This thesis presents a new modeling framework and application methodology for the study of aircraft structures. The framework provides a ‘cradle-to-grave’ approach to structural analysis of a component, where structural integrity encompasses all phases of its lifespan. The methodology examines the holistic structural design of aircraft components by integrating fatigue and damage tolerance methodologies. It accomplishes this by marrying the load inputs from a fatigue analysis for new design, into a risk analysis for an existing design. The risk analysis incorporates the variability found from literature, including recorded defects, loadings, and material strength properties. The methodology is verified via formal conceptualization of the structures, which are demonstrated on an actual hydraulic accumulator and an engine nacelle inlet. The hydraulic accumulator is examined for structural integrity utilizing different base materials undergoing variable amplitude loading. Integrity is accomplished through a risk analysis by means of fault tree analysis. The engine nacelle inlet uses the damage tolerance philosophy for a sonic fatigue condition undergoing both constant amplitude loading and a theoretical flight design case. Residual strength changes are examined throughout crack growth, where structural integrity is accomplished through a risk analysis of component strength versus probability of failure. Both methodologies can be applied to nearly any structural application, not necessarily limited to aerospace.

The development of structural monitoring systems is a critical research area because of the age and sustainment costs associated with many aircraft in use today. Specifically, integrated structural health monitoring (SHM) systems are advantageous because they allow for automated, near real-time assessment of the state of the structure, where the automation improves both the accuracy of the measurements and allows for more frequent system interrogation than possible with traditional nondestructive evaluation methods. Ultrasonic techniques are particularly well-suited for SHM systems because of their potential to detect and track damage well before structural failure using in situ sensors. The research problem considered in this thesis is detection and tracking of fatigue cracks emanating from fastener holes in metallic structural components. The sensing method utilizes attached ultrasonic transducers, and tracking of damage is achieved by employing a state estimation framework that incorporates a well-known empirical model for crack growth and a measurement model relating the ultrasonic response to crack size. The state estimation process is preceded by an automated crack detection algorithm, and can be followed by a prediction of remaining life assuming future usage. The state estimation framework provides a better estimate of crack size than either the ultrasonic measurement model or crack growth model alone. Although the example application is monitoring of fastener holes, the general approach is applicable to a variety of SHM problems.