
How the French "measure" the structural life limit and the fatigue of the Rafale
https://doureios.com/pos-metroun-oi-gal ... on-rafale/
The announcement that the first Rafale of the 12 second-hand aircraft to be delivered to the Air Force is the "B305", because it is the first Rafale to enter service in 2004 and is now in its 17th year of service, has created a sensation. The impression is that this fact invalidates the official statements that the used aircraft to be received will still have a large margin of flight hours available. However, things are not exactly like that and, addressing the professionals, we will try to describe in simple terms what is true in the case of the Rafale in terms of measuring its structural life.
According to official reports, the Rafale has a structural life of 5 000 flight hours and this can be extended to 7 000 and later to 9 000 flight hours. It should therefore be made clear that the design philosophy of French aircraft is based on the 'safe life' concept, according to which certain structural elements have a safety factor sufficient for the entire operational life of the aircraft. This concept is considered to be a more conservative approach and is accompanied by heavier designs, which are more durable and reduce the need for structural inspections. This is why in the Rafale only random inspections of a small percentage of the fleet are foreseen (if indeed it is deemed appropriate) rather than regular inspections of all aircraft.
https://doureios.com/wp-content/uploads ... .57.26.png
Thus, the French aircraft are more robust and durable, compared to the American aircraft, which follow the "Damage Tolerance" design principle, in which the safety factors are more marginal, thus allowing some cracks to develop in the structural elements of the aircraft. All these are updated through a structural integrity monitoring programme and sometimes structural checks or reinforcements are required. It can therefore be seen that due to this design concept, the structural integrity monitoring programme is more critical in the case of the US aircraft fleet. On the other hand, the "Damage Tolerance" concept, due to lower safety factors, allows for lighter designs however, consistent structural monitoring is highly necessary.
Under the French "Safe Life" concept, an increased safety factor of 5 is used in critical areas so that no structural inspections are required and, by implication, no reinforcement is needed. For each individual aircraft, data is recorded on the loads on each flight and as a parallel study is carried out using finite element models, a lower safety factor is allowed. The recording of the loads on the aircraft is done through the Rafale's computer, which collects all the key flight data and of course the cases where the G limits are exceeded. This is why it matters how "hard" or "soft" the utilisation is, i.e. whether the aircraft is constantly flying demanding profiles or more relaxed training flights. The data collected on the aircraft's computer is transferred via the Maintenance Data Cartridge to the aircraft's Health and Usage Monitoring System, which among other things calculates how much "consumption" of the Fatigue Index, has taken place after each flight. The Fatigue Index or 'Fatigue Coefficient' of the aircraft is not just one single parameter but a combination of individual factors.
What we can say with certainty is that, apparently, the extension of the structural life limit on the Rafale will apply to all users. But precisely because of the "conservatism" in the design concept of the aircraft, in which much stricter criteria and a much harsher stress range were taken into account, the monitoring of the data and the calculation of the Fatigue Index automatically leads to an extension of the service life limit. And this is done without structural upgrades and at a much lower cost than the time-consuming structural upgrades carried out on American aircraft.
https://doureios.com/wp-content/uploads ... .00.09.png
As we have stated from the outset, the 3 500 flight hours margin allows the aircraft to be operated for 20 years, with an annual number of 180 flight hours, which is normal. Therefore, any structural upgrade will be a matter for the Air Force in a second year and certainly not immediately.
https://doureios.com/wp-content/uploads ... x564-1.jpg
But to return to the first Rafale to be received by the Air Force, the two-seater "B305", if we accept that over the years it has been completing 180 flight hours per year, it means that it has "exhausted" 2,800-2,900 flight hours out of the 5,000 of the original structural life calculation. In theory, it will reach 5 000 hours in 2033, i.e. in 11.5 years. However, if we consider that it is used primarily for training purposes, then we can assume that it has a relatively "soft" consumption in Fatigue Index and the upgrade of the structural life limit to 7,000 flight hours is given and "automatic".
ANd a small comment by KK on air-defense.net :
http://www.air-defense.net/forum/topic/ ... nt=1392281
First, the Rafales do not fly 180 hours per year but rather 230-280 hours. The fleet leaders already had 3,300 Hdv in mid-2018. The B305 being the 3rd delivered ops aircraft, it must be at the top of this ranking with potentially ~4,000 Hdv on the clock today.
Then I'm not sure if the methods of calculating and monitoring fatigue are different in the US. If some US aircraft need structural upgrades, it's mainly because Uncle Sam flies them a lot (for example 10,000 Hdv for an F/A-18, which let's face it, is a lot for an airborne aircraft that undergoes efforts at each catapult/landing). And they are aiming for 12,000 Hdv for their F-16s and 15,000 Hdv for their F-15s.