Repair of Aerospace Composite Structures Using Liquid Thermoplastic Resin

Abstract

In this study, two types of carbon-fiber-reinforced plastic (CFRP) composite scarf geometries were created using two scarf angles, i.e., 1.43° and 5.71°. The scarf joints were adhesively bonded using a novel liquid thermoplastic resin at two different temperatures. The performance of the repaired laminates was compared with pristine samples in terms of residual flexural strength using four-point bending tests. The repair quality of the laminates was examined by optical micrographs, and the failure modes after flexural tests were analyzed using a scanning electron microscope. The thermal stability of the resin was evaluated by thermogravimetric analysis (TGA), whereas the stiffness of the pristine samples was determined using dynamic mechanical analysis (DMA). The results showed that the laminates were not fully repaired under ambient conditions, and the highest recovery strength at room temperature was only 57% of the total strength exhibited by pristine laminates. Increasing the bonding temperature to an optimal repair temperature of 210 °C resulted in a significant improvement in the recovery strength. The best results were achieved for laminates with a higher scarf angle (5.71°). The highest residual flexural strength was recorded as 97% that of the pristine sample repaired at 210 °C with a scarf angle of 5.71°. The SEM micrographs showed that all the repaired samples exhibited delamination as the dominant failure mode, whereas the pristine samples exhibited dominant fiber fracture and fiber pullout failure modes. The residual strength recovered using liquid thermoplastic resin was found to be much higher than that reported for conventional epoxy adhesives.

Circular Production, Designing, and Mechanical Testing of Polypropylene-Based Reinforced Composite Materials: Statistical Analysis for Potential Automotive and Nuclear Applications

“…In parallel, bend testing explored the flexural properties of recycled composite materials under compressive conditions [ 101 ]. Maximum flexural stress, strain, and elongation of plastics [ 102 ], thermosetting [ 103 ], elastomers [ 104 ], composites, and metals are investigated for customer satisfaction [ 105 ]. The degree of surface finishing is evaluated using erosion [ 106 ], fatigue, creep testing, and surface characterization [ 107 ].…”

Experimental and Numerical Study of Healing Effect on Delamination Defect in Infusible Thermoplastic Composite Laminates

“…Continuous fiber-reinforced thermoplastic composites (CFRTPC) are preferred in various industries because of their recyclability properties [1,2], possibility of thermal welding [3,4], easy repair [5][6][7], high fracture toughness [8], damage tolerance [9], and applicability in additive manufacturing technology with in-situ consolidation of thermoplastic automated fiber placement processes [10]. The recent development of thermoplastic liquid resin systems has increased the trend toward using thermoplastic composites [7,11,12].…”

“…Monitoring and assessing structural integrity is essential for economic and safety reasons. Early detection of this phenomenon using non-destructive testing (NDT) techniques [14] enables predicting the residual strength of the composite structure and adhesive joints [15][16][17] and selecting appropriate methods for repair [5][6][7]18,19]. Identification and mitigation of damage-tailored repair of composite components is a time-consuming and costly procedure.…”