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Tube-and-fabric construction is a method of building airframes, which include the fuselages and wings of airplanes. It consists of making a framework of metal tubes (generally welded together) and then covering the framework with an aircraft fabric covering. The tubes are usually of steel or aluminum.
A typical metal spar in a general aviation aircraft usually consists of a sheet aluminium spar web, with L- or T-shaped spar caps being welded or riveted to the top and bottom of the sheet to prevent buckling under applied loads. Larger aircraft using this method of spar construction may have the spar caps sealed to provide integral fuel tanks.
Aerospace materials are materials, frequently metal alloys, that have either been developed for, or have come to prominence through their use for aerospace purposes. These uses often require exceptional performance, strength or heat resistance, even at the cost of considerable expense in their production or machining.
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Improper maintenance: undetected metal fatigue: 34 Starboard wing failed outboard of engine 1977-05-14 1977 Dan-Air Boeing 707 crash: Near Lusaka Airport, Lusaka, Zambia Boeing 707: Metal fatigue and aircraft design flaw 6 Structural failure of the right horizontal stabiliser due to metal fatigue and aircraft design flaw 1978-06-26
Today the metal forming industry is making increasing use of simulation to evaluate the performing of dies, processes and blanks prior to building try-out tooling. Finite element analysis (FEA) is the most common method of simulating sheet metal forming operations to determine whether a proposed design will produce parts free of defects such as fracture or wrinkling.
Wing ribs of a de Havilland DH.60 Moth. In an aircraft, ribs are forming elements of the airframe structure of a wing, especially in traditional construction.. By analogy with the anatomical definition of "rib", the ribs attach to the main spar, and by being repeated at frequent intervals, form a skeletal shape for the wing.
Aircraft manufacturing in Australia 1943. Note the circular lightening holes in the wing ribs. Lightening holes are often used in the aviation industry. This allows an aircraft to be as lightweight as possible, retaining the durability and airworthiness of the aircraft structure. [4] [5]