Title: Innovative Repair Technique For Polymer Composite Laminates

Authors: Mohammad B. Uddin, Shashwata Chakraborty, Ajit D. Kelkar

DOI: 10.33599/nasampe/s.21.0610

Abstract: During the last few decades, the use of lightweight composite materials has increased dramatically. They are widely used for a variety of applications including aerospace, automotive, wind turbine blades and numerous others. Usually, these composites are exposed to various types of loads like axial, flexural, fatigue, impact, etc. Out of these loadings, the impact loading causes severe damage to the composite laminate which may prove catastrophic. Thus, when laminates are damaged, there needs to be an effective methodology to repair these damages. Composite repairs are normally considered as a cumbersome process. Hence, this paper proposes a novel repair technique to address this issue. This paper focuses on the study of composite laminates subjected to impact loading, and then replacing the damaged area with various shapes of cutouts to facilitate the load transfer after repair and reduce the loss of compressive strength significantly in the process. Composite laminates of carbon fiber with epoxy resin were fabricated using Heated Vacuum-Assisted Resin Transfer Molding (HVARTM) method. The laminates were subjected to low-velocity impact loading. The resulted damage areas were cut using a water jet cutter and replaced with innovatively designed shapes of cutouts. The compressive strengths of the repaired laminates were compared with undamaged and impact damaged laminates.

