To accurately describe and predict the overall strength and residual life of selective repair bonded structures, an integrated simulation model of crack propagation including bonding strength is established. Based on two methods, an integrated simulation model including a cohesive zone method model for predicting the residual life of a selective repair structure is established. By comparing the computational efficiency and accuracy of both the stress intensity factor and residual life of selective repair structures using different calculation methods, the modelling scheme is optimised. Based on this optimised scheme, the effect of adhesive thickness on the stress intensity factor and residual life of the repair structure is analysed. FM94 adhesive measuring 0.2–0.4 mm thickness is used to decrease the stress intensity factor and improve the remaining life such that material utilisation efficiency is guaranteed.
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