RuAviation

Researchers at the Moscow Aviation Institute (MAI) are developing an advanced methodology for early prediction of the durability of aircraft featuring polymer composite structural elements. The primary objective is to enable engineers to identify potential damage zones in composite components during the design phase, particularly under variable load conditions. According to MAI’s press office, this research aims to optimize aircraft service life and reduce overall lifecycle costs.

Composite materials are widely used in modern aerospace engineering due to their high specific strength and low weight. However, repeated cyclic loads experienced during each flight lead to the accumulation of fatigue damage. Additionally, subtle defects may form during operation, potentially resulting in critical structural failures. The Russian aerospace sector currently lacks a standardized system for assessing the durability of composite structures, complicating objective evaluation of reliability and remaining service life.

The methodology under development at MAI relies on computer-aided modeling. Engineers create simplified digital models of aircraft structures to predict the rate and nature of defect progression and to identify the most hazardous damage scenarios. This tool empowers designers to make informed decisions early in the design process, minimizing the risk of structural failure. MAI reports that design-phase errors can result in significant financial losses, especially if airframe failure occurs during certification testing.

The project involves experts from Research Division NIO-101, laboratories of the Center for Aerospace Materials and Technologies, and the MAI Center for Composite Structures. Consultants with expertise in testing, manufacturing technologies, and materials science are also engaged. At the current stage, model parameters have been calibrated, and software has been patented. Validation of simulation results is underway using data from real-world component tests. Project completion is expected within two years.

Implementation of this methodology will enhance the accuracy of composite structure life assessment and accelerate the design and certification of new aircraft models. This is particularly relevant as the use of composites expands in both civil and military aviation.