金属裂纹板复合材料单面胶接修补结构应力分析

考虑金属裂纹板复合材料单面胶接修补结构的几何非线性和边界条件,建立了考虑弯曲变形单面修补结构力学分析模型,计算出承受面内载荷时修补结构的弯矩和挠度,将补片自由端和金属板裂纹处的弯矩作为胶层应力控制微分方程的边界条件,推导出剪应力和剥离应力的解析解,及裂纹张开位移的表达式,并与有限元数值结果进行对比。分析结果表明,胶接修补结构应力分析理论模型和相关简化假设合理、正确。利用所建立的解析模型研究了金属裂纹复合材料单面胶接修补结构的应力分布特点及胶层主导破坏模式的失效机制,为胶接修补结构的承载能力分析以及结构改进设计提供了一定的理论依据。     

炭纤维/ 环氧复合材料单面修补中心裂纹铝合金板的静态和疲劳特性

利用真空袋压工艺, 采用单向炭纤维复合材料补片对中心裂纹铝合金板进行了单面胶接修补。测试了复合材料修补板的静态拉伸强度及修补板在拉拉疲劳过程中的裂纹扩展、界面脱粘和剩余拉伸强度等疲劳性能。结果表明, 复合材料补片胶接修补能有效地提高裂纹板的破坏强度和刚度, 降低裂纹板的疲劳裂纹扩展速率, 提高其疲劳寿命。裂纹板经单向炭纤维/ 环氧复合材料补片修补后, 其破坏强度从311. 48 MPa 提高到364. 74 MPa ,疲劳寿命从32217 次提高到77546 次。疲劳导致修补结构的粘接界面脱粘, 脱粘区域近似椭圆形; 脱粘面积随疲劳周次的增加而增加, 且增加的幅度与疲劳周次相关。      

复合材料胶接修补件力学性能的实验研究与数值模拟

进行复合材料修补的铝合金板的静强度实验,测定载荷-位移曲线,分析破坏机理,并讨论了胶层材料性能、复合材料补片性能与厚度等因素对修补件静强度的影响;建立了修补件的三维有限元模型,模拟修补件的载荷-位移曲线和应力分布,验证了模型的有效性;根据应力分布计算结果和失效准则,预测初始损伤及裂纹产生的位置,并估算破坏强度,预测结果...     

单向拉伸条件下补片参数对复合材料胶接修复结构的影响

建立含中心半穿透圆孔的损伤金属板修补结构的三维有限元模型,以应力集中系数(Stress Concentration Factor,SCF)和挠度w作为复合材料胶接修复效果的指标,分析单向拉伸条件下,正方形补片的长度、厚度和铺层方式对修复效果的影响。结果表明:补片长度取孔直径的3.5倍、厚度取孔深度的0.6~0.8倍、铺层方式取0°/90°铺层时,复合材料单面修复含损伤裂纹板的效果较好。根据分析结果制备了实验件,进行了单向静拉伸实验,修补实验件的破坏强度比未修补实验件提高了10.1%。     

基于全试验设计方法的含裂纹铝合金板复合材料修补参数优化

建立含穿透裂纹铝合金板复合材料单面胶接修补板条的三维有限元模型,基于位移外推法对裂纹尖端的应力强度因子(SIF)进行求解。使用全试验设计的方法对不同修补参数下修补板条的单向拉伸试验进行仿真模拟,利用二次方程描述并研究了补片长度、补片厚度及胶层弹性模量共同作用时对SIF的影响,确定了以SIF为评价指标时对修补效果影响最大的修补参数,优化了修补设计,并应用优化修补参数进行单向静拉伸试验。结果表明,当三类修补参数共同作用时,补片长度对修补效果影响最大;使用优化修补参数单面修补试验件的破坏强度比未修补板的提高了12.1%,恢复到完好板的90.5%。     

金属裂纹板复合材料修补结构的超奇异积分方程方法

根据应力强度因子在线弹性范围内具有可叠加性,将金属裂纹板复合材料修补结构进行简化,在表面裂纹线弹簧模型的基础上,建立了基于超奇异积分方程的Line-Spring模型。利用第二类Chebyshev多项式展开的方法,将超奇异积分方程转化为线性方程组,推导出以裂纹面位移表示的应力强度因子表达式,得到了裂纹尖端应力强度因子的数值解,并利用虚拟裂纹闭合法加以验证。参数分析确定了影响对称修补裂纹板应力强度因子的两个主要参数:胶层界面刚度和补片与金属板刚度比,为胶接修补结构的承载能力分析以及改进设计提供理论依据。     

铝合金裂纹板的阳极化处理与复合材料补片胶接修理效果

采用磷酸阳极化方法对胶接修理铝合金裂纹板的粘接表面进行了处理,并用单向碳纤维/环氧复合材料补片对铝合金进行了修补.测试了阳极化铝合金的粘接性能、修补结构的静态力学性能和疲劳性能,考察了粘接表面的阳极化处理对修补结构的静态力学性能和疲劳性能的影响.结果表明,磷酸阳极化在铝合金表面形成多孔膜,复合材料补片修补胶接时胶粘剂能渗透进入阳极化铝合金表面的多孔膜,在粘接界面上形成一层过渡层,该过渡层的形成能有效提高其与复合材料的粘接性能,其粘接副的拉剪强度提高了104%;铝合金裂纹板胶接修理前的粘接表面的阳极化处理能大幅度地提高修复结构的静态强度和疲劳寿命,当用单向碳纤维/环氧复合材料补片单面修补时,修补结构的破坏强度为418.13MPa,恢复到完好板的93.42%;修补结构的疲劳寿命相对裂纹板延长了1.42倍,比未阳极化的修补板的疲劳寿命增加了27.59%.修补前的阳极化处理也使修补结构在一定周次疲劳后的剩余强度有所提高.     

