Techniques employing advanced computational finite element analysis and analytical stress analysis have been developed to reduce peak stresses in materials and consequently extend the life of highly loaded aging aircraft components. Examples include the optimisation of bonded composite reinforcement designs to maximise structural effectiveness, and the specification of optimal re-work shapes to remove cracks and reduce local stresses. Advanced repair techniques Hundreds of millions of dollars of savings are being made in military and civil aircraft throughout the world through DSTO's pioneering development of composite repairs for metallic components. Composite repairs are now being developed for application to damaged primary aircraft structures and can be used in conjunction with structural optimisation techniques. Stores clearance and flutter analysis Aircraft in flight, particularly those carrying external stores, may be affected by flutter instability, resulting in structural failure.
Flutter studies determine theoretically the speeds at which aircraft can fly to avoid flutter.
Flight trials are also used to identify the flutter characteristics of specific aircraft. Full-scale static and fatigue testing This testing aims to identify the most likely locations and time of failure of critical points within an aircraft structure. In recent years much of this testing has been undertaken in partnership with other countries operating aircraft of similar specification. Test loads, simulating aircraft flight conditions, are generated and compiled into a loading sequence to represent operational missions. These loads are then applied to the test structure within a purpose designed test rig via a computer controlled loading system.