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© RTO/NATO 2001
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RTO LECTURE SERIES 218 bis

Aging Aircraft Fleets: Structural and

Other Subsystem Aspects
(le Vieillissement des flottes d’avions militaires : aspects
structures et autres sous-systèmes)

The material in this publication was assembled to support a Lecture Series under the
sponsorship of the Applied Vehicle Technology Panel (AVT) and the Consultant
and Exchange Programme of RTO presented 13-16 November 2000 in Sofia, Bulgaria.

Published March 2001

Distribution and Availability on Back Cover

This page has been deliberately left blank

Page intentionnellement blanche

 RTO-EN-015
AC/323(AVT-053)TP/33
NORTH ATLANTIC TREATY ORGANIZATION

RESEARCH AND TECHNOLOGY ORGANIZATION

BP 25, 7 RUE ANCELLE, F-92201 NEUILLY-SUR-SEINE CEDEX, FRANCE

RTO LECTURE SERIES 218 bis

Aging Aircraft Fleets: Structural and Other

Subsystem Aspects
(le Vieillissement des flottes d’avions militaires : aspects structures et autres
sous-systèmes)

The material in this publication was assembled to support a Lecture Series under the
sponsorship of the Applied Vehicle Technology Panel (AVT) and the Consultant
and Exchange Programme of RTO presented 13-16 November 2000 in Sofia, Bulgaria.
 The Research and Technology
Organization (RTO) of NATO
RTO is the single focus in NATO for Defence Research and Technology activities. Its mission is to conduct and promote
cooperative research and information exchange. The objective is to support the development and effective use of national
defence research and technology and to meet the military needs of the Alliance, to maintain a technological lead, and to
provide advice to NATO and national decision makers. The RTO performs its mission with the support of an extensive
network of national experts. It also ensures effective coordination with other NATO bodies involved in R&T activities.
RTO reports both to the Military Committee of NATO and to the Conference of National Armament Directors. It comprises a
Research and Technology Board (RTB) as the highest level of national representation and the Research and Technology
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particular importance especially as working together in the field of research is one of the more promising areas of initial
cooperation.
The total spectrum of R&T activities is covered by the following 7 bodies:
• AVT Applied Vehicle Technology Panel
• HFM Human Factors and Medicine Panel
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• NMSG NATO Modelling and Simulation Group
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• SET Sensors and Electronics Technology Panel
These bodies are made up of national representatives as well as generally recognised ‘world class’ scientists. They also
provide a communication link to military users and other NATO bodies. RTO’s scientific and technological work is carried
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solid base for the future.

The content of this publication has been reproduced

directly from material supplied by RTO or the authors.

Published March 2001

Copyright  RTO/NATO 2001

All Rights Reserved

ISBN 92-837-1056-8

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ii
 Aging Aircraft Fleets: Structural and Other
Subsystem Aspects
(RTO EN-015 / AVT-053)

Executive Summary
Aging aircraft concerns have dramatically escalated in the military community during the past decade.
The percentage of aircraft, operated beyond their original design life both in terms of flight hours
and/or calendar years is steadily increasing. Some models, which have already been in service for more
than 30 years, will need to be retained for another two decades or longer, often serving in roles and in
theaters very different from what was envisioned when they were originally designed.
Aging Aircraft has several connotations. Among them: (a) technological obsolescence, (b) the need for
system upgrading, (c) changing mission requirements, (d) the specter of runaway maintenance costs,
(e) concern about safety, (f) impairment of fleet readiness and (g) possible unavailability of home
depot facilities. However, if there is one thread that runs through the above list, it is the adverse impact
on sustainment of the fleet.
There are other considerations when dealing with the Aging Aircraft issue; for example, availability of
spare parts, processes and tooling may no longer be available, logistic procedures may have changed
and suppliers may be out of the business. Budgetary limitations and higher fleet utilization will
increase the demand to cope with aging aspects for the structure and major subsystems like engines
and avionics. Awareness in the user community about typical challenges and technical solutions can
ameliorate some of the concerns. New technologies are now available for dealing with many of the
aging aircraft concerns. They relate to inspection, repair and corrosion-resistant materials, structural
modeling and more sophisticated maintenance scheduling. Thus a Lecture Series (LS) under the
auspices of the NATO Partnership for Peace (PfP), is proposed, the main emphasis of which will be an
in-depth discussion of these new technologies and methods. The LS will cover aspects of systems
upgrades and structural airworthiness linked to fixed wing and helicopter fleets with emphasis on life
enhancement strategies used by NATO nations.
The material in this publication was assembled to support Lecture Series 218 bis under the sponsorship
of the Applied Vehicle Technology Panel (AVT) and the Consultant and Exchange Programme of RTO
presented 13-16 November 2000 in Sofia, Bulgaria.

