The USAF Aircraft Structural Integrity Program, that traces its origin to B-47 failures in 1958, was established based on the recognition that repeated loads were a threat to the safety of operational aircraft. Later, it was recognized that manufacturing and in-service damage also had the potential to degrade their safety. This threat has been successfully controlled through the adoption of the damage tolerance approach in 1975. This approach, also referred to as retirement for cause, is used as a basis for an inspection/modification program to maintain safety throughout the life of the aircraft. However, when the aircraft structure has degraded to the point that multiple site damage has occurred, then the inspection program that was developed for the pristine structure needs to be changed. It is the purpose of this paper to review the occurrences of multiple site damage on USAF aircraft and how this has influenced their lives. This will be done through the experiences derived from the KC-135, C-5 and C-141 aircraft.


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