腐蚀环境下复合材料修补件力学特性研究

采用复合材料补片胶接修补含裂纹LY12CZ铝合金板,开展了试验室大气环境和加速预腐蚀环境下复合材料修补件静强度拉伸和疲劳裂纹扩展对比试验研究.结果表明,复合材料补片均能显著提高损伤结构的拉伸强度和疲劳寿命,且短周期的预腐蚀环境对修补件两种力学特性的影响可以忽略不计.同时,基于Paris公式和Rose分析模型,建立了常规环境和预腐蚀环境下疲劳裂纹扩展寿命预测模型,通过与试验结果的对比证明了该模型的工程有效性.     

A photoelastic study of crack repair

Birefringent coatings have been employed to study the effectiveness of an adhesively bonded repair of a center-cracked tension panel. The repair was one sided, with photoelastic coatings applied to the opposite side. Photoelastic coatings were also applied over the patch. Analysis methods are presented to permit the stress intensity factor to be determined from the isochromatic fringe patterns recorded from both continuous andX- andY-edged coatings. The results showed that the one-sided adhesively bonded patch reduced the stress intensity factor; however, the repair did not markedly change the character of stress distributions. Fringe loops formed near the crack tips for both the cracked and repaired tension panels. The primary difference was in the size of the loops. The reduction inK _I due to repair was smaller than anticipated, but even small improvements in ΔK _I markedly enhance the life of a repaired panel. The Paris power law is used to show the relation between the reduction in ΔK _I and the improvement in the crack growth rateda/dN. Fringe patterns from the birefringent coatings applied to the patch provided a means not only to investigate the stresses in the patch but also to detect the initiation of the local debonding of the adhesive in the neighborhood of the crack. The birefringent coating on the patch is an approach for producing an optically “smart” repair.     

Thermal effects on adhesively bonded composite repair of cracked aluminum panels

This study introduces the two-dimensional finite element analysis involving three layer technique to investigate the adhesively bonded composite repair of cracked metallic structure under thermo-mechanical loading. The thermal loading involves, in this study, the temperature drop such as seen during the bonding process. Three patch materials having different stiffnesses and coefficients of thermal expansion are investigated to analyze the thermal effects on the damage tolerance of the crack in the repaired structure and of the debond in the adhesive bondline. For the single sided repair, the patch material having the maximum mismatch in the coefficient of thermal expansion with that of the cracked aluminum plate provides the better damage tolerance capability for both the crack in the panel and the debond in the adhesive. On the other hand, for double sided repair, the patch material having the minimal mismatch in the coefficient of thermal expansion with that of the cracked plate provides the better damage tolerance capability.     

Delamination effects on cracked steel members reinforced by prestressed composite patch

Prestressed composite patch bonded on cracked steel section is a promising technique to reinforce cracked details or to prevent fatigue cracking on steel structural elements. It introduces compressive stresses that produce crack closure effect. Moreover, it modifies the crack geometry by bridging the crack lips and reduces the stress range at crack tip. Fatigue tests were performed on notched steel plate reinforced by CFRP strips as a step toward the validation of crack patching for fatigue life extension of riveted steel bridges. A debond crack in the adhesive–plate interface was observed by optical technique. Debond crack total strain energy release rate is computed by the modified virtual crack closure technique. A parametric analysis is performed in order to investigate the influence of some design parameters such as the composite patch Young’s modulus, the adhesive thickness and the pretension level on the adhesive–plate interface debond.     

复合材料修补结构腐蚀扩展特性实验研究

为了研究腐蚀环境对复合材料修补结构疲劳特性的影响,开展以某型飞机加速环境谱为基础的预腐蚀试验,并采用递进式的试验方法分别完成对未修补未腐蚀、修补但未腐蚀、又修补又腐蚀的试样疲劳裂纹扩展试验。利用试验数据计算了复合材料修补构型、腐蚀环境对裂纹尖端应力强度因子影响的修正系数,并确定了通过试验验证的修补结构疲劳裂纹扩展修正模型。该模型预测腐蚀环境下修补结构的疲劳寿命与试验值一致。试验数据和预测模型可为海军飞机复合材料修补结构的损伤容限设计提供参考。     

