Structural integrity assessment can be undertaken to demonstrate component integrity at the design stage, throughout operating life or following abnormal loading conditions. FCL engineers have extensive expertise in the use of finite element stress and thermal analysis techniques, fatigue life prediction methods and defect assessment procedures which can be used, for example, to develop durable designs able to withstand exceptional loading conditions.

Case Study: FCL has recently completed work for a client in the aerospace industry to determine the integrity of a new mobile aeroengine test frame under engine thrust, torque and wind loads. The need for the work arose because the magnitudes of the applied forces were significantly greater than those considered previously on a similar test frame. FCL’s initial investigation confirmed that the proposed frame design was unsuitable for the imposed loading conditions and a modified design was developed making use of heavier tubular sections in highly stressed regions of the structure.

Subsequent work concentrated on proving the modified frame design, and included development of beam and solid element finite element models to determine stresses and deflections occurring under worst case static and cyclic loading conditions, evaluation of predicted stresses against suitable assessment criteria, calculations to estimate the frame fatigue life and definition of defect acceptance criteria to be applied to non-destructive testing during manufacture and in-service inspections.