DSTO

The facility that is now known as DSTO Melbourne has been a centre of significant scientific achievements ever since.

Today the research conducted at Fishermans Bend spans the air, land and sea domains, and beyond, and the local aerodrome has long since been closed.

But the mission to provide the best possible scientific advice and technical support endures, as the Defence Science and Technology Organisation enters a period of transition while a new strategic plan is implemented.

Safety is obviously of critical importance in aviation and has certainly been a key element of work at Fishermans Bend over the years.

DSTO Melbourne boasts impressive forensic science laboratories, and has a long history of excellence in defect and failure analysis that includes nurturing the concept of installing ‘black box’ flight recorders in aircraft.

As well as investigating the causes of accidents, DSTO’s forensic engineering specialists are tasked with analysing failure and deterioration of aircraft components in an effort to prevent potentially dangerous incidents from ever occurring.

A wide range of expertise is required as all aspects of air platforms are covered, down to the equipment worn by pilots.

On a tour of the DSTO Melbourne facility, Australian Aviation was shown the non-destructive testing and metrology labs, where aircraft components are examined to check they were originally manufactured to specification.

In the forensic examination and photography labs, the condition of aircraft parts is carefully documented so that a chain of evidence can be established.

Australian Aviation spotted a broken wheel from an unidentified Army helicopter awaiting examination.

And over in the metallography, optical microscopy and electron microscopy labs, the structure of the materials from which components are made is painstakingly investigated in even greater detail.

DSTO Melbourne’s transonic wind tunnel is the only facility of its kind in Australia.

Aerodynamic testing is conducted in the wind tunnel by simulating flight at up to Mach 1.

4 using models of aircraft.

When Australian Aviation visited, researchers were investigating the likely trajectory of the JDAM ER when released in flight from a classic Hornet.

The final stop on the highly informative tour of the Fishermans Bend facility was the hall where

We are already working on several aspects of autonomous vehicles in the air domain.

a Hawk 127 airframe stands enclosed in a test rig.

DSTO is recognised as a world leader in structural fatigue testing and has worked on a wide range of military platforms over the years.

Through their full-scale fatigue testing program, researchers can determine in advance when and where to look for cracks during inspections of in-service Hawk aircraft.

Components can be replaced on the test airframe and the effects of any modifications analysed before they are adopted on the flying Lead-In Fighter fleet.

The test airframe will be put through the equivalent of about 50,000 flying hours.

So far, roughly 27,000 hours have been simulated, with Hawk fatigue testing anticipated to continue through until 2017.

Support savings

Acquiring and sustaining military aircraft is a highly complex and very expensive business that requires the provision of specialist support.

Research undertaken by DSTO’s Aerospace Division is often primarily an effort to reduce cost of ownership.

“Much of the work we do results in savings to Australian taxpayers, in some cases by ensuring that our aircraft can safely operate for longer,” a Defence spokesperson told Australian Aviation.

“For example, by the careful application of new and innovative technologies such as additive manufacturing, it is possible to repair and refurbish aircraft components rather than replace them, and this results in considerable cost savings over the life of an aircraft.

“Another good example is the sustainment work DSTO has undertaken in relation to the RAAF F/A-18A/B Hornet,” the Defence spokesperson continued.

“DSTO has developed a structural shape optimisation algorithm; oneuse of this has been to design a modification to increase the service life of cracked missile launcher housings, representing significant savings and an improvement to availability.

“DSTO testing of centre barrels removed from service aircraft has led to significant availability, schedule and cost relief.

Approximately $400 million was saved through the reduction of the number of centre barrel replacements required.

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Acquisitions advice

In addition, DSTO’s Aerospace Division is tasked with supporting the acquisition and introduction into service of new aircraft and airborne systems, helping the government make significant decisions armed with a proper appreciation of technical risks.

“A key driver for this work is to reduce acquisition and sustainment risk,” the spokesperson explained.

“A current example is thescientific and technical advice DSTO is supplying on proposed upgrades, operational utility and technical risk for the Airborne Early Warning and Control AIR 5077 Phase 5A project, which is on track for first pass approval this year.

We conduct applied research in relevant aerospace technologies and their integration so that we can provide informed advice to acquisition projects.

”DSTO carries out a significant amount of work analysing the human factors aspects of acquiring newly designed aircraft, such as investigating optimal crewing concepts and each platform’s human-machine interface.

“This can either enable us to use the delivered aircraft to their maximum potential or, in some cases, we may be able to influence the design of the aircraft systems,” the Defence spokesperson said.

“Even though in many cases we are buying [military off-the-shelfplatforms] the way we intend to operate the capability and the support structures we have in place can be quite different.

”On the Joint Strike Fighter (JSF) program, DSTO is working to provide science and technology advice to support the acquisition and introduction into Australian service of the F-35 Lightning II.

Research relating to the F-35 that has been carried out at DSTO Melbourne spans operations analysis, human factors, simulation, airframe life, structural fatigue and corrosion, propulsion, materials and processes, vehicle systems, performance and prognostics, and health monitoring.

Strategic shift

DSTO’s ‘Strategic Plan 2013‑ 2018’ reveals changes in capability prioritisation that are anticipated to take place over the next five years or so.

The organisation is set to reduce investment in its platforms, propulsion and energy, and weaponscapability areas by between five and 10 per cent.

Specifically in the platforms capability area, the document envisages a “modest reduction in the areas of aircraft structural integrity, aerodynamic facilities support, and platform sensors and prognostics”.

Human science and operations analysis are expected to be cut by up to 20 per cent.

On the plus side, the strategic plan foreshadows growth of five to 10 per cent in DSTO’s cyber, surveillance and space systems, and autonomous systems capabilities.

Questioned about how this shift would affect the work undertaken by the Aerospace Division, the Defence spokesperson commented: “DSTO’s strategic plan outlines our aim of building capabilities that are distinctive and sustainable, and which demonstrably create impact.

The changes in the strategic plan are broad directions, and evolution in our capabilities will be aligned with Defence guidance to ensure we remain relevant and responsive to Defence and national security.

”DSTO’s Aerospace Division carries out research on autonomous aircraft systems and conducts limited development activities working in collaboration with universities.

“We are already working on several aspects of autonomous vehicles in the air domain and expect to see increasing activity in this capability,” the spokesperson added.

This collaborative approach is mirrored in partnerships with industry.

“DSTO is reinvigorating its industry alliance program to strengthen important research-and-development relationships withkey Australian companies,” the spokesperson said.

“Our alliance relationships have delivered significant benefits over the years and the new alliances, which will establish longer-term relationships, are expected to provide significantly improved outcomes for Defence.

”Striving to save money looks set to remain at the heart of DSTO’s industrial engagement in the aviation sector, as the Defence spokesperson explained: “Given the very high costs associated with through-life support for military aircraft, the Aerospace Division tends to focus slightly more on ways to help industry to reduce these costs, while the land and maritime divisions have a slightly greater role to play in the development of new capabilities and the enhancement of existing capabilities.

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