What are the best practices for incorporating fatigue and damage tolerance data into the design process?

1 Identify FDT requirements

The first step is to identify the FDT requirements for the aircraft, based on the intended mission, operation, and environment. These requirements may include load spectra, stress levels, damage scenarios, inspection intervals, and repair methods. You should also consider the relevant standards and regulations, such as the Federal Aviation Administration (FAA) or the European Aviation Safety Agency (EASA) guidelines, that specify the FDT criteria and methods for different types of aircraft.

2 Select FDT methods and tools

The next step is to select the appropriate FDT methods and tools for the design process, depending on the level of detail and complexity required. FDT methods can range from empirical formulas and charts to numerical models and simulations, each with their own advantages and limitations. FDT tools can include software, databases, test rigs, and sensors, that help you generate, analyze, and validate FDT data. You should choose the FDT methods and tools that best suit your design objectives, resources, and capabilities.

3 Generate FDT data

The third step is to generate FDT data for the aircraft components and systems, using the selected FDT methods and tools. You should aim to obtain FDT data that covers the entire range of loading conditions, material properties, and damage modes that the aircraft may encounter during its service life. You should also account for the uncertainties and variabilities that may affect the FDT data, such as manufacturing tolerances, environmental effects, and human factors.

4 Incorporate FDT data into design

The fourth step is to incorporate FDT data into the design of the aircraft, using various techniques and criteria. You should use FDT data to optimize the geometry, material, and configuration of the structures, to achieve the desired strength, stiffness, weight, and durability. You should also use FDT data to evaluate the failure modes, damage tolerance, and residual strength of the structures, to ensure that they meet the safety and reliability requirements. You should also use FDT data to define the inspection and repair procedures, to maintain the structural integrity and performance of the aircraft.

5 Validate FDT data and design

The fifth step is to validate the FDT data and the design of the aircraft, using experimental and operational tests. You should compare the FDT data obtained from the tests with the FDT data obtained from the methods and tools, to verify the accuracy and adequacy of the FDT models and assumptions. You should also compare the design of the aircraft with the FDT requirements, to confirm that the design meets the FDT criteria and standards. You should also identify and resolve any discrepancies or issues that may arise from the validation process.

6 Update FDT data and design

The final step is to update the FDT data and the design of the aircraft, based on the feedback and information gathered from the validation process and the service experience. You should use the updated FDT data to refine the design of the aircraft, to improve its performance, efficiency, and longevity. You should also use the updated FDT data to revise the inspection and repair schedules, to optimize the maintenance costs and availability of the aircraft. You should also use the updated FDT data to enhance the FDT methods and tools, to increase their reliability and robustness.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?