用三维有限元模型计算复合材料粘接修补裂纹板的J积分

用复合材料单边粘接修补带裂纹金属板是三维应力问题,而采用简化的二维有限元分析模型计算则有一定近似性。本文建立了三维有限元模型,并计算了其断裂参数J积分。计算分析结果表明,厚度方向上J积分值是变化的,并且修补边比未修补边的J积分值有明显减小;修补前后裂纹面的张开位移明显不同;裂纹板模型的J积分值与裂纹长度在修补前为二次关系,修补后,变成线性关系;粘胶和补片的厚度、粘胶的模量对J积分的影响比较显著。为了提高修补性能,需要对粘胶和补片的几何尺寸和材料性能进行优化。     

Progressive damage modelling of bonded composite repairs

Presented is a three-dimensional progressive damage model that can assess the mechanical behaviour of bonded composite repairs of cracked metallic plates. The model is able to assess the stress intensity factor (SIF) at the crack tip, patch debonding and damage accumulation in the composite patch as functions of the applied load. Considered are the stress analysis, failure analysis and material property degradation. Stress analysis is performed using a three-dimensional detailed parametric finite element (FE) model developed using the ANSYS FE code. Failure analysis is performed using a set of stress-based polynomial failure criteria. Material property degradation of the failed material (patch and adhesive) is performed using appropriate degradation rules. The three model components have been programmed in the ANSYS FE code creating a user-friendly parametric macro-routine, which can be easily applied to bonded repairs of different materials and configuration.     

Investigation on 3D fatigue crack propagation in surface-cracked specimens

In the present work the fatigue crack growth in AISI304 specimens is investigated experimentally. In 3D finite element analysis the virtual crack closure technique is applied to calculate distributions and variations of the stress intensity factor along the surface crack front. It is confirmed that the stress intensity factor along the surface crack front varies non-uniformly with crack growth. Crack growth rate is proportional to the stress intensity factor distribution in the 3D cracked specimen. The fatigue crack growth in surface cracked specimens can be described by the Forman model identified in conventional compact tension specimens. For crack growth in the free specimen surface the arc length seems more suitable to quantify crack progress. Geometry and loading configuration of the surface cracked specimen seem to not affect the fatigue crack growth substantially.     

Edge-cracked stiffened panels analyzed by caustics

Externally bonded composite patches have been proven to be an effective method for repairing damaged aircraft structural components. They are ease in application and provide excellent in-service performance. The major function of a repair is to reduce the stress intensity factor at the crack tip. Calculation of stress intensity factor of a repaired crack has been performed by analytical and numerical methods. However, these methods are based on simplifying assumptions regarding material behavior and repair conditions. In the present paper an experimental determination of mode-I stress intensity factor (SIF), K_I, at the tip of an edge-crack or a V-notch reinforced with double bonded strips or with compression pre-stresses applied along the crack surfaces is undertaken by using the optical method of caustics. This method is simple in its application and has successfully been used for the solution of a host of crack problems of engineering importance.     

FRP加固金属裂纹板的断裂力学分析

传统的金属结构加固方法会形成新的疲劳源,而粘贴FRP加固则具有明显的优势．提出了“三维实体-弹簧-壳元”有限元模型,金属板采用三维实体单元, FRP采用壳单元,用弹簧单元来模拟FRP与金属板之间的胶层,对金属裂纹板粘贴FRP加固后的性能进行了线弹性断裂力学分析,并对影响金属板裂纹前缘应力强度因子的参数进行了讨论．分析结果表明,采用高弹性模量的FRP和增加FRP的厚度对改善加固效果非常明显．     

含裂粘补结构胶层剪应力的计算

提出了一种计算含裂粘补结构胶层剪应力的新方法。采用有限元计算补片的影响系数，使用已有解析解计算蒙皮的影响系数。利用位移协调条件，列出有限多组联立方程。解出含裂粘补结构胶层剪应力。计算结果较好的反映了含裂粘补结构胶层剪应力的实际变化趋势，该方法同样可应用于其他结构如高梯度基膜复合材料剪应力的计算。     

