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.

Recent advancements in machine learning-based methods have demonstrated great potential for improved property prediction in material science. However, reliable estimation of the confidence intervals for the predicted values remains a challenge, due to the inherent complexities in material modeling. This study introduces a novel approach for uncertainty quantification in fatigue life prediction of metal materials based on integrating knowledge from physics-based fatigue life models and machine learning models. The proposed approach employs physics-based input features estimated using the Basquin fatigue model to augment the experimentally collected data of fatigue life. Furthermore, a physics-informed loss function that enforces boundary constraints for the estimated fatigue life of considered materials is introduced for the neural network models. Experimental validation on datasets comprising collected data from fatigue life tests for Titanium alloys and Carbon steel alloys demonstrates the effectiveness of the proposed approach. The synergy between physics-based models and data-driven models enhances the consistency in predicted values and improves uncertainty interval estimates.

Machine learning as a data-driven solution has been widely applied in the field of fatigue lifetime prediction. In this paper, three models for wideband fatigue life prediction are built based on three machine learning models, i.e. support vector machine (SVM), Gaussian process regression (GPR) and artificial neural network (ANN). The generalization ability of the models is enhanced by employing numerous power spectra samples with different bandwidth parameters and a variety of material properties related to fatigue life. Sufficient Monte Carlo numerical simulations demonstrate that the newly developed machine learning models are superior to the traditional frequency-domain models in terms of life prediction accuracy and the ANN model has the best overall performance among the three developed machine learning models.