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Unconventional machining processes, particularly ultrasonic vibration cutting (UVC), can overcome such technical bottlenecks. However, the precise mechanism through which UVC affects the in-service functional performance of advanced aerospace materials remains obscure. This limits their industrial application and requires a deeper understanding.

The surface integrity and in-service functional performance of advanced aerospace materials are important guarantees for safety and stability in the aerospace industry. For advanced aerospace materials, which are difficult-to-machine, conventional machining processes cannot meet the requirements of high in-service functional performance owing to rapid tool wear, low processing efficiency and high cutting forces and temperatures in the cutting area during machining.

To address this literature gap, this study is focused on the quantitative evaluation of the in-service functional performance (fatigue performance, wear resistance and corrosion resistance) of advanced aerospace materials. First, the characteristics and usage background of advanced aerospace materials are elaborated in detail. Second, the improved effect of UVC on in-service functional performance is summarized. We have also explored the unique advantages of UVC during the processing of advanced aerospace materials. Finally, in response to some of the limitations of UVC, future development directions are proposed, including improvements in ultrasound systems, upgrades in ultrasound processing objects and theoretical breakthroughs in in-service functional performance.

This study provides insights into the optimization of machining processes to improve the in-service functional performance of advanced aviation materials, particularly the use of UVC and its unique process advantages.

The purpose of this paper is to present the author’s method of conservative load spectrum (LS) derivation and close-proximity LS extrapolation applying a correction for measurement uncertainty caused by too low sampling frequency or signal noise, which may affect the load histories collected during the flying session and cause some recorded load increments to be lower than the actual values.

Having in mind that the recorded load signal is burdened with some measurement error, a conservative approach was applied during qualification of the recorded values into 32 discrete load-level intervals and derivation of 32 × 32 half-cycle arrays. A part of each cell value of the half-cycle array was dispersed into the neighboring cells placed above by using a random number generator. It resulted in an increase in the number of load increments, which were one or two intervals higher than those resulting from direct data processing. Such an array was termed a conservative clone of the actual LS. The close-proximity approximation consisted of multiplication of the LSs clones and their aggregation. This way, the LS for extended time of operation was obtained. The whole process was conducted in the MS Excel environment.

Fatigue life calculated for a chosen element of aircraft structure using conservative LS is about 20%–60% lower than for the actual LS (depending on the applied value of dispersion coefficients used in the procedure of LSs clones generation). It means that such a result gives a bigger safety margin when operational life of the aircraft is estimated or when the fatigue test for an extended operational period is programed based on a limited quantity of data from a flying session.

This paper presents a proposal for a novel, conservative approach to fatigue life estimation based on the short-term LS derived from the load signal recorded during the flying session.