The airframe structures of most fighter aircraft in the Royal Malaysian Airforce have been in service for 10 to 20 years. The effect of fatigue loading, operating conditions, and environmental degradation has led to the structural integrity of the airframe being assessed for its airworthiness. Various NDT methods were used to determine the current condition of the aircraft structure after operation of beyond 10 years, and their outcomes are summarized. In addition, although there are six critical locations, the wing root was chosen since it has the highest possibility of fatigue failure. It was further analyzed using simulation analysis for fatigue life. This contributes to the development of the maintenance task card and ultimately assists in extending the service life of the fighter aircraft. Using the concept of either safe life or damage tolerance as its fatigue design philosophy, the RMAF has adopted the Aircraft Structural Integrity Program (ASIP) to monitor the structural integrity of its fighter aircraft. With the current budget constraints and structural life extension requirements, the RMAF has embarked on the non-destructive testing method and engineering analysis. The research outcome will enhance the ASIP for other aircraft platforms in the RMAF fleet for its structure life assessment or service life extension program.
Keywords: Su-30MKM; aircraft structural integrity program; critical fatigue location; non-destructive testing; structure life extension.