United States Department of Transportation
i
Bonded Repairs to Composite Wing Panel Structure: Phase 2, Baseline Study
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2020-12-01
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[PDF-33.95 MB]
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Edition:Final Report
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Abstract:In a collaborative effort, the Federal Aviation Administration (FAA) and the Boeing Company are assessing bonded repair technologies of composite panels representative of transport airplane wing structures through test and analysis using the FAA’s Aircraft Beam Structural Test (ABST) fixture. Emphasis has been placed on investigating methods and tools used to conduct analysis and predict structural performance of bonded repairs and those used to monitor and evaluate repair quality over the life of the part. This project is undertaken in a phased approach, where phase 1 was fixture development and verification. In this current second phase, baseline testing was undertaken on carbon fiber reinforced polymer (CFRP) panels in the unnotched pristine and open-hole configurations to characterize the material response, to verify analysis models and to provide an initial reference point for inspection and monitoring system. Panels were 24-inches wide and 40-inches long consisting of an 18-ply quasi-isotropic layout attached as top-side components (e.g., skins) of a cantilevered wingbox structure subjected to constant-moment loading. Fatigue loading conditions were applied that produce typical operational strain levels for transport-category wing panels for three design service objectives (~165,000 cycles). Results from this second phase effort verified the test-fixture loading, validated analysis models, and provided an initial baseline for Nondestructive inspection (NDI) and other monitoring systems to detect damage. For the unnotched panel, structural integrity was maintained through testing with no signs of damage in the test section. Measured strains in the test section were relatively constant and remained unchanged during fatigue. For the open-hole panel strain surveys revealed excellent correlation between test and analysis. Strain concentrations measured using strain gages and a digital image correlation (DIC) system matched finite element analysis results. Future, phase 3 efforts will be focused on Bonded Repair Size Limit (BRSL) study, where the goal is to develop data to support BRSL assessment methods for solid laminate panels. The test results of phase 3 panels will be provided in forthcoming technical notes.
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