
PART II: Safety Management Summation217
Chapter 18 Elements of Safety and Engineering Practices219
18.1 Safety background222
18.2 Initial information and updating225
18.3 The 'World of Composites'226
18.3.1 A priori probabilities227
18.3.2 Composites safety management228
18.4 Conclusions229
PART III: Improved Structural Safety of Composites231
Chapter 19 Improvement in Structural Safety of Composites233
19.1 Widespread defects234
19.2 Discrete source damage integrity235
19.2.1 Bird strike235
19.2.2 Tire burst237
19.2.3 Hailstone impact in flight238
19.2.4 Engine turbine blade penetration238
19.3 Unsafe states and safety improvements239
19.4 Conclusions240
Chapter 20 Process Quality and Integrity of Requirements Formulation241
20.1 Process for regulations242
20.1.1 Sizing requirements and criticality242
20.1.2 Fail-safe design and loss of fail-safe integrity244
20.2 Conclusions245
Chapter 21 Safety Management and Process Quality246
21.1 Manufacturing process safety management requirements247
21.1.1 Defects and structural properties247
21.1.2 Defects in manufacturing causing increased internal loads249
21.2 General process defects and effects249
21.3 Maintenance defects in safety management251
21.4 Operational defects251
21.5 Deficient requirements251
21.6 Defect and effect review252
21.7 Structural safety252
Chapter 22 Unsafe State256
22.1 Unsafe elements of safety256
22.1.1 Unsafe design256
22.1.2 Unsafe manufacturing256
22.1.3 Unsafe maintenance257
22.1.4 Unsafe operation257
22.1.5 Unsafe formulation in requirements257
22.2 Total probability of an unsafe state257
Chapter 23 Summary of Safety Management259
23.1 Design process and practices260
23.1.1 Design criticality260
23.1.2 Widespread defects261
23.1.3 Discrete damage integrity261
23.2 Discrete source damage design262
23.3 Tire-burst262
23.4 Fail-safe back-up for reduced damage tolerance due to manufacturing defects263
23.5 Hailstone impact in flight263
23.6 Process development264
23.7 Conclusions266
Chapter 24 Philosophy – Design to Explicit Safety Constraints267
24.1 Probability of failure269
24.2 Design process270
24.3 Requirements formulation271
24.4 In-service monitoring272
24.5 Process development272
24.6 Conclusions273
Chapter 25 Elements of Safety and Structural Integrity274
25.1 Ultimate integrity274
25.2 Damage tolerance integrity274
25.3 Discrete source integrity274
Appendix I: Undetected Loss of Integrity or Rare Loss fo Integrity276
Appendix II: Sizing to Safety Constraints – Damage Tolerance Critical Structure279
Appendix III: Potential Defects in Design Criticalities, Elements of Safety Processes, Purpose, Rati280
Bibliography288
Index289
A289
B289
C289
D289
E290
F290
G290
H290
I290
J291
L291
M291
N291
O291
P291
Q292
R292
S292
T293
U293
W294

Book details

Vendor Elsevier S & T
SKU 9780080548098
ISBN-13 9780080564975
Author Backman, Dr. Bjorn F.
Edition 2nd
Category Technology & Engineering
Subject Materials Science

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This book extends the focus to all the entities that participate in the successful quest for safety and demonstrates how design, manufacturing, maintenance, (inspection), operation, and requirements (regulations) all are part of successful, safe innovation and necessary to assure safe flight through the life of the vehicle. It addresses the notion that safety is a function of time and that vigilant risk management is only successful if it includes all participating entities.

It is a companion to the author's first volume, Composite Structure: Design, Safety and Innovation, published by Elsevier in June 2005.

The book

- eliminates an unacceptable 'gap' in the world of safety

- represents a 'new' approach to designing, manufacturing, maintaining, operating and regulating composite airplane structures

- for professionals in the aerospace structural development arena whether in indusrty, academia or government

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