How do you analyze thermal stresses in aircraft structures?

Thermal stress analysis considers: Temperature distribution from aerodynamic heating, engine proximity, or environmental conditions; Material CTE (Coefficient of Thermal Expansion) differences causing stress at joints; Constrained expansion creating stress even in uniform temperature fields; Temperature-dependent material properties; and Combined thermal-mechanical loading. Analysis methods include FEM with thermal loads, classical thermal stress equations for simple geometries, and operational envelope definition for worst cases. Particularly critical for: composite-metal joints (large CTE mismatch), engine mounts, leading edges (high-speed flight), and structures near hot bleed air ducts. Design solutions include expansion joints, flexible mounts, and thermal barriers.