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When Airplanes Feel Fatigued

Gemini Sparkle

Key Takeaways:

  • Metal fatigue is a long-understood phenomenon where repeated stresses cause materials to fail at loads far below their ultimate strength, often accumulating invisibly until sudden, catastrophic cracking occurs.
  • Unlike corrosion, fatigue is difficult to detect, manifesting without warning, leading to a false sense of security in older aircraft that have not yet shown visible signs of cracking.
  • The issue of metal fatigue is projected to become more prevalent in the future due to an aging civil aviation fleet, increased aircraft utilization, the repurposing of ex-military aircraft for demanding roles, and the ongoing administrative challenge of balancing safety risks with remediation costs.
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One of the time-honored conventions of aviation journalism is that every article about metal fatigue has to start with mention of the “ill-fated Comet.”

That requirement has now been met.

Peter Garrison

Peter Garrison taught himself to use a slide rule and tin snips, built an airplane in his backyard, and flew it to Japan. He began contributing to FLYING in 1968, and he continues to share his columns, ""Technicalities"" and ""Aftermath,"" with FLYING readers.

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