PICASSO - imProved reliabIlity inspeCtion of Aeronautic structure through Simulation Supported POD
Overview
Background & policy context:
With ageing engines and the expected increase of air traffic in the next 20 years, a central challenge in the aeronautical industry will concern the increase of efficiency in maintenance which still represents around 20% of an operator's indirect operating costs. This challenge is particularly important for metallic parts within the engine and aircraft industry. Maintenance is directly related to the concept of Probability of Detection ("POD") curves which are obtained by expensive experimental campaigns.
Furthermore, the aeronautics regulations and expectations regarding safety are increasing. New aeronautic regulations require appropriate damage tolerance assessments for critical parts (for example compressor and turbine disc), to address the potential for failure from material, manufacturing and service induced anomalies within the Approved Life of the part.
Objectives:
The concept of using Non Destructive Testing ('NDT'), using low cost simulations to obtain POD curves, will be evaluated within the PICASSO project.
The aim of PICASSO was to build a new and original concept of 'simulation supported POD curves, based on NDT simulation in addition to existing experimental data bases'. The main objectives of the PICASSO project were to increase the accuracy, and reduce the cost of, a POD campaign with NDT simulation techniques.
Methodology:
This was achieved by:
- Completing experimental NDT inspections by simulated NDT inspections: suppressing the needs of manufacturing expensive samples with defects;
- More representative samples of the population for the POD campaign: enhancing the accuracy of the POD samples and increasing their numbers thanks to simulation techniques;
- Delta POD approach: suppressing the need of a new POD campaign for similar parts or inspection configurations.
The main impacts of the project are:
- To improve the answer to FAA/EASA damage tolerance requirements with higher knowledge and accuracy on NDT inspection PODs;
- Savings in costs, concerning aircraft maintenance and engine development.
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