The environmental condition in which the Royal Malaysian Airforce is currently operating its aircraft is prone to corrosion. This is due to the high relative humidity and temperature. With most of its aircraft being in the legacy aircraft era, the aircraft’s main construction consists of the aluminium 2024 material. However, this material is prone to corrosion, thus reducing fatigue life and leading to fatigue failure. Using the concept of either Safe Life or Damage Tolerance as its fatigue design philosophy, the RMAF adopts the Aircraft Structure Integrity Program (ASIP) to monitor its structural integrity. With the current problem of not having the structural limitation on corrosion-damaged structure, the RMAF has embarked on its fatigue testing method. Finite Element (FE) studies and flight tests were conducted, and the outcome is summarized. The conclusion is that the longeron tested on the aircraft can withstand the operational load, and its yield strength is below the ultimate yield strength of the material. These research outcomes will also enhance the ASIP for other aircraft platforms in the RMAF fleet for its structure life assessment or service life extension program.

The airframe structures of most fighter aircraft in the Royal Malaysian Airforce have been in service for 10 to 20 years. The effect of fatigue loading, operating conditions, and environmental degradation has led to the structural integrity of the airframe being assessed for its airworthiness. Various NDT methods were used to determine the current condition of the aircraft structure after operation of beyond 10 years, and their outcomes are summarized. In addition, although there are six critical locations, the wing root was chosen since it has the highest possibility of fatigue failure. It was further analyzed using simulation analysis for fatigue life. This contributes to the development of the maintenance task card and ultimately assists in extending the service life of the fighter aircraft. Using the concept of either safe life or damage tolerance as its fatigue design philosophy, the RMAF has adopted the Aircraft Structural Integrity Program (ASIP) to monitor the structural integrity of its fighter aircraft. With the current budget constraints and structural life extension requirements, the RMAF has embarked on the non-destructive testing method and engineering analysis. The research outcome will enhance the ASIP for other aircraft platforms in the RMAF fleet for its structure life assessment or service life extension program.

The critical aircraft structure, being the load-bearing members, is a vital component for any aircraft. The effect of fatigue loading, operating conditions, and environmental degradation has caused the structural integrity of the airframe to be assessed for its airworthiness requirement. Using the fatigue design concept of Safe Life, the RMAF adopts the Aircraft Structure Integrity Program (ASIP) to monitor the structural integrity of its critical components. RMAF has produced the task card using the engineering analysis concept on the aircraft’s critical structure. Various Computer-Aided Engineering (CAE) methods were used, and for this analysis, the Crack Growth Prediction method was used to determine the crack growth behavior and its ultimate failure point in case of any crack occurrences. Although there are six critical locations, the wing root is chosen since it has the highest possibility of fatigue failure. The analytical methods which were discussed are Crack Growth Analysis and Low Cycle Fatigue. For the numerical method, NX Nastran was used for the simulation of crack growth. The result from the crack growth analysis was validated with the numerical result. The conclusion is that, based on the fatigue life cycle, the wing root structure condition is not affected by severe damage, and its failure is approximately around 30 to 100 years for both the through hole and through side crack. Thus, its structural life can be extended. The research outcome will be on the extension of the structure life of the aircraft wing.