Thermal error compensation in length inspection of large-scale aircraft spars in nonuniform temperature environments

As the primary load -bearing structures, large-scale aircraft spars are subject to the influence of nonuniform temperatures in field conditions, resulting in thermal errors during on -site length inspections. These errors require accurate compensation. Conventional linear scaling methods, based on the assumption of uniform temperatures and a retrieved coefficient of thermal expansion (CTE), suffer from low accuracy in nonuniform temperature environments. To address this issue, this paper proposed a thermal error compensation method that incorporates CTE recalibration. First, we established a predictive model for thermal errors in nonuniform temperature fields through differential thermoelastic analysis. Secondly, a recalibration technique for the sensitive parameter, CTE, was introduced to enhance the prediction accuracy. Finally, leveraging the equivalent form of the model, an uncertainty assessment approach tailored for nonuniform temperature conditions was formulated for the compensated lengths. Numerical and case studies of a nearly 1 m long simplified wing spar were implemented to validate the performance of the thermal error compensation method. The results indicate that the presented method improved accuracy by over 57.6% in terms of RMSE compared to the linear scaling method using average temperatures, which would provide a viable approach to achieve a more accurate on -site length inspection of aircraft components.