Fatigue Crack Propagation Estimation Based on Direct Strain Measurement during a Full-Scale Fatigue Test.

Military aircraft are subjected to variable loads, which are the main cause of initiation and propagation of cracks in the most stressed locations of the airframe. The aim of a Full-Scale Fatigue Test (FSFT) is to represent actual load conditions in such a way that the results obtained are a good representation of the actual loads and may be used as data that give insight into the development of real fatigue damage in critical locations. The FSFT load spectrum is a generalized depiction of the expected service loads and is designed to give an overall good representation of loads exerted on the airframe's structural elements during operation. Moreover, the discrete method of load application on the structure (exerting loads with hydraulic actuators rather than pressure fields or inertia loads expected in actual operation) may cause some local effects, which may not be present in operation. The proposed usage of direct strain data from the test include such local effects. Moreover, operational loads may vary between individual aircraft, therefore it is crucial to understand the whole process of fatigue crack onset and development in order to determine safe inspection intervals and thereby mitigate risk. This paper presents crack propagation calculations regarding the development of a crack in a critical location of the PZL-130 "Orlik" TC-II aircraft, discovered during FSFT. The discussed crack was found already developed, hence the information about nucleation and initial propagation of the crack was not available. Therefore, there was a need to recreate the whole propagation process by means of numerical estimations using the FSFT results like location of the crack and total life for model validation. Moreover, in order to gather real load data for calculations a dedicated stain gage was installed on the damaged load path to monitor the actual remote strain in the element during the FSFT. This allowed for the definition of load sequence exerted on the damaged element directly during the test rather than estimating it from the general load conditions of the wing. The calculations allowed for the estimation of crack propagation curves from initiation to critical crack length causing fatal damage. The obtained curves allowed to visualize the crack behavior due to applied load and furthermore define initial and recurring inspection intervals for the entire fleet during operation, which allowed to define which cracks could be found before they reach critical size in order to carry out mitigation actions like repair or replacement of the damaged part. The authors present the methodology for load spectrum development based on direct strain measurements and furthermore crack propagation curves estimation, validated with the actual FSFT results, which allowed to propose nondestructive inspection intervals for future operation.

Numerical and Experimental UAV Structure Investigation by Pre-Flight Load Test.

This paper presents the preparation and execution of on-ground static and engine load tests for the composite unmanned aerial vehicle (UAV). The test was conducted for pre-flight structural strength verification of the remotely piloted aerial target named HORNET, after introducing some structural modifications. The ground tests were performed before the flight test campaign, to ensure the strength and operational safety of the modified structure. The panel method and Computer Aided Design (CAD) modelling were adopted for numerical evaluation of aerodynamic and inertial forces' distribution to simulate loading scenarios for launch, flight and parachute deploying conditions during the static test. Then, the multi-stage airframe static test was prepared and executed with the use of a designed modular test rig, artificial masses, as well as a wireless strain measurement system to perform structure verification. The UAV was investigated with 150% of the typical load spectrum. Furthermore, an engine test was also conducted on a ground test stand to verify strain and vibration levels in correspondence to engine speed, as well as the reliability of data link and the lack of its interferences with wireless control and telemetry. In the article, data achieved from the numerical and experimental parts of the test are discussed, as well as post-test remarks are given.

Application of Operational Load Monitoring System for Fatigue Estimation of Main Landing Gear Attachment Frame of an Aircraft.

In this paper, we present an approach to fatigue estimation of a Main Landing Gear (MLG) attachment frame due to vertical landing forces based on Operational Loads Monitoring (OLM) system records. In particular, the impact of different phases of landing and on ground operations and fatigue wear of the MLG frame is analyzed. The main functionality of the developed OLM system is the individual assessment of fatigue of the main landing gear node structure for Su-22UM3K aircraft due to standard and Touch-And-Go (T&G) landings. Furthermore, the system allows for assessment of stress cumulation in the main landing gear node structure during touchdown and allows for detection of hard landings. Determination of selected stages of flight, classification of different types of load cycles of the structure recorded by strain gauge sensors during standard full stop landings and taxiing are also implemented in the developed system. Based on those capabilities, it is possible to monitor and compare equivalents of landing fatigue wear between airplanes and landing fatigue wear across all flights of a given airplane, which can be incorporated into fleet management paradigms for the purpose of optimal maintenance of aircraft. In this article, a detailed description of the system and algorithms used for landing gear node fatigue assessment is provided, and the results obtained during the 3-year period of system operation for the fleet of six aircraft are delivered and discussed.