Bonded Repair of Aircraft Structures

Front Cover
A. Baker, Jones
Springer Science & Business Media, May 31, 1988 - Technology & Engineering - 214 pages
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The conventional approach to through-life-support for aircraft structures can be divided into the following phases: (i) detection of defects, (ii) diagnosis of their nature and significance, (iii) forecasting future behaviour-prognosis, and (iv) pre scription and implementation of remedial measures including repairs. Considerable scientific effort has been devoted to developing the science and technology base for the first three phases. Of particular note is the development of fracture mechanics as a major analytical tool for metals, for predicting residual strength in the presence of cracks ( damage tolerance) and rate of crack propagation under service loading. Intensive effort is currently being devoted to developing similar approaches for fibre composite structures, particularly to assess damage tolerance and durability in the presence of delamination damage. Until recently there has been no major attempt to develop a science and tech nology base for the last phase, particularly with respect to the development of repairs. Approaches are required which will allow assessment of the type and magnitude of defects amenable to repair and the influence of the repair on the stress intensity factor (or some related parameter). Approaches are also required for the development and design of optimum repairs and for assessment of their durability.
 

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Contents

Introductory chapter
1
11 Bonded vs bolted repairs
3
12 Combined bondedbolted repairs
8
13 Adhesives
9
14 Adhesive testing
11
15 Surface Preparation
13
16 Environmental Behaviour
14
17 Summary
17
Appendix A
76
Theoretical analysis of crack patching
77
52 Formulation and notation
79
53 Load transfer to bonded reinforcements
81
54 Twostage analytical solution
83
55 Residual thermal stress due to adhesive curing
90
56 Bending effects
92
57 Partial reinforcement
99

Surface treatments for bonded repair of metals
19
22 Background
21
23 Structural aluminum alloys
22
24 Phosphoric acid anodizing
23
25 Chromic acid anodizing
28
Design and analysis of bonded repairs for metal aircraft structures
31
32 Design of adhesivebonded repairs in thin sheet metal contruction
32
33 Residual strength of flawed or damaged adhesive bonded joints
34
34 Acceptance criteria for bond flaws and damage
39
35 The pitfalls of life prediction for adhesivebonded joints
41
36 Surface preparation for adhesivebonded repair of metal structure
45
37 Conclusions
46
Crack patching design aspects
49
42 The finite element formulation
50
43 Repair of cracks in Mirage III lower wing skin a design study
53
44 Neutral axis offset effects
57
46 Comparison with experimental and 3D results
59
47 Repair of semielliptical surface flaws
63
48 Repair of cracked holes
65
49 Repair of cracked fastener holes
74
58 Conclusion
105
Crack patching experimental studies practical applications
107
62 Adhesive system and process selection
109
63 Thermal and residualstress problems
122
64 Design correlations and materials allowables
131
65 A preliminary design approach
146
66 Crack propagation behaviour in patched specimen
153
67 Applications of crackpatching
162
Repair of composite aircraft
175
72 Composite fabrication
178
73 Defects
180
74 Repair materials
183
75 Composite repair concepts
187
76 The effect of moisture on bonded repair of composites
196
77 Design of bonded repairs
199
78 Composite service damage experience
202
79 Specific component repair
203
710 Future requirements
209
Index
213
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