双斜接修补复合材料层合板的拉伸行为及影响因素双斜接修补复合材料层合板的拉伸行为及影响因素

基于试验和有限元数值方法对双斜接修补碳纤维增强聚合物（CFRP）复合材料层合板在拉伸载荷作用下的力学行为开展研究。通过试验分析了两种不同厚度的双斜接修补复合材料结构的承载能力和失效形式。结果表明,对于不同厚度的双斜接修补复合材料结构,失效强度接近,主要破坏形式均以胶层内聚破坏为主,伴随局部的90°基体开裂。利用连续介质损伤力学模型和内聚力模型分别对复合材料和胶层失效进行描述,通过数值方法开展双斜接修补结构的强度预测和损伤演化分析。数值结果与试验吻合较好,并且指出复合材料基体开裂起始早于胶层失效。通过有限元模型讨论了附加层、双斜接内部尖端所处位置和修补胶层参数对修补性能的影响。      

纤维增强复合材料胶接结构疲劳特性研究进展

纤维增强复合材料胶接结构的疲劳特性与纤维、环氧树脂以及胶黏剂的特性紧密相关,为了开展复合材料胶接结构的疲劳性能研究,本文提出适用于复合材料胶接结构的疲劳分析方法,完成复合材料胶接结构的抗疲劳设计,从复合材料层压板、层间以及胶接界面等研究对象的疲劳特性分析方法入手,全面综述了国内外学者在复合材料结构、金属胶接结构以及复合材料胶接结构的疲劳特性及寿命预测方法等方面的研究进展.结果表明:采用S-N曲线拟合得到寿命预测模型对复合材料胶接结构进行寿命预测是行之有效的,以此为依据开发基于物理机制的有限元寿命预测模型可以对疲劳裂纹扩展及疲劳特性进行分析,对于层间损伤和界面损伤,多采用粘聚区模型进行模拟分析,可以为复合材料胶接结构的疲劳失效分析方法的建立提供指导.     

复合材料胶结修补缺损金属结构的力学性能研究

进行了未修补与复合材料胶结修补的含穿透性裂纹金属试样的力学性能实验,测定了失效载荷,并分析了失效机理;采用实体层单元模拟复合材料补片和胶层,建立了复合材料胶接修补缺损金属结构的三维有限元分析模型,数值模拟了两种试样的载荷-位移曲线和应力分布,预测了破坏位置,与实验现象吻合良好。研究发现,与未修补的试样相比,经复合材料修补后的缺损结构承载能力得到明显提高。     

Static Tensile and Transient Dynamic Response of Cracked Aluminum Plate Repaired with Composite Patch – Numerical Study

In this study, the central cracked aluminum plates repaired with two sided composite patches are investigated numerically for their response to static tensile and transient dynamic loadings. Contour integral method is used to define and evaluate the stress intensity factors at the crack tips. The reinforcement for the composite patches is carbon fibers. The effect of adhesive thickness and patch thickness and configuration in tensile loading case and pre-tension, pre-compression and crack length effect on the evolution of the mode I stress intensity factor (SIF) (K_I) of the repaired structure under transient dynamic loading case are examined. The results indicated that K_I of the central cracked plate is reduced by 1/10 to 1/2 as a result of the bonded composite patch repair in tensile loading case. The crack length and the pre-loads are more effective in repaired structure in transient dynamic loading case in which, the 100 N pre-compression reduces the maximum K_I for about 40 %, and the 100 N pre-tension reduces the maximum K_I after loading period, by about 196 %.     

Nonlinear analysis of bonded composite patch repair of cracked aluminum panels

Analyses of adhesively bonded composite patches to repair cracked structures have been the focus of many studies. Most of these studies investigated the damage tolerance of the repaired structure by using linear analysis. This study involves nonlinear analysis of the adhesively bonded composite patch to investigate its effects on the damage tolerance of the repaired structure. The nonlinear analysis utilizes the three-layer technique which includes geometric nonlinearity to account for large displacements of the repaired structure and also material nonlinearity of the adhesive. The three-layer technique uses two-dimensional finite element analysis with Mindlin plate elements to model the cracked plate, adhesive and composite patch. The effects of geometric nonlinearity on the damage tolerance of the cracked plate is investigated by computing the stress intensity factor and fatigue growth rate of the crack in the plate. The adhesive is modeled as a nonlinear material to characterize debond behavior. The elastic-plastic analysis of the adhesive utilizes the extended Drucker-Prager model. A detailed discussion on the effects of nonlinear analysis for a bonded composite patch repair of a cracked aluminum panel is presented in this paper.     

