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During design of the 777 Airplane, light gage, near net section 2090-T86 extrusions were considered to reduce aircraft weight. The need to evaluate effects of fastener installation on 2090-T86 was indicated by a previous study documenting problems due to low short transverse tensile strength. Tests by Boeing installing fasteners into holes using interference fits showed 2090-T86 was more susceptible to damage from fastening than previously reported. Damage consisted of cracks normal to the short transverse direction around the periphery of the fastener hole. This report documents the test program conducted at Boeing.

With the increasing shift toward automation with respect to fastener installation, the need has evolved for clearer definition of the process capability of new fastener installation automation systems. In light of Engineering design requirements, and to address the process capability issue, Boeing has developed and implemented D6- 56617, a machine certification process for automated fastening of fuselage structure. This philosophy was a new approach in the following ways: 1. Previously, engineering oversight of automated fastening systems was limited to wing structure applications. 2. The process requires that process capabilities and performance of the automated machinery itself be established by test. 3. The process requires that detailed Process Control Documents be developed and followed. 4. The process links the statistical test data to the day to-day operating parameters of the machine.