Abstract
This chapter delineates a preliminary design approach for corrosion repairs. It presents a design algorithm for bonded repairs of corroded metallic structures. The design algorithm uses simple closed-form solutions for an elliptical patch and analytical result from a 1D bonded joint theory and accounts for thermal stresses. The algorithm is robust and versatile, which can greatly reduce the patch design cycle time in practice. The designed patch that is output from this approach will be a cross-ply patch with the 0° and 90° plies dispersed throughout the patch thickness and with the 0° plies aligned parallel to the primary loading direction. The ratio of the number of 90° plies to the number of 0° plies will be approximately the same as the applied biaxial stress ratio. The chapter summarizes that the patch of a corrosion repair may also need to be tapered in both length and width direction as the patch stiffness in the width direction may be no longer negligible when compared to the skin stiffness because of a possible presence of 90° plies.
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