Influence of localised corrosion shape on adhesive damage and a bonded assembly under thermo-mechanical loading
DOI:
https://doi.org/10.14311/AP.2025.65.0155Keywords:
composite repair, corrosion, crack, stress intensity factor (SIF), thermo-mechanical loadings, damaged area ratio, ultimate strengthAbstract
This study explores the damage prediction of repairs on bonded assemblies through a two-part analysis: simulation and experimentation. The effects of corrosion geometry on adhesive and plate damage were evaluated. In the first part, a three-dimensional finite element method (FEM) was used to analyse a cracked and corroded AL 2024 T3 alloy with a V-notch under thermo-mechanical loading. The analysis included calculating the stress intensity factor (SIF) at the crack tip in mode I at thermo-viscoelastic state, assessing the influence of corrosion geometry, determining the damaged area ratio (DR) for various adhesive configurations, optimising the patch shape for repairs, and examining the effects of crack depth on SIF.
The second part involved an experimental investigation on the same bonded assembly under identical conditions. The findings reveal that the circular corrosion shape has minimal impact compared to the square shape, while the rectangular composite patch demonstrated superior performance as an optimal repair solution.
Downloads
References
A. Baker. Bonded composite repair of fatigue-cracked primary aircraft structure. Composite Structures 47(1–4):431–443, 1999. Tenth International Conference on Composite Structures. https://doi.org/10.1016/S0263-8223(00)00011-8
J.-D. Mathias, M. Grédiac, X. Balandraud. Design of optimized patches to reinforce damaged wings. AIAA Journal 46(1):46–53, 2008. https://doi.org/10.2514/1.24300
A. C. Umamaheshwer Rao, V. Vasu, M. Govindaraju, K. V. Sai Srinadh. Stress corrosion cracking behaviour of 7xxx aluminum alloys: A literature review. Transactions of Nonferrous Metals Society of China 26(6):1447–1471, 2016. https://doi.org/10.1016/S1003-6326(16)64220-6
M. Ely, J. Światowska, A. Seyeux, et al. Role of post-treatment in improved corrosion behavior of trivalent chromium protection (TCP) coating deposited on aluminum alloy 2024-T3. Journal of The Electrochemical Society 164(6):C276, 2017. https://doi.org/10.1149/2.0431706jes
H. Nakano, S. Oue, S. Taguchi, et al. Stress-corrosion cracking property of aluminum-magnesium alloy processed by equal-channel angular pressing. International Journal of Corrosion 2012(1):543212, 2012. https://doi.org/10.1155/2012/543212
M. Holmes. Aerospace looks to composites for solutions. Reinforced Plastics 61(4):237–241, 2017. https://doi.org/10.1016/j.repl.2017.06.079
M. Khodja, G. Govender, G. Corderley, H. Fekirini. Insights and innovations in structural engineering, mechanics and computation, chap. Repaired crack in AA7075-T6 structures subjected to biaxial tensile stresses, p. 563–566. CRC Press, 2016. https://doi.org/10.1201/9781315641645-93
A. El Mourid, R. Ganesan, M. Brochu, M. Lévesque. Effect of temperature on the failure modes of a triaxially braided polymer matrix composite. International Journal of Solids and Structures 97–98:1–15, 2016. https://doi.org/10.1016/j.ijsolstr.2016.08.005
A. Albedah, B. B. Bouiadjra, S. M. A. K. Mohammed, F. Benyahia. Fractographic analysis of the overload effect on fatigue crack growth in 2024-T3 and 7075-T6 Al alloys. International Journal of Minerals, Metallurgy and Materials 27(1):83–90, 2020. https://doi.org/10.1007/s12613-019-1896-4
X.-J. Gong, P. Cheng, S. Aivazzadeh, X. Xiao. Design and optimization of bonded patch repairs of laminated composite structures. Composite Structures 123:292–300, 2015. https://doi.org/10.1016/j.compstruct.2014.12.048
R. Liu, T. Chen, L. Li, K. Tateishi. A practical stress intensity factor formula for CFRP-repaired steel plates with a central crack. Journal of Constructional Steel Research 162:105755, 2019. https://doi.org/10.1016/j.jcsr.2019.105755
M. Berrahou, M. Salem, B. Mechab, B. Bachir Bouiadjra. Effect of the corrosion of plate with double cracks in bonded composite repair. Structural Engineering and Mechanics 64(3):323–328, 2017. https://doi.org/10.12989/sem.2017.64.3.323
D. Boumaiza, K. Sadek, B. Aour, S. Poncet. Application of machine learning for predicting adhesive damage used for joining structural steel with GFRP under hygrothermal effect. Journal of Composite Materials 59(10):1287–1305, 2025. https://doi.org/10.1177/00219983241310556
B. Belarbi, B. Mohammed Salah, K. Sadek, et al. Effect of the influence of the different corrosion level on the repair efficiency of marine and offshore structures by bonded composite. Journal of Theoretical and Applied Mechanics 54(3):308–322, 2024. https://doi.org/10.55787/jtams.24.54.3.308
M. Berrahou, H. Benzineb, M. Serier. Analysis of the adhesive damage for different shapes and types patch’s in aircraft structures corroded with an inclined crack. Fracture and Structural Integrity 16(60):331–345, 2022. https://doi.org/10.3221/IGF-ESIS.60.23
Hibbit, Karlsson and Sorensen, Inc. Abaqus analysis user’s manual (6.11), 2011.
A. Deheeger, C. Badulescu, J. D. Mathias, M. Grédiac. Experimental study of thermal stresses in a bonded joint. Journal of Physics: Conference Series 181(1):012041, 2009. https://doi.org/10.1088/1742-6596/181/1/012041
C.-S. Ban, Y.-H. Lee, J.-H. Choi, J.-H. Kweon. Strength prediction of adhesive joints using the modified damage zone theory. Composite Structures 86(1–3):96–100, 2008. https://doi.org/10.1016/j.compstruct.2008.03.016
Downloads
Published
Issue
Section
License
Copyright (c) 2025 Mohamed Berrahou, Mehdi Zahraoui, Kamel Hocine, Samir Djebbar, Youcef Guermit, Hayet Benzineb
This work is licensed under a Creative Commons Attribution 4.0 International License.