焊趾表面裂纹的形态发展曲线与疲劳寿命预测

以作者建立的焊地椭圆表面裂纹应力强度因子数据库以及复杂应力场中焊践半随圆表面裂纹前缘应力强度因子分布计算的基本模式法为基础上,给出了复杂应力场中焊践表面表纹在疲劳扩展过程中形态变化规律及寿命的工程分析方法。     

Linear coupled bending and extension of an unbalanced bonded repair

An unbalanced repair is a composite patch bonded to one side of a cracked structure for the purpose of preventing or reducing damage growth in the substrate. A single-sided repair offsets the load path within the structure, inducing out-of-plane bending. This bending increases the stress intensity in the underlying crack and causes adhesive peel stresses and bending of the repair which can, relative to a repair that is restrained against bending, lead to early failure. In this article the authors correct the analysis of Wang and Rose [Wang, C.H., Rose, L.R.F., 1997. On the design of bonded patches for one-sided repair. In: Proceedings of the 11th International Conference on Composite materials, Gold Coast, Australia, vol. 5, pp. 347–356] developed by using an energy analysis of a single-sided or unbalanced repair applied to a very long-crack, to comply with Maxwell’s reciprocal theorem and to account for transverse normal and shear stresses at the crack tip and the accompanying shear deflections. The authors then develop closed-form equations useful for bonded composite repair design and damage tolerance assessment of cracks of arbitrary length by developing a new method for interpolation between this long-crack limit and a short-crack limit based on the stress intensity and crack face displacements for an unreinforced crack. The interpolation method is then tested against an advanced line-spring model that has been created by using a 6th order generalized plane strain plate formulation in extension and a new 8th order formulation in bending, thus allowing for the inclusion of transverse shear and normal stresses. The closed-form equations are found to be accurate when compared to the line-spring model, and to provide reasonable results when compared to a three-dimensional finite element model of a bonded repair. Inaccuracies are shown to exist principally in the determination of the nominal stresses in the vicinity of the crack.     

Plasticity induced fatigue crack growth retardation model for steel elements reinforced by composite patch

Fatigue tests on notched steel plates reinforced by composite patch showed that the application of carbon fiber reinforced polymers (CFRP) strips with pretension of the overlays prior to bonding. This resulted in a significant amount of additional fatigue life. In particular, the pre-tension produces a compressive field in the steel plate which reduces the stress ratio that enhances crack growth retardation. The fatigue crack propagation rate is postulated to be a function of the effective strain energy density factor range. Fatigue crack growth data showed that standard crack growth retardation model cannot be used to evaluate the minimum effective stress. Hence, an ad hoc plasticity model is introduced and validated using experimental results. The proposed technique is an extension of the well know Newman’s model. The bridging effect due to the reinforcing strips is analytically modeled in order to estimate the reduction of crack opening displacement and finally the magnification of the crack growth retardation. Numerical and experimental results match well and show a significant influence of the pre-tension level on the expected fatigue crack growth rate of a reinforced steel plate.     

Composite patch reinforcement of cracked aircraft upper longeron: analysis and specimen simulation

The use of composite patches on cracked portions of metallic aircraft structures is an accepted means of improving fatigue life and attaining high structural efficiency. As more and more advanced composite materials are beng developed, the wider use of the repair technology is anticipated even for the reinforcement of primary aircraft structure. The objective of this work is to illustrate how the composite patch repair technology can be successfully applied to restore the structural integrity of cracked components.The Phosphoric Acid Anodize (PAA) surface treatment on aluminum when applied in conjunction with the AVI13/HV998 adhesive were essential for achieving the appropriate patch bonding strength. Such a process was done without immersing the component into the PAA tank; dismantling the component from the aircraft was not necessary. Boron/epoxy and carbon/epoxy patches were applied at room temperature to the 7075-T6511 cracked specimens and tested under fatigue simulating the load spectrum for the upper longeron attached to the access door of the electronic equipment bay. Considerable improvement in the fatigue life was observed after the repair. Equivalent flight test hours were increased from approximately two thousand hours at which the component fractured completely when not repired to twelve thousand hours when the repair was made with only a small amount of crack growth. A six times increase fatigue life is obtained. The laboratory developed technique has been applied to several in-service aircraft which have now been flown for more than 700 h without detection of crack growth.     

