A full-scale durability test airframe of the F-35A aircraft has successfully completed its third life testing, equivalent to 24,000 hours of ‘flying’, in a unique testing facility at BAE Systems’ site in Brough, East Yorkshire.

The airframe, known as AJ-1, is representative of the F-35A Conventional Take-Off and Landing (CTOL) variant of the jet.

While in the 350-tonnes structural test rig it has been subjected to and tested on the range of loads it would experience in actual flight, with durability tests carried out to simulate real-life fleet usage based on projected operational requirements.

BAE Systems’ durability test rig is the only one of its kind in the United Kingdom and it has supported the testing of AJ-1 since it arrived in Brough in 2009. It is fitted with more than 20 miles of wiring, 2,500 strain gauges and 160 loading actuators which are attached to the airframe during testing.

The F-35A durability test airframe will now leave the rig and travel to the United States where it will undergo further detailed inspections.

Kathy Nesmith, F-35 Joint Program Office Airframe Team Lead, said: “The F-35 programme requires a service life of 8,000 flight hours.  This is verified through durability testing to two lifetimes or 16,000 hours. Completing third life testing on the F-35A durability article will provide us with the data to enable the warfighter to maintain and sustain this aircraft beyond 2050.”

BAE Systems leads structural testing on other variants as well. Both the F-35B and F-35C durability test articles have completed 16,000-hour second life testing and are continuing with additional testing to maximize the life of the aircraft.