For the safe design of aircraft bleed air system ducts and assessment of ducts with minor cracks found in the quality inspection, it is required to understand and predict the crack behavior and leak-before-break air leakage. A leak before break is desired so a leak can be detected and a repair made before a structural failure. Measuring the leaked air temperature is a widely used technique to detect the leakage flow. The ground maintenance team uses thermal imagining and temperature probe, while the on-board system uses temperature sensor wires to detect the hot air leakage. In this study, the Extended Finite Element Method (XFEM) is used to evaluate if an initial crack will grow into unstable failure.
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