COMPOSITE REPAIR

What is Composite?
Composites are one of the most advanced and adaptable engineering materials known to men.
Progresses in the field of materials science and technology have given birth to these fascinating
and wonderful materials. Composites are heterogeneous in nature, created by the assembly of
two or more components with fillers or reinforcing fibers and a compactable matrix .The matrix
may be metallic, ceramic or polymeric in origin. The primary advantages of composite materials
are their high strength, relatively low weight, and corrosion resistance.
Why Composite Repair
Even though composite materials poses excellent mechanical, thermal, corrosion resistance and
environmental resistance properties, they are also subject manufacturing and in-service failures.
Sources of manufacturing defects include:
Improper cure or processing
Improper machining
Mishandling
Improper drilling
Tool drops
Contamination
Improper sanding
Substandard material
Inadequate tooling
Misalocation of holes or details.
In-service defects include:
Environmental degradation
Impact damage
Fatigue
Cracks from local overload
Debonding
Delamination
Fiber fracturing
Erosion

Defect Detection in Composites

Defects in composites can be detected by:
Nondestructive Inspection (NDI) such as

Visual Inspection
Audible Sonic Testing (Coin Tapping)
Automated Tap Test
Ultrasonic Inspection
Through Transmission Ultrasonic Inspection
Pulse Echo Ultrasonic Inspection
Radiography
Thermography

Composite Repair
The need for repairs can be categorized into three types of damage or defect; negligible or
acceptable damage, repairable or correctable damage and non-repairable.
Types of Repair

Easy Repair
Complex Repair

Easy Repair
Usually small and does not affect a parts structural integrity. These repairs are made to protect
the surface of the component and do not require reinforcing materials.
Complex Repair
Complex repairs are required when the damage interferes with the structural performance of the
composite. It is sometimes necessary to make temporary repairs to the composite to keep severe
mechanical problems at bay until it is possible to perform a complete repair.
Types of Complex Repair

Fill
Injection
Bolted or Bonded

Fill Repair: Simple fill repairs are conducted with paste adhesives to repair non-structural damage
such as minor scratches, gouges, nicks and dings.

Injection: Injection repairs use low-viscosity adhesives that are injected into composite
delaminations or adhesive unbonds.

Bolted or Bonded: Bolted repairs are usually done on thick highly loaded composite laminates
while bonded repairs are often required for thin skin honeycomb assemblies.