Substrate geometry effect on the strength of repaired plates: Combined XFEM and CZM approach

Aluminum alloys are commonly used in aeronautical applications because of their specific strength and improved corrosion resistance. These structures, during their service, are exposed to various loading cycles, eventually leading to failure at the loci of geometric discontinuities. Repairing by metal or composite patch bonding is widespread to extend the structures’ life by limiting stress concentrations and delaying crack initiation. This work consists of a numerical study, validated by experimental test data, to assess the effect of a central circular notch in an aluminum plate, either reinforced or not by an adhesively bonded composite patch, on the global tensile response of the structure. The constitutive law of the aluminum and adhesive is assumed nonlinear and follows Von Mises equivalent stress flow theory with a hardening variable in incremental form. Damage initiation in the aluminum alloy is modeled by the XFEM (eXtended Finite Element Method), using the maximum principal stress criterion (MAXPS) for damage initiation prediction. Damage evolution is based on the energy approach. The adhesive layer was modeled by CZM (Cohesive Zone Model). A good agreement was found between the experimental results of the tensile curves of the repaired and unrepaired plates with those resulting from numerical modeling. Once the numerical model was validated, several parameters werenumerically studied, namely the shape of the composite patch, the size of the notch, the nature of the adhesive and repair mode by single and double patch, to reduce maximum stress of the damaged area and provide maximum repair efficiency.