A Certifiable Machine Learning-Based Pipeline to Predict Fatigue Life of Aircraft Structures

Abstract: Fatigue life prediction is essential in both the design and operational phases of any aircraft, and in this sense safety in the aerospace industry requires early detection of fatigue cracks to prevent in-flight failures. Robust and precise fatigue life predictors are thus essential to ensure safety. Traditional engineering methods, while reliable, are time consuming and involve complex workflows, including steps such as conducting several Finite Element Method (FEM) simulations, deriving the expected loading spectrum, and applying cycle counting techniques like peak-valley or rainflow counting. These steps often require collaboration between multiple teams and tools, added to the computational time and effort required to achieve fatigue life predictions. Machine learning (ML) offers a promising complement to traditional fatigue life estimation methods, enabling faster iterations and generalization, providing quick estimates that guide decisions alongside conventional simulations. In this paper, we present a ML-based pipeline that aims to estimate the fatigue life of different aircraft wing locations given the flight parameters of the different missions that the aircraft will be operating throughout its operational life. We validate the pipeline in a realistic use case of fatigue life estimation, yielding accurate predictions alongside a thorough statistical validation and uncertainty quantification. Our pipeline constitutes a complement to traditional methodologies by reducing the amount of costly simulations and, thereby, lowering the required computational and human resources.