AirbusFDTSubject14-Is 1

Airbus Fatigue & Damage Tolerance Course January 2005
Presented by
(Hans-Jürgen Schmidt
Retired from Airbus
AeroStruc – Aeronautical Engineering
Subject 14
Reporting
F+DT course, H.-J. Schmidt, AeroStruc

Contents
• Reporting – general
• Reporting for certification
• F&DT analysis report
• Airframe Certification Document (ACD)
• ACD6 – Fatigue and Damage Tolerance Justification
• ACD9 – Comparison Fatigue and Damage Tolerance Tests /
Calculations
• ALI justification document (AJD)
© AIRBUS DEUTSCHLAND GmbH. All rights reserved. Confidential and proprietary document.
• Archiving of documents prepared by the engineering
F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 2

Reporting – general
• In general all major activities and work performed for (pre-)
development, design, certification and operation of an aircraft
should be appropriately documented.
• Most of the manufacturers have defined specific types of
documents for reporting, e.g. technical report, technical note etc.
• This subject deals with the reporting for certification, especially
fatigue and damage tolerance (F&DT) certification.
• Fatigue and damage tolerance evaluation is performed by analysis
as well as structural tests, which has to be covered by the
documentation.
• This subject describes the reporting about fatigue and damage
tolerance analysis for certification. The contents of test reports are
described in the relevant subjects.

Reporting for certification
• In principle three types of reports exist to document the F&DT
analyses:
- F&DT analysis report:
containing the complete information about the analyses, I.e.
geometry, loads, stresses, all results
- Airframe Certification Document (ACD):
containing a summary of the analyses results including
location of items analyzed. For F&DT analysis Airbus ACD
Volume 6 is applicable and is an example for documentation.
- ALI Justification Document:

containing the structural fatigue related maintenance
requirements (inspection and/or modification) which are
required to prevent catastrophic failure within the DSG or ESG.
• These three types of documents are described in the following.

F&DT analysis report – list of contents
The following list describes the typical content of a F&DT analysis
report (example for Airbus A318-100, section 17, A-D HAM part):
Table of contents
1. Introduction
1.1 Summary of the justification report
1.2 Fatigue sensitive areas in section 17, A-D HAM part
2. Methods of determination
2.1 Fatigue life determination
2.2 Crack propagation
2.3 Critical crack length

3. Loads / stress determination
3.1 Circumferential stress in skin panel (∆p+1g+VG)
3.2 Longitudinal stress in skin panel (∆p+1g+VG)
3.3 Longitudinal stress in skin panel at landing impact (3.5 ft/s)

F&DT analysis report – list of contents
- contd. -
4. da/dn – and SN – data
4.1 da/dn - data
4.2 SN -data
5. Summary of results and sketches
6. References
6.1 Documents
6.2 Loads data and computer programs
7. Fatigue and damage tolerance determination
7.1 Page numbering
7.2 Fatigue life and damage tolerance determination
The following pages contain the typical content of a F&DT analysis

report for one specific item (example for A318-100, section 15, item
15.16, window forging forward upper corner, section 15, Frame 36 –
37, Stringer 14 – 18, LH + RH).

F&DT analysis report – example
Description of stress
Location of item determination
and geometry

stresses for the relevant load cases
- contd. -
Description of
data storage
Description of SN
data and crack
growth calculation

- contd. -
Stress-time-history for
a severe flight type
Loads and stresses for

the relevant load cases

- contd. -
Stress-time-history for
a smooth flight type
Fatigue damage
calculation

