Experimental and numerical multiscale testing of CFRP bonded stepped repairs
Résumé
Bonded stepped repairs to aircraft composite structures offer many advantages, such as a smooth aerodynamic
surface, high strength, and low mass addition. However, their design remains challenging due to the varying
stiffness along the bondline in a thin laminate. This study investigates, numerically and experimentally, to what
extent an “equivalent” stepped joint can be used to design a stepped repaired panel. In the proposed case, failure
is driven by laminate fracture instead of patch disbonding. Tension tests on stepped repairs at the scale of
coupons and panels were carried out in 11 different configurations. Specimens were obtained by hot-bonding as
it would be done to perform in-situ repairs. Finite element modelling was performed with cohesive zone
modelling to account for disbonding and delamination, and continuum damage mechanics to simulate composite
failure. This multiscale experimental study showed that stepped repaired coupons have a similar behaviour to
repaired panels in terms of damage mechanisms, failure onset location, and tensile strength. It supports the idea
to use coupons instead of whole panels to carry out experimental testing of stepped repairs. A good agreement
with 2D and 3D numerical simulations was also found. They predicted accurately the strength of the repairs and
highlighted a failure location compatible with the experimental results. As a conclusion, an equivalent stepped
joint can be representative for the strength of a stepped repaired panel, including when failure occurs inside the
laminates.
Origine | Publication financée par une institution |
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