Predictive modeling of stress intensity factors in composite-repaired cracked aluminum plates : a finite element-based computational framework

Abstract

The utilization of bonded composite patches for repairing fatigue-related damage in metallic structures has been acknowledged as an efficient and cost-effective approach, especially within the aerospace sector. However, accurate prediction of stress intensity factors (SIFs) in such repairs remains challenging for structural engineers. This work examines the mechanical behavior of a cracked AA2024T3 plate repaired with a carbon/epoxy composite patch under Mode I loading using finite element analysis (FEA). The study incorporates numerical results to develop a new computational model for precisely determining the repaired plate’s SIF. The developed predictive model, derived directly from FEA data analysis, demonstrates high accuracy with deviations ranging from 0.0006 to 0.0037 when compared to the finite element results. The model successfully predicts repair effectiveness and quantifies the patch’s influence on stress concentration near the crack tip. This computational framework offers a reliable method for forecasting repair efficacy and serves as a practical tool for structural engineers in the analysis and optimization of composite patch repairs. The high-precision model enables improved design decisions for structural repair applications.