Aircraft structures - The aircraft doubler joint/connection definition and description.

The doubler joint/connection is by definition a reinforcement of a structural part. Doubler do not transfer the total load applied to the structure, they are not splice connections. Doublers are reinforced structural parts that increase the strength of a specific area of the primary/main structure. Doublers are used to increase the strength when a geometric change or requirement decreases the primary structural component strength. If this happens we must use a doubler. Generally the doubler as the same material of the primary structure and must be applied to and extension in order to be effective and do the job. Doublers are found in several structural parts of the aircraft they are used for:

Used on Structural openings, all aircraft fuselages do not present sealed or closed cylindrical shells, the fuselage as several required openings, holes all over the place.The passengers doors holes, cargo doors holes, systems door holes, antennas holes, drain holes, static holes, pitot holes are present all over the fuselage skin. When we apply a hole in a structural part, we are decreasing the net area, reducing the part strength, increasing the applied tension and decreasing the fatigue life of the primary structure. All this bad things for the fuselage structure must be counterbalanced by something. This something is a doubler, the doubler is applied all around the hole to increase the net area, increasing the part strength, reducing the applied tension and increasing the fatigue life of the structure. This is the objective of the doubler: help the primary structure to support the applied loads. Part of the load will be transferred by the doubler and the other part by the primary structure.

Used on Structural repairs, other big use of doublers is in the aircraft structural repair. When we find a damage in the aircraft structure we must do the damage evaluation, the damage is classified and a repair solution is established. From this repair solutions, 80% of the repairs are made using doublers. Doublers configurations are the most used type of joints for structural repairs, why? because generally the damage being a crack or corrosion in the end is simply the reduction of the strength by the reduction in the net area of the part. If we reduce the area, we must add the missing area caused by the damage using the doubler. Doublers will replace the net area removed given to the structure the strength loss by the damage. Doubler will absorb part of the running load transmitted to the structure part. Primary structure pick up 100 % of the load, if a damage occur and remove 20% of the primary structure capability, then failure will occur. To avoid failure we must install a doubler, in order to pick up the 20% running load missing in the primary structure. When the 100% running load is applied to the primary structure, 80% will pass through the primary structure and 20% will pass through doubler. Doubler will pick up the missing strength of the structure, given safety to the design. Doublers are widely used for repairs.

Used on Reinforcements, if a assembled structural parts required locally an increase in strength because of a specific attachment, then a doubler must be used. Doublers will increase strength of a simple structural element, by increasing the effective working area of the part. For example in a frame with web, upper and lower cap, all riveted together. If in one specific point of this frame an increase in strength is required, because of floor beams attachments, cabinets attachment, toilets attachment, etc, the doubler is used to increase locally the strength of this frame and maintain the margin of safety of the assembly. As described above doublers are quite different of splices, doubler transfer only a percentage of the running load (XX%) and not the total load (100%). If total load is transferred then is not a doubler but a splice. Doubler are used to reinforce, compensate or restore the strength lost by the primary structural part. They are used on repairs, holes and reinforcements of aircraft parts. Use correctly the doubler and understand well the difference between them and the splices connections.