Verification of an individual aircraft fatigue monitoring system

Fatigue monitoring of airframes has developed over the decades to the stage where it is now incumbent for the certification of fighter type aircraft to incorporate a fatigue monitoring system. These systems typically collect operational data for the calculation of the airframe’s safe-life or crack inspection intervals. Many of these systems are complex, incorporating such features as data integrity checking, strain gauge calibration algorithms and damage calculation algorithms to name a few. Whilst it may be possible to validate the robustness and accuracy of specific system components (e.g. the damage algorithm can be tested against fatigue coupon results), the verification of the performance of the in-service system as a whole presents a much bigger challenge. In this paper, the verification of the Royal Australian Air Force’s F/A-18A/B Hornet individual aircraft fatigue monitoring system is outlined. The availability of a significant number of ex-service centre fuselage sections with known usage has facilitated this effort. Using an enhanced teardown procedure, in-service fatigue crack growth has been identified at a significant number of locations. All the in-service cracking corresponded to the same locations found cracked in the fatigue certification full-scale test article that was used to calibrate the usage monitoring system, so that by comparing the measured in-service growth with the test-demonstrated growth the functionality of the monitoring system could be assessed. This assessment should reveal the effectiveness of the system in providing robust fatigue life expended indices to help ensure that structural integrity boundaries are not exceeded. For this comparison, the crack growth was measured using quantitative fractography. It is believed that this work is the first example of using the crack growth in retired structure of known usage to verify a fatigue tracking system that incorporated significant aircraft structural integrity elements including tracking philosophy, structural fatigue lifing methodology, full-scale fatigue test results, design standard interpretation and retirement considerations.