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Probabilistic methods are used in calculating composite part design factors for, and are intended to conservatively compensate for worst case impact to composite parts used on space and aerospace vehicles. The current method to investigate impact damage of composite parts is visual based upon observation of an indentation. A more reliable and accurate determinant of impact damage is to measure impact energy. RF impact sensors can be used to gather data to establish an impact damage benchmark for deterministic design criteria that will reduce material applied to composite parts to compensate for uncertainties resulting from observed impact damage. Once the benchmark has been established, RF impact sensors will be applied to composite parts throughout their life-cycle to alert and identify the location of impact damage that exceeds the maximum established benchmark for impact.

In order to support the T-38 Wing Life Improvement program, the Materials and Process Product Support group was requested to perform a metallurgical examination of a test article containing several cold expanded holes drilled in an aluminum/aluminum and an aluminum/steel assembly. The assembly, complete with a wing skin which were composed of a trunnion or landing ear rib, and a tip rib, was designed to represent a miniature T-38 wing and was used to determine the feasibility of cold expanding or cold working of holes drilled in T-38 wings using automated machinery incorporating a split mandrel process per Process Specification FH-114.