- contd. -
Fatigue damage Fatigue life calcul-

calculation - contd. - ation incl. statistics

- contd. -
Data for crack Load spectrum for

growth analysis crack growth analysis

- contd. -
Crack growth results

Crack growth and critical crack length
curve

Airframe Certification Document (ACD)
- Objective
• The objective of the ACD is to provide the compliance
demonstration for the airframe with respect to overall design, static
strength, fatigue and damage tolerance evaluation, bird strike and
rotor burst structural design assessment.
• The ACD demonstrates the compliance with the Airworthiness
requirements in one set of documents with a defined format.
• The ACD contains the complete compliance demonstration for the
metallic structure. For the composite structure the following
justifications are included in the ACD:
- Methods for compliance demonstration
- Static justification
- Bird impact
All other aspects are covered by the Composite Summary Report
(CSR).
• All details about the ACD are provided by the Airbus Procedure
AP2040.
- Volumes
The ACD is divided into the following volumes:
Volume name ACD title

ACD vol. 3 Methods for Compliance Demonstration
ACD vol. 2 Description of the Structure
ACD vol. 2.4 Corrosion Protection
ACD vol. 2.5 Material Specification and Design Allowables
for Metallic Parts
ACD vol. 2.7 Fabrication Methods – Metallic Parts
ACD vol. 4 Static Justification
ACD vol. 4.1 Flight Controls – Static Justification

ACD vol. 8 Comparison Static Calculations / Tests
ACD vol. 6 Fatigue and Damage Tolerance Justification
ACD vol. 9 Comparison Fatigue Calculations / Tests
ACD vol. 12 Bird impact
ACD vol. 13 Rotor Burst Structural Design Assessment

- complete and partial sets
• A complete ACD set is
created for a new a/c family or
a derivative model exceeding
the validity of the basic
means of compliance.
• A partial ACD set may be
created for derivative models
and are generally appendices
to previous ACDs.
• The table defines the
possibilities:
X : Basic or appendix ACD3
C : volume containing all
justifications
P : volume containing at
least changed items

ACD6 – Fatigue and Damage Tolerance
Justification
• The ACD6 volume provides the compliance demonstration of the
metallic aircraft structure with the F&DT requirements by a
summary of the F&DT justifications in form of tables and sketches.
It contains the following chapters:
- Chapter I - General:
overview on methods and assumptions applied for the
justifications with emphasis on new or revised approaches.
- Chapter II – Aircraft configuration:
copies of pages from ACD 3 which are relevant for the ACD6.
- Chapter III - Loads:
overview on the loads used for justifications (fatigue mission,

residual strength loads), cross-reference to the relevant loads
document, table with load case names.
- Chapter IV – Methods for compliance demonstration:
copies of pages from ACD 3 which are relevant for the ACD6.

Justification - contd. -
- Chapter VI – Fatigue and Damage Tolerance Justification:
a comprehensive summary per section of the F&DT justification
for the primary structure and specific detail design points acc.
to the applicable requirements.
The structural items presented shall give a representative
overview covering:
- Structural items with small fatigue lives, crack lives or residual
strength values in the section.
- Structural items with high importance for the aircraft safety (e.g.
fittings, bolts, pressure bearing structure, items under complex
loading).
- Structural items representing the typical design concepts applied
in the section.
Depending on the type of DT analysis summary tables for the
deterministic analysis or for the residual fatigue analysis are
used.
Examples of ACD6 chapter VI are given in the following pages.

Justification – examples

Justification – examples - contd. -



ACD6 – F&T Justification –
form for residual fatigue analysis

ACD9 – Comparison Fatigue and
Damage Tolerance Tests / Calculations
• The ACD9 volume provides a summary of the full scale fatigue and
crack propagation test results. It contains the following chapters:
- Chapter I - General:
abstract on the approach chosen for the compliance
demonstration to the F&DT requirements by means of full scale
and major component tests.
- Chapter II – Test summary:
summary of the full scale and separate component fatigue test
progress.
- Chapter III – Test loads:
general information on the loads applied on the specimen.

- Chapter IV – Overview on Test methods :
F&DT test progress (test schedule, number of cycles achieved,
number of initial flaws and artificial damages).