References: [1] A. K. Noor, Structures Technology for Future Aerospace Systems. Reston ,VA: American Institute of Aeronautics and Astronautics, 2000. [2] Viswas Jadhav and Ajit Kelkar, “Effect of Curing Temperature on the Fundamental Properties of Laminated Composites Fabricated Using Plain Weave and Non Crimp Fiber and Epoxy Resin,” presented at the CMAX, 2019. [3] F. Rezaei, R. Yunus, N. A. Ibrahim, and E. S. Mahdi, “Development of Short-Carbon-Fiber-Reinforced Polypropylene Composite for Car Bonnet,” Polym.-Plast. Technol. Eng., vol. 47, no. 4, pp. 351–357, Mar. 2008, doi: 10.1080/03602550801897323. [4] M. Bannister, “Challenges for composites into the next millennium — a reinforcement perspective,” Compos. Part Appl. Sci. Manuf., vol. 32, no. 7, pp. 901–910, Jul. 2001, doi: 10.1016/S1359-835X(01)00008-2. [5] E. J. Barbero, Introduction to Composite Materials Design. CRC Press, 2017. [6] R. P. S. Tomar, M. Ghazizadeh, E. H. Martin, and A. D. Kelkar, “Low Velocity Impact Response of Bio-inspired Fiberglass Woven Composites,” Am. Soc. Compos. - 30th Tech. Conf., vol. 0, no. 0, Nov. 2015. [7] “Composites Materials Market Report - Composites & Advanced Materials Market Research Reports | Lucintel.” [Online]. Available: https://www.lucintel.com/reports/composites-market-report.aspx. [Accessed: 18-Jan-2020]. [8] K. Mason, “Non-destructive inspection broadens its scope,” High Perform. Compos., 2006. [9] H. Zabala, L. Aretxabaleta, G. Castillo, J. Urien, and J. Aurrekoetxea, “Impact velocity effect on the delamination of woven carbon–epoxy plates subjected to low-velocity equienergetic impact loads,” Compos. Sci. Technol., vol. 94, pp. 48–53, Apr. 2014, doi: 10.1016/j.compscitech.2014.01.016. [10] E. Panettieri, D. Fanteria, M. Montemurro, and C. Froustey, “Low-velocity impact tests on carbon/epoxy composite laminates: A benchmark study,” Compos. Part B Eng., vol. 107, pp. 9–21, Dec. 2016, doi: 10.1016/j.compositesb.2016.09.057. [11] S. Rivallant, C. Bouvet, E. Abi Abdallah, B. Broll, and J.-J. Barrau, “Experimental analysis of CFRP laminates subjected to compression after impact: The role of impact-induced cracks in failure,” Compos. Struct., vol. 111, pp. 147–157, May 2014, doi: 10.1016/j.compstruct.2013.12.012. [12] G. C. Papanicolaou and C. D. Stavropoulos, “New approach for residual compressive strength prediction of impacted CFRP laminates,” Composites, vol. 26, no. 7, pp. 517–523, Jul. 1995, doi: 10.1016/0010-4361(95)96809-K. [13] R. Hosseinzadeh, M. M. Shokrieh, and L. Lessard, “Damage behavior of fiber reinforced composite plates subjected to drop weight impacts,” Compos. Sci. Technol., vol. 66, no. 1, pp. 61–68, Jan. 2006, doi: 10.1016/j.compscitech.2005.05.025. [14] G. A. O. Davies and X. Zhang, “Impact damage prediction in carbon composite structures,” Int. J. Impact Eng., vol. 16, no. 1, pp. 149–170, Feb. 1995, doi: 10.1016/0734-743X(94)00039-Y. [15] P. Kumar and B. Rai, “Delaminations of barely visible impact damage in CFRP laminates,” Compos. Struct., vol. 23, no. 4, pp. 313–318, Jan. 1993, doi: 10.1016/0263-8223(93)90231-E. [16] S. Abrate, “Impact on Laminated Composites: Recent Advances,” Appl. Mech. Rev., vol. 47, no. 11, pp. 517–544, Nov. 1994, doi: 10.1115/1.3111065. [17] J. C. Prichard and P. J. Hogg, “The role of impact damage in post-impact compression testing,” Composites, vol. 21, no. 6, pp. 503–511, Nov. 1990, doi: 10.1016/0010-4361(90)90423-T. [18] K. B. Katnam, L. F. M. Da Silva, and T. M. Young, “Bonded repair of composite aircraft structures: A review of scientific challenges and opportunities,” Prog. Aerosp. Sci., vol. 61, pp. 26–42, Aug. 2013, doi: 10.1016/j.paerosci.2013.03.003. [19] K. Armstrong, W. Cole, and G. Bevan, “Care and Repair of Advanced Composites,” in Care and Repair of Advanced Composites, SAE, 2005, pp. i–xxviii. [20] P. K. Mallick, Fiber-reinforced composites: materials, manufacturing, and design, 3rd ed., [Expanded and Ed.]. Boca Raton, FL: CRC Press, 2008. [21] www.aircraftspruce.com, “ASA THE AVIATION MECHANIC HANDBOOK,” Aircraft Spruce. [Online]. Available: https://www.aircraftspruce.com/catalog/pspages/av_mechhdbk_asa.php. [Accessed: 15-Feb-2020]. [22] B. A. C. Loomans et al., “Is there one optimal repair technique for all composites?,” Dent. Mater., vol. 27, no. 7, pp. 701–709, Jul. 2011, doi: 10.1016/j.dental.2011.03.013. [23] C. Soutis, D.-M. Duan, and P. Goutas, “Compressive behaviour of CFRP laminates repaired with adhesively bonded external patches,” Compos. Struct., vol. 45, no. 4, pp. 289–301, Aug. 1999, doi: 10.1016/S0263-8223(99)00033-1. [24] P. Cheng, X. Gong, and S. Aivazzadeh, “Design and optimization of composite laminates repaired by bonding external patches,” in Proceedings of 18th International Conference on Composite Materials, 2011. [25] P. Cheng, X.-J. Gong, and S. Aivazzadeh, “Optimisation of patched repair for CFRP laminates,” in Proceedings of 17th International Conference on Composite Materials, 2009. [26] M. Thunga, W. Y. Lio, M. Akinc, and M. R. Kessler, “Adhesive repair of bismaleimide/carbon fiber composites with bisphenol E cyanate ester,” Compos. Sci. Technol., vol. 71, no. 2, pp. 239–245, Jan. 2011, doi: 10.1016/j.compscitech.2010.11.021. [27] K.-W. Wu, C.-L. Lee, Y.-C. Chang, and C.-L. Ong, “Compressive strength of delaminated and repaired composite plates,” Mater. Chem. Phys., vol. 43, no. 2, pp. 173–177, Feb. 1996, doi: 10.1016/0254-0584(95)01633-6. [28] D30 Committee, “Test Method for Compressive Residual Strength Properties of Damaged Polymer Matrix Composite Plates,” ASTM International. [29] D30 Committee, “Test Method for Measuring the Damage Resistance of a Fiber-Reinforced Polymer Matrix Composite to a Drop-Weight Impact Event,” ASTM International

Conference: SAMPE NEXUS 2021

Publication Date: 2021/06/29

SKU: TP21-0000000610

Pages: 9

Price: FREE