Practical Application of Structural Repair Fatigue Life Determination on the AP-3C Orion Platform

Author:

Ayling James1,Bowler Adam2,Brick Gregory3,Ignjatovic Mladen4

Affiliation:

1. Australian Aerospace (Aus Aero)

2. Aircraft Structural Integrity Section

3. Aircraft Structural Integrity – Directorate General Technical Airworthiness (ASI-DGTA)

4. QinetiQ

Abstract

The AP-3C Orion aircraft is the oldest aircraft in the Royal Australian Air Force (RAAF) inventory. The planned fleet withdrawal has been extended far beyond the original design service objective. Continued safe and effective operation has required the development of a robust ageing aircraft management approach. A fundamental aspect was supplementing the structural certification basis with appropriate standards in the form of fatigue management requirements from Federal Aviation Regulations (FAR) 25.571 and Federal Aviation Administration Advisory Circular (FAA AC) 120-93. To develop and underpin the ageing aircraft management plan and transition to the supplementary fatigue management standards, the RAAF collaborated with the Original Equipment Manufacturer, Lockheed Martin Aeronautics Company, the United States Navy (USN) and other operators to form the P-3C Service Life Assessment Program (SLAP). This program provided Full Scale Fatigue Test (FSFT) data, associated analyses and analysis tools to support management in accordance with FAR 25.571. An important element of the ageing aircraft management plan included the introduction of a rigorous Safety By Inspection (SBI) maintenance regime to assure structural airworthiness. FAA AC 120-93 requires assessment of structural repairs to determine revised fatigue management and inspection requirements. Often, this information is derived using tailored analysis tools and detailed models on a case-by-case basis. This approach is specialized, expensive and usually occurs after the repair has been designed and installed. To avoid these limitations, the AP-3C Repair Assessment Manual (RAM) was developed to provide the repair designer with a design handbook approach to fatigue analysis. In conjunction with some simple Finite Element (FE) models, the RAM supports complete repair analysis prior to an aircraft leaving the maintenance venue. This paper will present the history of the SBI program, the genesis of the RAM and actual examples of assessing structural repairs on the P-3 platform using the RAM.

Publisher

Trans Tech Publications, Ltd.

Subject

General Engineering

Reference11 articles.

1. US Federal Aviation Regulations 25. 571, Airworthiness Standards -Transport Category Airplanes, Damage-Tolerance and Fatigue Evaluation of Structure, Amendment 25-96, March (1998).

2. Federal Aviation Administration, Advisory Circular (AC) 120-93– Damage Tolerance Inspections for Repairs and Alterations, U.S. Department of Transportation, 20 November (2007).

3. RAAF, P-3 Orion, AP-3C Repair Assessment Manual, Issue 5, DAVENG - DGTA.

4. Defence Science and Technology Organisation, P-3C Australian Test Interpretation Report for 2010 Structural Management Plan Review, DSTO-TR-2655, Draft, 20 April (2012).

5. RAAF, P-3 Orion Structural Management Plan, Volumes 1 and 2, Issue 2, 31 January (2013).

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