ACD9 – Comparison Fatigue and
Damage Tolerance Tests / Calculations
- Chapter V – Inspection program:
description of the different inspection types performed during
the tests.
- Chapter VI – Test results:
This chapter can be divided in three main parts:
- Natural damages (summary, repercussions on production
and in-service a/c)
- Artificial damages
- Tear down results
Depending on the type of DT analysis summary tables for the

deterministic analysis or for the residual fatigue analysis are
used.
Examples of ACD9 forms are given in the following pages.

ACD9 – Comparison F&DT Tests /
Calculations – Example of forms

Calculations – Example of forms - contd.

Calculations – Example of forms - contd.

ALI justification document (AJD)
• An Airworthiness Limitation Item (ALI) is any detail, element or
assembly which is fatigue critical and that requires maintenance
action to prevent catastrophic failure within the design service goal
(DSG) or extended service goal (ESG) of the aircraft.
• The maintenance requirements resulting from F&DT evaluation
have to be included on the Airworthiness Limitation Section (ALS)
of the Instructions for Continued Airworthiness (ICA) as required by
JAR/FAR 25.1529 Appendix H25.4.
• The ALI justification document (AJD) contains the structural fatigue
related maintenance requirements (inspection and/or modification)
together with a requirement to control corrosion to an acceptable

level.
• More details about ALI are given in Subject 13.
• The following page includes an example (extract) of an AJD.

Airworthiness limitation items (ALI) for
structure – example

Archiving of documents prepared by the
engineering
• Archiving of documents established in frame of certification is
required by the relevant FAR/JAR regulations.
• At Airbus (Germany) the archiving is described in instructions for
procedure of quality assurance, the so-called “Qualitätssicherungs-
verfahrensanweisungen” (QVA).
• QVA-Z05-03-01 includes the archiving of engineering documents
(“Archivierung von Dokumenten des Entwicklungsbetriebes”). This
QVA is a binding document.
• QVA-Z05-03-01 is a supplement to QVA-Z05-03-00 (Archiving and
retention of documents.
• The QVA-Z05-03-01 covers the following subjects:

purpose, validity, additional documents, responsibilities, definitions
and abbreviations, archiving of engineering documents.
• The QVA-Z05-03-01 is also valid for electronic documents.

This document and all information contained herein is the sole
property of AIRBUS DEUTSCHLAND GmbH. No intellectual
property rights are granted by the delivery of this document or
the disclosure of its content. This document shall not be
reproduced or disclosed to a third party without the express
written consent of AIRBUS DEUTSCHLAND GmbH. This
document and its content shall not be used for any purpose
other than that for which it is supplied.
The statements made herein do not constitute an offer. They

are based on the mentioned assumptions and are expressed
in good faith. Where the supporting grounds for these
statements are not shown, AIRBUS DEUTSCHLAND GmbH
will be pleased to explain the basis thereof.

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Airbus Fatigue & Damage Tolerance Course January 2005

F+DT course, H.-J. Schmidt, AeroStruc

• Archiving of documents prepared by the engineering

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 2

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 3

- ALI Justification Document:

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 4

2.3 Critical crack length

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 5

7.2 Fatigue life and damage tolerance determination

The following pages contain the typical content of a F&DT analysis

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 6

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 7

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 8

Loads and stresses for

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 9

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 10

Fatigue damage Fatigue life calcul-

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 11

Data for crack Load spectrum for

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 12

Crack growth results

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 13

Volume name ACD title

ACD vol. 4.1 Flight Controls – Static Justification

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 15

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 16

overview on the loads used for justifications (fatigue mission,

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F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 18

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general information on the loads applied on the specimen.

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 24

Depending on the type of DT analysis summary tables for the

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 25

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 26

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 27

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 28

together with a requirement to control corrosion to an acceptable

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 29

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 30

• The QVA-Z05-03-01 covers the following subjects:

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 31

The statements made herein do not constitute an offer. They

F+DT course, H.-J. Schmidt, AeroStruc January 2005 Page 32

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