Comparison between rectangular and trapezoidal bonded composite repairs in aircraft structures: A numerical analysis

The optimization of the patch shape of bonded composite repair in aircraft structures is a good way to improve the repair performance. In this study, the three-dimensional finite element method is used to compare the repair performance of patches with rectangular and trapezoidal shapes in aircraft structures. The comparison is done by analysing the stress intensity factor (SIF) at the tip of repaired crack and the distribution of the adhesive stresses for the two patch shapes. The obtained results show that, when the crack length is ranged from 5 to 20 mm, the trapezoidal shape presents lower stress intensity factor at the crack tip, which is beneficial for the fatigue life and lower adhesives stresses, which is beneficial for the repair durability. These advantages disappear when the crack length reaches the value of 40 mm. It is also shown that the use of the trapezoidal shape reduce the mass of the patch, which can reduce the repair cost.