复合材料补片止裂性能的方法研究

含裂纹金属板经复合材料补片胶接修补后的应力强度因子计算可分为两个阶段：首先假设复合材料补片胶接到一块没有裂纹的金属板上,根据广义平面应力的弹性包容理论计算胶接修补区内金属板上的应力值;其次在金属板上引入一条长度为2c的裂纹,并用近似方法估算裂纹尖端的应力强度因子和疲劳寿命。所得结果与有限元计算结果和疲劳寿命试验结果吻合较好。     

Fracture Analysis of Double-Side Adhesively Bonded Composite Repairs to Cracked Aluminium Plate Using Line Spring Model

A line spring model is developed for analyzing the fracture problem of cracked metallic plate repaired with the double-sided adhesively bonded composite patch. The restraining action of the bonded patch is modeled as continuous distributed linear springs bridging the crack faces provided that the cracked plate is subjected to extensional load. The effective spring constant is determined from 1-D bonded joint theory. The hyper-singular integral equation (HSIE), which can be solved using the second kind Chebyshev polynomial expansion method, is applied to determine the crack opening displacements (COD) and the crack tip stress intensity factors (SIF) of the repaired cracked plate. The numerical result of SIF for the crack-tip correlates very well with the finite element (FE) computations based on the virtual crack closure technique (VCCT). The present analysis approaches and mathematical techniques are critical to the successful design, analysis and implementation of crack patching.     

Characterization of fatigue crack growth in aluminium panels with a bonded composite patch

This study introduces an analytical procedure to characterize the fatigue crack growth behavior in an aluminium panel repaired with a bonded composite patch. This procedure involves the computation of the stress intensity factor from a two-dimensional finite element method consisting of three layers to model cracked plate, adhesive and composite patch. In this three layer finite element analysis, as recently introduced by the authors, two-dimensional Mindlin plate elements with transverse shear deformation capability are used. The computed stress intensity factor is then compared with the experimental counterpart. The latter was obtained from the measured fatigue crack growth rate of an aluminium panel with a bonded patch by using the power law relationship (Paris Law) of an unpatched aluminum panel. Both a completely bonded patch (with no debond) and a partially bonded patch (with debond) are investigated in this study. This procedure, thus, provides an effective and reliable technique to predict the fatigue life of a repaired structure with a bonded patch, or alternatively, it can be used to design the bonded composite patch configuration to enhance the fatigue life of cracked structure.     

Blast response of cracked steel box structures repaired with carbon fibre-reinforced polymer composite patch

In this paper the blast resistance of cracked steel structures repaired with fibre-reinforced polymer (FRP) composite patch are investigated. The switch box which has been subjected to blast loading is chosen to study. The steel material is modelled using isotropic hardening model, pertaining to Von Mises yield condition with isotropic strain hardening, and strain rate-dependent dynamic yield stress based on Cowper and Symonds model. Three different cracked structures are chosen to investigate their capability in dissipating the blast loading. To improve the blast resistance, the cracked steel structures are stiffened using carbon fibre-reinforced polymer (CFRP) composite patches. The repaired patches reduce the stress field around the crack as the stress is transferred from the cracked zone to them. This situation prevents the crack from growing and extends the service life of the steel structure. It will be shown that CFRP repairing can significantly increase the blast resistance of cracked steel structures.     

Progressive edge cracked aluminium plate repaired with adhesively bonded composite patch under full width disbond

In this study, the crack growth behaviour of an aluminium plate cracked at the tip and repaired with a bonded boron/epoxy composite patch in the case of full-width disbond was investigated. This effect is the imperfection which could result during the bonded patch of the repaired structure. Disbonds of various sizes and situated at different positions with respect to the crack tip as well as the effect of adhesive and patch thickness on repair performance were examined. An analysis procedure involving the efficient finite element modelling applied to cracked plate, adhesive and composite patch was used to compute the stress intensity factors. The crack growth rate is dominated by the stress intensity factor near the location and size of the pre-existing disbonds. The cracked plate and disbond propagation result in an increase in the patch deformation. The patch does not have an influence on the crack growth when the ratio 2a/d_R exceeds 0.8.     

Study of composite patch repair by analytical and numerical methods

A combined analytical and numerical study of an isotropic cracked plate that was repaired by using a bonded composite patch was conducted. The analytical work was based on Rose's equations, whereas for the numerical investigation a three-dimensional finite element analysis was implemented. A number of cracked plates with different crack lengths and overall dimensions of the composite repair were considered. The composite patch was made of unidirectional laminates with different stacking sequences. Both, one- and two-sided patches were analysed. Results are presented for the stress intensity factor in the patched crack and the maximum stress reinforcement stress and adhesive strain. It was found that for the case of a two-sided reinforcement the results obtained by both methods were in good agreement. However, for the case of a single reinforcement the accuracy of the analytical method decreased due to the tendency to out-of-plane bending as a result of bonding a reinforcing patch to only one face of a plate, which is ignored in the analysis.