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Methodology to analyse aerospace structures repaired with a bonded composite patch

Abstract Adhesively bonded composite repair of metallic structures is one of the candidate technologies that has enormous potential in the ageing aircraft. A computational tool to analyse the repaired aerospace structure using an adhesively bonded composite patch is presented. This involves the three-layer technique based on the two-dimensional finite element method for adhesively bonded composite patch repair of cracked structures. This technique is capable of characterizing the crack growth and debond growth behaviour, as well as predicting the fatigue life extension of the repaired structure with a perfectly or imperfectly bonded patch. Also, the thermal effects which may develop during bonding or during service and the non-linear material behaviour of the adhesive are incorporated in this technique. The results from the three-layer technique show good agreement with experimental results as well as a previous investigator's published numerical results. Besides the accuracy of the technique, the advantage of the two-dimensional three-layer technique is cost-effectiveness when compared with the three-dimensional finite element or performing expensive experiments on various patch configurations for design purposes. An overview of the three-layer technique to investigate a cracked metallic plate repaired with bonded composite patch is presented in this paper.