Performance assessment and optimization of hybrid composite patch repair of aircraft structure

Abstract

PurposeIn this article, a novel hybrid composite patch consisting of unidirectional carbon fiber and glass fiber is considered for repair of the aircraft structure. The purpose of this paper is to assess the performance of hybrid composite patch repair of cracked structure and propose an optimized solution to a designer for selection of the appropriate level of a parameter to ensure effective repair solution.Design/methodology/approachElastic properties of the hybrid composites are estimated by micromechanical modeling. Performance of hybrid composite patch repair is evaluated by numerical analysis of stress intensity factor (SIF), shear stress, and peel stress. Design of experiment is used to determine responses for a different combination of design parameters. The second-order mathematical model is suggested for SIF and peel stress. Adequacy of the model is checked by ANOVA and used as a fitness function. Multiobjective optimization is carried out with a genetic algorithm to arrive at the optimal solution.FindingsThe hybrid composite patch has maintained equilibrium between the SIF reduction and rise of the peel stress. The repair efficiency and repair durability can be ensured by selection of an optimum value of volume fraction of glass fiber, applied stress, and adhesive thickness.Originality/valueThe composite patch with varying stiffness is realized by hybridization with different volume fraction of fibers. Analysis and identification of optimum parameter to reduce the SIF and peel stress for hybrid composite patch repair are presented in this article.

New investigation of delamination using the VCCT method to predict the damage in bonded composite repair plates subjected to tensile load

“…This bonding method reduces stress concentration around the crack's leading edge, resulting in an overall improvement in the structural fatigue life. The principal benefit of the composite patch repair technique lies in its ability to evenly distribute stress across the adhesive area, stress concentrations are the avoided, unlike riveting or bolting where stress concentration zones are inevitable (Makwana and Shaikh, 2020; Chamorro-Cruz et al. , 2023).…”

Improving the performance of damage repair in thin-walled structures with analytical data and machine learning algorithms

“…Recent studies have adopted a design of experiments (DOE) approach to investigate the effect of material properties and dimensions on repair performance, to reduce computational and experimental time [11]. The hybridization of multiple volume fractions of fibers in composite patches of varying stiffness has been studied to identify optimal parameters for minimizing SIF [12]. The lamina composite patch has significant effect while having the fiber direction perpendicular to the crack length and this has been proved through the finite element (FE) simulations [13].…”

Effect of fiber orientation-based composite lamina on mitigation of stress intensity factor for a repaired plate: a finite element study

“…Aabid et al [11] demonstrated the utilization of composite patches with varied parameters in their studies. Makwana and Shaikh [12] examined the hybridization of different fiber volume fractions in composite patches with varying stiffness for minimizing the SIF. The study demonstrated the combination of bonding and drilled holes knowing a hybrid repair approach to repair the aircraft structures (thin-plates) through elastoplastic analysis [13].…”