Repair performance of damaged aircraft metal structure with one-sided composite patch
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摘要: 针对航空金属构件损伤碳纤维增强树脂基复合材料(CFRP)单面修补结构，研究了3种贴补修复工艺(湿铺法、预浸料法、预固化法)、复合材料补片厚度、补片长度与修复界面形貌、胶接特性、失效形式和极限载荷之间的对应关系；建立了三维有限元模型，基于三维Hashin失效准则模拟复合材料补片的层内损伤和演化过程，基于内聚力模型模拟胶层和复合材料补片的层间破坏，通过与试验和理论分析对比，验证了该有限元模型的有效性。研究结果表明：3种修补工艺具有不同的界面形貌和失效形式，湿铺法工艺的修复效果最好，是预固化法的3.3倍、预浸料法的1.3倍；随着复合材料补片厚度的增加，修补结构的极限失效载荷先增大后减小，最后趋于稳定，失效形式逐渐从复合材料补片分层崩裂、纤维断裂与胶层损伤的混合失效逐渐演化到胶层的剪切失效，得到修复效果最好的补片厚度为7层约1.05 mm；随着补片长度的增加，修补结构的极限失效载荷先增大后线性减小，胶层的损伤从接头中央和两端起始并往中间区域演化，得到修复效果最好的补片长度为80 mm。该结论为航空维修工程应用提供了良好依据和建议。Abstract: For the repair structures of aircraft metal components with one-sided carbon fiber-reinforced polymer (CFRP) patches, the tensile tests on repair specimens with different repair processes (wet lay-up, prepreg and pre-curing methods) and CFRP patch parameters were carried out. The ultimate load, failure mode and interface of the specimens were observed. The three-dimensional (3D) finite element (FE) model had been established. Based on 3D Hashin failure criteria, the damage initiation and evolution in CFRP were simulated. The damages of the adhesive layer and delamination of CFRP were simulated with cohesive zone model. The FE model was validated by experimental and theoretical analysis. The results show that the three repair processes have different interface morphology and failure modes. The wet lay-up method has the best repair effect, 3.3 times of the pre-curing method and 1.3 times of the prepreg method. With the increase of patch thickness, the ultimate load first increases, then decreases, and finally tends to be stable. The failure mode gradually evolves from patch delamination, mixed failure of fiber breakage and adhesive layer damage to adhesive layer shear failure. The best patch thickness is 7 layers, about 1.05 mm in thickness. With the increase of patch length, the ultimate load first increases and then decreases linearly. The damage of the adhesive layer starts from the center and both ends of the joint and evolves to the middle region. The best patch length is 80 mm. The results reported herein could provide useful guidance for the application of aviation maintenance engineering.
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Key words:
- composite patch /
- aviation metal /
- adhesive bonded structure /
- finite element analysis /
- repair effect
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图 1 金属损伤碳纤维增强树脂(CFRP)复合材料单面贴补修复结构示意图
Figure 1. Schematic illustration of one-side repair of damaged metal structure using carbon fiber-reinforced polymer (CFRP)
tp—Patch thickness; tA—Adhesive thickness; L—Patch length
图 4 基于双线性软化的损伤演化过程
Figure 4. Bilinear softening based damage evolution process
σ0—Damage initiation stress; K—Stiffness; d—Damage variable; δ0—Damage initiation displacement; δc—Failure displacement
图 5 Cohesive单元的双线性本构模型
Figure 5. Bilinear constitutive model of cohesive element
δn 0, δs 0—Normal and tangential crack opening displacement; δf—Final cracking displacement; tn 0, ts 0—Normal and shear strength; δm 0, tm 0, GC—Crack opening displacement, strength and critical strain energy release rate in mixed-mode law
图 6 单面修复结构的有限元模型
Figure 6. Finite element model of one-side repair structure
Ux, Uy, Uz—Displacement in x, y and z directions, respectively
图 7 3种修复试件的极限载荷与变异系数(CV)