On a semi-infinite crack penetrating a piezoelectric circular inhomogeneity with a viscous interface

We investigate a semi-infinite crack penetrating a piezoelectric circular inhomogeneity bonded to an infinite piezoelectric matrix through a linear viscous interface. The tip of the crack is at the center of the circular inhomogeneity. By means of the complex variable and conformal mapping methods, exact closed-form solutions in terms of elementary functions are derived for the following three loading cases: (i) nominal Mode-III stress and electric displacement intensity factors at infinity; (ii) a piezoelectric screw dislocation located in the unbounded matrix; and (iii) a piezoelectric screw dislocation located in the inhomogeneity. The time-dependent electroelastic field in the cracked composite system is obtained. Particularly the time-dependent stress and electric displacement intensity factors at the crack tip, jumps in the displacement and electric potential across the crack surfaces, displacement jump across the viscous interface, and image force acting on the piezoelectric screw dislocation are all derived. It is found that the value of the relaxation (or characteristic) time for this cracked composite system is just twice as that for the same fibrous composite system without crack. Finally, we extend the methods to the more general scenario where a semi-infinite wedge crack is within the inhomogeneity/matrix composite system with a viscous interface.     

SGBEM modeling of fatigue crack growth in particulate composites

The symmetric-Galerkin boundary element method (SGBEM) has previously been employed to model 2-D crack growth in particulate composites under quasi-static loading conditions. In this paper, an initial attempt is made in extending the simulation technique to analyze the interaction between a growing crack and clusters of perfectly bonded particles in a brittle matrix under cyclic loading conditions. To this end, linear elastic fracture mechanics and no hysteresis are assumed. Of particular interest is the role clusters of inclusions play on the fatigue life of particulate composites. The simulations employ a fatigue crack growth prediction tool based upon the SGBEM for multiregions, a modified quarter-point crack-tip element, the displacement correlation technique for evaluating stress intensity factors, a Paris law for fatigue crack growth rates, and the maximum principal stress criterion for crack-growth direction. The numerical results suggest that this fatigue crack growth prediction tool is as robust as the quasi-static crack growth prediction tool previously developed. The simulations also show a complex interplay between a propagating crack and an inclusion cluster of different densities when it comes to predicting the fatigue life of particulate composites with various volume fractions.     

Crack growth under alternating loading

Crack propagation under alternating loading is investigated. Relations between the growth rate of a fatigue defect and loading parameters and the expression for the stress intensity factor are derived for compression of a cracked solid taking into account the possible contact of the crack faces. A model for the deformation of a small region near the crack tip is proposed which allows one to formulate the conditions of residual opening of a growing fatigue crack. The experimental data obtained in tests of steel samples are compared with the results of calculation using the developed procedure. __________ Translated from Prikladnaya Mekhanika i Tekhnicheskaya Fizika, Vol. 49, No. 5, pp. 190–198, September–October, 2008.     

Preface

The BFRP crack-patching technique has been applied to the field repair of fatigue cracks in the aluminium alloy wing skins of Mirage III fighter aircraft. Finite-element procedures were used in patch design. The repair was qualified using fatigue-crack propagation studies on panels simulating the cracked and repaired area. A field support unit was designed to allow repairs to be carried out by air force personnel during routine maintenance of the aircraft. To date over 150 patches have been applied and nearly three years of operational history gained. While some crack growth was observed after repair of a few wings, the patch stopped further growth and no wing skin has required further repair.     

A new photoelastic model for studying fatigue crack closure

The photoelastic analysis of crack tip stress intensity factors has been historically developed for use on sharp notches in brittle materials that idealize the cracked structure. This approach, while useful, is not applicable to cases where residual effects of fatigue crack development (e.g., plasticity, surface roughness) affect the applied stress intensity range. A photoelastic model of these fatigue processes has been developed using polycarbonate, which is sufficiently ductile to allow the growth of a fatigue crack. The resultant stress field has been modeled mathematically using the stress potential function approach of Muskhelishvili to predict the stresses near a loaded but closed crack in an elastic body. The model was fitted to full-field photoelastic data using a combination of a generic algorithm and the downhill simplex method. The technique offers a significant advance in the ability to characterize the behavior of fatigue cracks with plasticity-induced closure, and hence to gain new insights into the associated mechanisms.