Innovative Approach to Full Scale Fatigue Testing using Hybrid Methodologies

We address main issues concerning full-scale airframe test in a systematic way by means of tests and analysis tool development. Our tests will start with idealized component testing subjected to multi-axial loading with and without HCF content to assess impact of HCF on failure initiation points and failure modes. We then build test setup for a reduced model airframe substructure testing using advanced hardware, sensor technology, and data acquisition systems. We also propose developing the kinematic model of the test set up above to optimize the location of the loading and sensing points and minimize the number of actuators and sensor used. We plan to carry out the test using a load spectrum appropriately scaled to the test article and capture data from the test using advanced technology. We develop high fidelity tools for spectrum editing to support accelerated testing without incurring alternate failure points and modes and damage, and multi-axial tools for test data analysis as well as predicting life limits and inspection intervals of service aircraft structure. Based on these proposed tests and analysis efforts, we will develop concrete plans for full-scale airframe testing.