DI-SESS-81485A

Durability and Damage Tolerance (DADT) Test Report

Describes the contractor's durability and damage tolerance test program under MIL-STD-1530, including test results, evaluations, and recommendations for fleet structural inspections or modifications.

Approval DateJune 2, 2015

AMSC NumberF9548

Preparing Activity11 (AFLCMC/EZFS)

Project NumberSESS-2015-039

OPR—

DTIC Applicable—

GIDEP Applicable—

Limitation—

Applicable Forms—

Approval Limitation—

Form Version—

DID Formatfree_text

963C CompliantYes

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

Supersedes

DI-MISC-81485

DI-SESS-81983

Description & Purpose

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Application & Interrelationship

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Use & Relationship

The report describes the durability and damage tolerance test program to include design development and full-scale tests as required by MIL-STD-1530 including facilities, hardware, procedures, loads and environments, inspections, results, evaluations, and conclusions. The report identifies changes and additions necessary to update the durability and damage tolerance analyses based on test results. The report documents the economic life of the airframe to include estimates of the onset of Widespread Fatigue Damage (WFD) and contractor recommendations for structural inspections or modifications to fleet aircraft as a result of testing.

This Data Item Description (DID) contains the format and content preparation instructions for the data product generated by the specific and discrete task requirements as delineated in the contract.

This DID interfaces with DI-SESS-81983, Durability and Damage Tolerance (DADT) Analysis Report.

This DID supersedes DI-MISC-81485.

Preparation Instructions

1Reference documentsThe applicable issue of the documents cited herein, including their approval dates and dates of any applicable amendments, notices, and revisions, shall be as specified in the contract.

2FormatThe contractor's format is acceptable.

3ContentThe report describes the contractor's test program for compliance with durability and damage tolerance test reporting requirements of the contract and requirements associated with testing in Tasks 2, 3, and 4 of MIL-STD-1530. The report shall include the following:

aPhotographs and descriptions of the test facilitiesPhotographs and descriptions of the test facilities, test articles, equipment, and test setup. Structural deviations of the test article from the operational configuration shall be stated with supporting rationale.

bDescriptions and sketches of the instrumented locationsDescriptions and sketches of the instrumented locations of the airframe, and the types and quantities of load, strain, and displacement monitoring devices. Descriptions and sketches shall also be included of the system used to apply and control loads on the test article. The report shall document the procedures used to calibrate the test loads. As part of the report, load peaks and valleys monitored during testing shall be stored on suitable media and made available to the government upon request. Labeling of the data shall allow the government to identify the recorded parameters.

cDescription of the loads spectra applied to the test articleDescription of the loads spectra applied to the test article. Deviations from the spectra used in the durability analyses shall be stated with rationale. Rationale for load clipping, truncation, elimination, or substitution of load cycles to include the results of verification testing shall be provided. Description of load sequencing or other methods to incorporate "marker bands" in the test spectra shall be included with rationale and supporting test evidence to verify test equivalence and effectiveness of the method.

dChemical, thermal, and environmental conditionsChemical, thermal, and environmental conditions imposed on the test article during all periods of testing.

eDescription of all pre-test strain surveys performedDescription of all pre-test strain surveys performed and predictions vs. measurements data for all locations.

fComparisons of analytical spectrum vs. design test jack loadsComparisons of analytical spectrum vs. design test jack loads in terms of durability crack growth analysis at key control points to assess adequacy of the test.

gComparisons of "actual" vs. "command" vs. "design" test jack loadsComparisons of "actual" vs. "command" vs. "design" test jack loads in terms of durability crack growth analysis at key control points for each block of testing to assess adequacy of the test.

hCriteria used for determining the success or failureCriteria used for determining the success or failure of structural components in the test article. The report shall provide rationale for repairs, replacements, or modifications of components that cracked, failed, or experienced functional impairment during testing and the implementations to fleet aircraft. The report shall state the basis for test termination of the full-scale test article and of individual components.

iList the locations, dimensions, and orientations of flawsList the locations, dimensions, and orientations of flaws artificially induced into the test article and damaged incurred in testing that is allowed to remain in the test article during the damage tolerance phase of the test. A table shall be provided of test inspection times (i.e., simulated flight hours, cycles, or pressurizations cycles), detected damage, crack sizes, and changes or repairs made to the test article during testing. The table shall also list the methods used to detect damage at each inspection time. Damage detected in any teardown inspection required by the contract and results of residual strength testing necessary to comply with the contract shall be listed in separate tables.

jThe report shall document the results of fractographicThe report shall document the results of fractographic or metallurgical examinations and the determination of the initial quality by determining the equivalent initial flaw size for all fatigue cracks found during durability testing.

kList design changes, repairs or replacementsList design changes, repairs or replacements, or in-service inspections recommended by the contractor for operational aircraft as a result of durability and damage tolerance testing and residual strength tests.

lDetailed descriptions of test article configuration changesDetailed descriptions of test article configuration changes during the course of testing.

mThe economic life of the airframeThe economic life of the airframe based on the results of durability testing.

nThe report shall provide evaluations of the test and inspection resultsThe report shall provide evaluations of the test and inspection results and identify critical structural areas of the airframe not previously identified by analyses of development testing. Changes to the previously predicted crack growth rates, critical crack sizes, and critical locations necessary to update the durability and damage tolerance analyses shall be stated.

oCost and schedule data associated with test executionCost and schedule data associated with test execution, inspections, repairs, and modifications.

References

Copies of these documents are available online http://quicksearch.dla.mil

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