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Abstract
This chapter reviews research by Defence Evaluation and Research Agency, UK (DERA) on bonded composite patch repair of aluminum alloy structures. It describes the repair of thin skin components, repair of thick sections, graphite/epoxy versus boron/epoxy patches, effect of bondline defects, effect of impact damage, effect of service temperature, effect of exposure to hot–wet environments, repair of battle damage, and future work. The early experimental work at DERA concerned the repair of central fatigue cracks in thin aluminum alloy panels and the influence of repair variables on the effectiveness of the patches in retarding crack growth, while the early theoretical work involved the development of collocation (strip patch and isotropic disc patch) and 2D boundary element models, and their application to cracked sheet repairs. Graphite/epoxy patches were used for the initial investigations because various forms of woven cloth and prepreg were readily available, and because wet layup of graphite cloth had shown considerable promise for battle damage repair. Since that time, repairs to stiffened panels and thick sections containing fatigue cracks, and thin panels containing simulated battle damage, have been investigated, and a 3D boundary element/finite element computer program for the analysis of bonded patch repairs has been developed.
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