Implication of unequal rivet load distribution in the failures and damage tolerant design of metal and composite civil aircraft riveted lap joints

Riveted lap joints are being used widely in civil aircraft structures. Conventional design procedures assume that the joint can be designed as if all rivets carry load equally. As found in literature associated with fatigue and fracture, forensic studies on structural failures, this assumption is not entirely valid. In this paper, the regulatory codes for civil aircraft as applicable to riveted joints in the form of FAR 25 regulations are briefly reviewed. The regulatory code discusses safety factors in an implied way, but has little specific recommendations for riveted joints. However, studies on the failures of specific aircraft illustrated in this paper add to the argument that both static strength and life are affected by the initial design procedures for the riveted joints. In this paper, finite element models for metal–metal, composite–metal, composite–composite lap joints are studied. A three row lap joint used in commercial aircraft and which was part of failure studies is also examined. Unequal rivet loads and in cases, nearly 50% more than conventional design has been seen in linear finite element analysis. Elasto-plastic analysis using rivet flexibility shows re-distribution of loads. Based on these observations, the effect of rivet loads on life estimation including the use of concepts such as by-pass stresses is discussed. These results have implications for static strength at ultimate load, damage tolerance and fail safety and are discussed in this paper. Next, in a composite–composite lap joint, the influence of ply-angle on the rivet loads is studied. Also, a composite–metal lap joint is studied for the rivet load distribution and life estimation. It is found that the load shared by the rivet rows in a composite–metal lap joint are not symmetric and therefore are more susceptible to cracking and subsequent failure as the unequal distribution can cause some of the rivet loads to be high. In conclusion, the issue of fail safe and damage tolerant design of civil aircraft structures with riveted joints are addressed, especially the implication of unequal load distribution on the failures of such joints and it is suggested that these unequal rivet load distributions be catered for at the early design stage itself via finite element analysis and the possibility of an over-arching safety factor could be considered that incorporates both ultimate load and damage tolerance conditions.