MIL-HDBK-1530B(USAF)
simulated, along with the load application on airframes where operational environments impose significant thermal effects. The primary purpose of the static test program is to verify the static strength analyses and the design ultimate strength capabilities of the airframe. Full-scale static tests to design ultimate loads should be conducted except:
a. where it is shown that the airframe and its loading are substantially the same as that used on previous air vehicles where the airframe has been verified by full-scale tests, or
b. where the strength margins (particularly for stability critical structure) have been demonstrated by major assembly tests.
When full-scale ultimate load static tests are not performed, it should be a program requirement to conduct a strength demonstration proof test. Deletion of the full-scale ultimate load static tests is generally unacceptable. Functional- and inspection-type proof test requirements should be developed with the guidance of JSSG-2006.
5.3.1.1 Schedule requirement. Full-scale static tests should be scheduled such that the tests are completed in sufficient time to allow removal of the 80-percent limit restrictions on the flight test air vehicle and allow unrestricted flight within the design envelope to be performed on schedule. The guidance of JSSG-2006 is recommended.
5.3.2 Durability tests. The detail verification guidance for Durability tests (4.11.1.2.2) in JSSG-2006 should be utilized. Prior to initiation of testing, the test plans, procedures, and schedules should be reviewed by the SPO and the contractor. Durability tests of the airframe should consist of repeated application of the flight-by-flight design service loads/environment spectra. The objectives of the full-scale durability tests are to:
a. demonstrate that the economic life of the test article is equal to or greater than the design service goal by the desired margin,
b. identify critical areas of the airframe not previously identified by analysis or component testing, and c. provide a basis for special inspection and modification requirements for force air vehicles.
5.3.2.1 Selection of test articles. The test article should be an early System Development & Demonstration-phase test airframe and should be as representative of the operational configuration as practical. If there are significant design, material, or manufacturing changes between the test article and production air vehicle, durability tests of an additional article or selected components and assemblies thereof should be required.
5.3.2.2 Test scheduling. The full-scale airframe durability test should be scheduled according to the verification guidance of Durability tests - Duration (4.11.1.2.2.f) in JSSG-2006. One lifetime of durability testing plus an inspection of critical structural areas should be completed prior to a full production go-ahead decision. Two lifetimes of durability testing plus an inspection of critical structural areas should be scheduled to be completed
prior to delivery of the first production air vehicle. If the economic life of the test article is reached prior to two lifetimes of durability testing, sufficient inspection in accordance with 5.3.2.3.a, 5.3.2.3.b, and data evaluation should be completed prior to delivery of the first production air vehicle to estimate the extent of required production changes and retrofit. In the event the original schedule for the production decision and production delivery milestones become incompatible with the above schedule requirements, a study should be conducted to assess the technical risk and cost impacts of changing these milestones. An important consideration in the durability test program is that it be completed at the earliest practical time, but after Critical Design Review (CDR).
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