iii
 le Vieillissement des flottes d’avions militaires :
aspects structures et autres sous-systèmes
(RTO EN-015 / AVT-053)

Synthèse
Le problème du vieillissement des aéronefs militaires s’est considérablement amplifié au cours de la
dernière décennie. Le pourcentage d’aéronefs en exploitation au-delà de leur durée de vie théorique,
tant du point de vue d’heures de vol que d’années de service, augmente régulièrement. Certains
modèles, déjà en service depuis plus de 30 ans, devront être maintenus pendant encore deux décennies
au moins, souvent pour des missions et des théâtres très différents de ceux qui étaient envisagés à
l’origine.
Le terme “aéronefs vieillissants” a plusieurs connotations différentes, parmi lesquelles l’on peut
distinguer : (a) l’obsolescence technologique, (b) la nécessité de procéder à la mise à niveau d’un
système, (c) l’évolution de la mission, (d) le spectre des coûts de maintenance incontrôlés, (e) des
considérations de sécurité, (f) l’atténuation de l’état de préparation de la flotte et (g) la non-
disponibilité des dépôts de base. Mais tous ces aspects ont un facteur commun : l’impact négatif sur le
maintien de la flotte.
Il y a aussi d’autres considérations à prendre en compte; par exemple la disponibilité de pièces de
rechange, de processus et d’outillage, les procédures logistiques qui peuvent avoir changé et les
fournisseurs qui peuvent avoir fait faillite. Les limitations budgétaires et l’utilisation accrue des flottes
aériennes nécessiteront de porter plus d’attention aux aspects de vieillissement de la structure et des
sous-systèmes principaux des aéronefs, tels que les moteurs et l’avionique. Une meilleure
sensibilisation des utilisateurs aux défis et aux solutions techniques typiques pourrait pallier certains de
ces problèmes. De nouvelles technologies, qui permettront de résoudre bon nombre de ces questions,
sont désormais disponibles. Elles concernent l’inspection, la réparation, les matériaux résistants à la
corrosion, la modélisation structurale et l’amélioration de la programmation de la maintenance.
Par conséquent, il est proposé d’organiser un Cycle de Conférences (LS) sous l’égide du programme
OTAN de Partenariat pour la paix (PfP), dont l’objectif principal sera de permettre une discussion
approfondie de ces nouvelles technologies et méthodes. Le Cycle de Conférences couvrira tous les
aspects de la modernisation des systèmes et de l’aptitude au vol du point de vue structural des flottes
d’avions à voilure fixe et d’hélicoptères, l’accent étant mis sur les stratégies d’extension de la durée de
vie adoptées par les pays membres de l’OTAN.
Cette publication a été rédigée pour servir de support de cours pour le Cycle de conférences 218 bis,
organisé par la Commission de AVT dans le cadre du programme des consultants et des échanges de la
RTO du 13-16 novembre 2000 à Sofia, Bulgarie.

iv
 Click inside the blue boxes or on the titles to view the corresponding section

Contents
Page
Executive Summary iii
Synthèse iv
List of Authors/Lecturers vi

Reference
Loads Monitoring and HUMS 1
by G. Günther
Aging Systems and Sustainment Technology 2
by J.W. Lincoln
Snecma ATAR Engines Cost Effective Maintenance in a 1960-2020 Life Time 3
by M. Coquelet
Repair Options for Airframes 4
by M.M. Ratwani
Risk Assessments of Aging Aircraft 5
by J.W. Lincoln
Occurrence of Corrosion in Airframes 6
by M. Colavita
Human Factors in Aircraft Inspection 7
by C.G. Drury
Extension of the Usable Engine Life by Modelling and Monitoring 8
by H. Pfoertner
Aircraft Loads 9
by M. Neubauer and G. Günther
Paper 10 withdrawn
Prevention and Control in Corrosion 11
by M. Colavita
Safety and Service Difficulty Reporting 12
by S.G. Sampath
Tutorial on Repair Software 13
by M.M. Ratwani
Inspection Technologies 14
by M.M. Ratwani
Human Factors in Aircraft Maintenance 15
by C.G. Drury
Material and Process Technology Transition to Aging Aircraft 16
by J.W. Lincoln

v
 List of Authors/Lecturers
Lecture Series Director: Dr S.G. SAMPATH
Chief, Aero-Mechanics Branch
European Research Office
Army Research Laboratory
223-231, Old Marylebone Road
London NW 15
UNITED KINGDOM