Figure 7. Ultimate load and coefficient of variation (CV) of three methods of repair specimens
图 9 CFRP补片的表面形貌：(a) 观察设备；(b) 预固化法补片；(c) 预浸料法补片；(d) 湿铺法补片
Figure 9. Surface morphologies of CFRP patch: (a) Observation equipment; (b) Pre-curing patch; (c) Prepreg lay-up patch; (d) Wet lay-up patch
图 10 CFRP补片的三维形貌：(a) 观测区域；(b) 预固化法补片；(c) 预浸料法补片；(d) 湿铺法补片
Figure 10. Three-dimensional morphologies of CFRP patch: (a) Observation zone; (b) Pre-curing patch; (c) Prepreg lay-up patch; (d) Wet lay-up patch
图 11 CFPR补片厚度为4层时修补结构的载荷-位移曲线
Figure 11. Load-displacement curves of the repair structure with the thickness of CFPR patch of 4 layers
图 12 不同厚度CFRP补片单面修补结构的极限失效载荷变化曲线
Figure 12. Ultimate failure load curves of one-side repair structure with CFRP patches of different thickness
图 13 A型失效模式：CFRP补片的分层和崩裂
Figure 13. A failure mode: CFRP patch delamination and splitting
SDEG—Damage variable of cohesive elements; SDV1—State variable of fiber damage
图 14 B型失效模式：CFRP补片分层和胶层剪切的混合失效(补片分层占比较大)
Figure 14. B failure mode: Mixed failure of CFRP patch delamination and shear failure of adhesive layer (Patch delamination accounts for a large proportion)
图 15 C型失效模式：CFRP补片分层和胶层剪切的混合失效(胶层损伤占比较大)
Figure 15. C failure mode: Mixed failure of CFRP patch delamination and shear failure of adhesive layer (Shear failure of adhesive layer accounts for a large proportion)
图 17 不同长度CFRP补片修补结构的极限失效载荷和剪切强度变化曲线
Figure 17. Ultimate failure load and shear strength curves of repair structure with CFRP patches of different lengths
图 18 单面修补结构的受力分析示意图
Figure 18. Schematic diagram of stress analysis of one-side repair structure
Fsh—Shear stress flow; M0—Bending moment; θ0—Included angle
图 19 补片长度为80 mm的单面修补结构胶层法向应力S33
Figure 19. Normal stress S33 of adhesive layer for one-side repair structure with 80 mm patch length
μ—Displacement at loading point
图 20 CFRP补片轴向的应变场分布
Figure 20. Axial strain field distribution of CFRP patch
eyy—Strain field in y direction
表 1 TC4钛合金板的材料参数
Table 1. Material parameters of TC4 titanium alloy plate
Parameter Value E/GPa 110 ρ/(kg·m−3) 4.51×103 v12 0.34 Note: E, ρ and v12—Elastic modulus, density and Poisson's ratio, respectively. 
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表 2 SY-24C胶膜的材料参数
Table 2. Material parameters of SY-24C adhesive film
Parameter Value E/MPa 5750 G/MPa 1920 σ/MPa 451.6 τ/MPa 225.8 GC,n/(N·mm−1) 0.48 GC,s, GC,t/(N·mm−1) 0.64 Notes: E, G—Elastic modulus in tension and shear; σ, τ—Failure strengths in tension and shear; GC,n—Toughness in tension; GC,s, GC,t—Toughness in shear.
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表 3 T300/7901碳纤维增强树脂(CFRP)复合材料层合板的材料参数
Table 3. Material parameters of T300/7901 carbon fiber reinforced polymer (CFRP) composite laminate
Parameter Value Parameter Value E11/GPa 125 Yc/MPa 280 E22, E33/GPa 11.3 S/MPa 120 G12, G13/GPa 5.43 Kn/(N·mm−3) 100000 G23/GPa 3.98 Ks/(N·mm−3) 100000 v12, v13 0.3 σ/MPa 28.5 v23 0.42 τ/MPa 35.5 Xt/MPa 2000 GC,n/(N·mm−1) 0.34 Xc/MPa 1100 GC,s/(N·mm−1) 0.38 Yt/MPa 80 GC,t/(N·mm−1) 0.38 Notes: Eii (i =1, 2, 3)—Young's modulus in the i direction; Gij (i, j=1, 2, 3)—Shear modulus in the i-j plane; vij (i, j=1, 2, 3)—Poisson's ratio in the i-j plane; Xt, Xc, and Yt, Yc—Tensile and compressive strengths in the 1 and 2 directions; S—Shear strength; Kn, Ks—Stiffness components in tension and shear.
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