Many of the aircraft that form the backbone of the U.S. Air Force operational fleet are 25 years old or older. A few of these will be replaced with new aircraft, but many are expected to remain in service an additional 25 years or more. This book provides a strategy to address the technical needs and priorities associated with the Air Force's aging airframe structures. It includes a detailed summary of the structural status of the aging force, identification of key technical issues, recommendations for near-term engineering and management actions, and prioritized near-term and long-term research recommendations.

Over the next 20 years, the further aging of already-old aircraft will introduce challenges and issues for aircraft operators. The technical challenges relate to structures, propulsion, and systems. The institutional challenges include limitations on independent verification of fleet status and future condition and on information needed for engineering analyses including risk assessment, and an overall scarcity of resources.

The U.S. Air Force requested the National Research Council to identify research and development (R & D) needs and opportunities to support the continued operation of their aging aircraft. Specifically, this study focuses on aging aircraft structures and materials and has the major objectives of 1. developing an overall strategy that addresses the Air Force aging aircraft needs 2. recommending and prioritizing specific technology opportunities in the areas of fatigue, corrosion fatigue, and stress corrosion cracking corrosion, prevention and mitigation, nondestructive inspection maintenance and repair, failure analysis and life prediction methodologies. The approach that the committee took to accomplish this study was to conduct working sessions to identify current aging aircraft problems and technology needs; review ongoing and planned aging aircraft R & D efforts by the Air Force; and review related research at other government agencies, within industry and in the academic research community.

Extending the life of an airframe has proven challenging and costly. Extending the life of an avionics system, however, is one of the most critical and difficult aspects of extending total aircraft system lifetimes. Critical components go out of production or become obsolete, and many former suppliers of military-grade components have gone out of business. From 1986 to 1996, for example, the percentage of discontinued military/aerospace electronic devices nearly doubledâ€"from 7.5 percent to 13.5 percent. In addition, legacy avionics systems, which were designed to meet requirements of the past, generally lack the full capability to perform new missions, meet new threats, or perform well in the new information-intensive battlefield environments. As the legacy aircraft fleet ages, avionics systems will become more and more difficult to support and maintain. Whereas the military once provided a large and profitable market for the electronics industry, the military electronics market today constitutes less than 1 percent of the commercial market. As a result, the military must increasingly rely on commercial off-the-shelf (COTS) technologies for its avionics hardware and software. Although COTS items are generally less expensive than comparable items designed especially to meet military specifications, the technology-refresh cycle for COTS is typically 18 months or less, which exacerbates the obsolescence problem for aircraft whose lifetimes are measured in decades. The short refresh cycle is driven mostly by the tremendous advances in computer systems, which comprise an increasing percentage of avionics content. In response to a request by the Assistant Secretary of the Air Force for Acquisition, the National Research Council convened the Committee on Aging Avionics in Military Aircraft, under the auspices of the Air Force Science and Technology Board, to conduct this study. This report summarizes the following: Gather information from DoD, other government agencies, and industrial sources on the status of, and issues surrounding, the aging avionics problem. This should include briefings from and discussions with senior industry executives and military acquisition and support personnel. A part of this activity should include a review of Air Force Materiel Command's study on diminishing manufacturing sources to recommend ways to mitigate avionics obsolescence. Provide recommendations for new approaches and innovative techniques to improve management of aging avionics, with the goal of helping the Air Force to enhance supportability and replacement of aging and obsolescing avionics and minimize associated life cycle costs. Comment on the division of technology responsibility between DoD and industry.

To help improve the Air Force's ability to foresee the implications for safety, aircraft availability, and cost of its plans to retain aircraft fleets for service lives that may be as long as 80 years, and to identify actions that will mitigate or avoid some of the more severe consequences, this study measures how the USAF aircraft fleets' ages relate to maintenance and modification workloads and material consumption.

Many of the aircraft that form the backbone of the U.S. Air Force operational fleet are 25 years old or older. A few of these will be replaced with new aircraft, but many are expected to remain in service an additional 25 years or more. This book provides a strategy to address the technical needs and priorities associated with the Air Force's aging airframe structures. It includes a detailed summary of the structural status of the aging force, identification of key technical issues, recommendations for near-term engineering and management actions, and prioritized near-term and long-term research recommendations.

"As many of its fleets of legacy aircraft types are kept in service well beyond their planned services lives (sometimes in age, sometimes in usage, sometimes both), the United States Air Force (USAF) faces numerous engineering and resource challenges for the continued, cost effective sustainment of those aging systems. This report details the recommendations made by the USAF Scientific Advisory Board's Sustaining Aging Aircraft (SAA) Study to best position the Air Force to meet those challenges. The SAA Study Panel visited a cross section of military and commercial aircraft maintenance organizations to assess sustainment practices and identify technologies that can extend system life and ease maintenance costs. The Study identified specific aircraft systems, in addition to structures and engines, that contribute to safety, availability, and effectiveness for aging aircraft; examined commercial practices in airlines, air freight services, and other industries, and evaluated how they might be applied to meet USAF needs; and identified technology needs and technology approaches that can be applied or developed to extend life or ease maintenance of these aircraft systems, while facilitating future adaptations and performance enhancements of the aircraft."--p. 211.