Crack Propagation Tests for Load Sequences Developed Using Different Flight Parameters of a Trainer Aircraft

Military aircraft are subjected to highly variable and unpredictable loads due to diverse mission profiles, armament configurations, and individual piloting styles. This variability complicates the definition of precise load spectra, particularly in cases where data loss occurs due to Flight Data Recorder (FDR) malfunctions or data mishandling. This paper investigates the use of different flight parameters, such as load factor (nz), barometric height (Hb), and horizontal velocity (Vp), to define load sequences for the PZL-130 “Orlik” TC-II military trainer aircraft. These sequences were then used to evaluate crack propagation using Compact Tension (CT) specimens. The results show that the incorporation of additional flight parameters improves the accuracy of crack propagation predictions when compared to direct strain measurements. This study highlights the potential of using available flight data to develop reliable load spectra for fatigue life estimation in military aircraft, even when direct load measurements are not financially feasible.