Abstract: The Brazilian F-5 was submitted to avionics and weapons upgrade. This "new" aircraft has proven to be heavier and more capable. A comprehensive damage tolerance analysis is being performed to evaluate how the new mission profiles and weight distribution may affect the airframe structural integrity. Operational data were collected at the Brazilian Air Force Bases where the fighter is flown. Software was developed in order to acquire, filter and anafyze flight data. This data was used for comparison between the pre and post modernization mission profiles and to determine the stress level in each of the known aircraft fatigue critical locations (FCL). The results show that the change in aircraft weight and balance and the new operational profile can significantly change the inspection intervals of certain fatigue critical locations of the structure. A preliminary result for the horizontal tail has shown that this component will have a much more restrictive maintenance schedule to assure flight safety.

Abstract: This paper presents an overview of the activities developed by the Structural Integrity Group at the Institute of Aeronautics and Space - IAE, Brazil, as well as the status of ongoing work related to the life extension program for aircraft operated by the Brazilian Air Force BAF. The first BAF-operated airplane to undergo a DTA-based life extension was the F-5 fighter, in the mid 1990s. From 1998 to 2001, BAFworked on a life extension project for the BAFAT-26 Xavante trainer. All analysis and tests were performed at IAE. The fatigue critical locations (FCLs) were presumed based upon structural design and maintenance data and also from exchange of technical information with other users of the airplane around the world. Following that work, BAF started in 2002 the extension of the operational life of the BAF T-25 "Universal". The T-25 is the basic training airplane used by AFA - The Brazilian Air Force Academy. This airplane was also designed under the "safe-life" concept. As the T-25 fleet approached its Service life limit, the Brazilian Air Force was questioning whether it could be kept inflight safely. The answer came through an extensive Damage Tolerance Analysis (DTA) program, briefly described in this paper. The current work on aircraft structural integrity is being performed for the BAF F-5 E/F that underwent an avionics and weapons system upgrade. Along with the increase in weight, new configurations and mission profiles were established. Again, a DTA program was proposed to be carried out in order to establish the reliability of the upgraded F5 fleet. As a result of all the work described, the BAF has not reported any accident due to structural failure on aircraft submitted to Damage Tolerance Analysis.