COURSE LECTURERS

Capt. M. COLAVITA Dr. C. DRURY

Chemistry Dept. of SCV Department of Industrial Engineering
Airport “M De Bernardi” University at Buffalo: SUNY
00040 Pomezia 342 Bell Hall
Rome Buffalo, New York 14260
ITALY UNITED STATES OF AMERICA
Mr. M. COQUELET Dipl.-Ing. G. GÜNTHER
SNECMA Moteur SA EADS Germany GmbH
Regional Export Military Engines Sales Military Aircraft Division
BP No 83 Postfach 80 11 60
91003 Evry Cedex 81663 Munich
FRANCE GERMANY
Dr. J.W. LINCOLN Mr Hugo PFOERTNER
ASC/EN MTU Aero Engines GmbH
2530 Loop Road West Dept. TPKF, Structural Mechanics
Wright Patterson AFB Dachauer Str.665
OH 45433-7101 80995 Muenchen
UNITED STATES OF AMERICA GERMANY
Dr M.M. RATWANI
R-Tec
28441 Highridge Road
Sug M 530
Rolling Hills Estates
CA 90274
UNITED STATES OF AMERICA

CO-AUTHORS

Dr. M. NEUBAUER
EADS Germany GmbH
Military Aircraft Division
Postfach 80 11 60
81663 Munich
GERMANY

LECTURER

Mr F. LIMPENS
Manager, Public Relations
Techspace Aero SA
Route de Liers, 121
4041 Herstal (Milmort)
BELGIUM

vi
 REPORT DOCUMENTATION PAGE
1. Recipient’s Reference 2. Originator’s References 3. Further Reference 4. Security Classification
of Document
RTO-EN-015 ISBN 92-837-1056-8 UNCLASSIFIED/
AC/323(AVT-053)TP/33 UNLIMITED
5. Originator Research and Technology Organization
North Atlantic Treaty Organization
BP 25, 7 rue Ancelle, F-92201 Neuilly-sur-Seine Cedex, France

6. Title
Aging Aircraft Fleets: Structural and Other Subsystem Aspects

7. Presented at/sponsored by
the Applied Vehicle Technology Panel (AVT) and the Consultant and Exchange
Programme of RTO in support of Lecture Series presented on 13-16 November 2000
in Sofia, Bulgaria.

8. Author(s)/Editor(s) 9. Date
Multiple March 2001

10. Author’s/Editor’s Address 11. Pages

Multiple 220

12. Distribution Statement There are no restrictions on the distribution of this document.
Information about the availability of this and other RTO
unclassified publications is given on the back cover.

13. Keywords/Descriptors
Military aircraft Risk Aircraft engines Design
Commercial aircraft Corrosion NATO forces Materials
Fleets Human factors engineering Aviation safety Structural integrity
Loads (forces) Aircraft maintenance Inspection Aging aircraft
Aging (metallurgy) Service life Reliability Transitions
Airframes Equipment health monitoring Airworthiness Process technology

14. Abstract
Aging Aircraft concerns have dramatically escalated in the military community and commercial aviation during the
past decade. Some models, which have already been in service for more than 40 years, will need to be retained for
another two decades or longer, often serving in roles and in theatres very different from what was envisioned when
they were originally designed. Aging Aircraft has several connotations. To name a few: technological obsolescence,
the spectre of runaway maintenance costs, and safety. Moreover, spare parts, processes and tooling may no longer be
available, logistic procedures may have changed and suppliers may be out of the business. Budgetary limitations and
higher fleet utilisation will increase the demand to cope with aging structures and major subsystems like engines and
avionics.
Specific topics covered by this Lecture Series are:
• Aircraft Loads
• Aging Systems and Sustainment Technology
• SNECMA ATAR Engines 1960-2020. Smarter Ideas and Less Money
• Repair Options for Airframes
• Risk Assessments of Aging Aircraft
• Occurrence of Corrosion in Airframes
• Human Factors in Aircraft Maintenance
• Extension of the Usable Engine Life by Modelling and Monitoring
• Loads Monitoring and Hums
• Depot Level Maintenance of U.S. Aircraft Engines in NATO Air Forces. Role of Private Industry and Procedures
with U.S. and European Air Forces
• Prevention and Control in Corrosion
• Safety and Service Difficulty Reporting
• Tutorial on Repair Software
• Inspection Technologies
• Inspection Reliability and Human Factors
• Material and Process Technology Transition to Aging Aircraft
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