On the Potential of Extending Aircraft Service Time Using Load Monitoring

Aircraft structures experience various kinds of loads over their entire lifetime, typically leading to fatigue, and ultimately structural failure. To avoid structural failure during operation, the maximum number of flight cycles and flight hours is regulated by laws ensuring continued airworthiness. However, because every flight impacts the aircraft differently, not all airframes are equally stressed at the time of decommissioning. This paper proposes a new retirement criterion based on the so-called fatigue damage index (FDI). The criterion takes into account that aircraft are differently operated and thus enables an individual decommissioning of aircraft without compromising its safety. Based on aircraft sample data covering 95% of the Airbus A320 fleet over two years, the enhanced decommissioning criterion is estimated to significantly extend the average aircraft service life. The impact varies within the fleet, depending on the experienced seat load factors, cruise altitudes, and taxi times considered for the individual aircraft during operation. Whereas seat load factors and flight altitudes significantly affect the defined FDI, the influence of taxi times is only minor. Based on the estimated increase in aircraft service life, the paper argues that for service life extensions, the FDI shall be considered as the limit of validity in the regulatory framework governing the decommissioning of aircraft.