Cure-induced residual stresses and viscoelastic effects in repaired wind turbine blades: Analytical-numerical investigation

• This paper provides a comprehensive framework to study the residual stresses induced during repair of wind turbine blades and the post-repair mechanical behaviour. • A hybrid analytical-numerical model is used together with a temperature and cure dependent viscoelastic model. • This framework can be used to find the optimal parameters for the repair process provided the external and internal conditions are known. During scarf repair of wind turbine blades, the difference in coefficients of thermal expansion and chemical shrinkage between the original part and the repair patch leads to the development of residual stresses. These residual stresses are detrimental when the repaired composite structures are subjected to operational cyclic loads and affect their post-repair lifetime. This paper uses a hybrid analytical-numerical model to evaluate the residual stresses in a scarf-repaired composite panel. A Prony series-based viscoelastic model is used to describe the material behaviour of the composite undergoing cure to replicate real-life effects more closely. Experiments on the repaired composite samples and numerical simulations on a model of the same are performed to study the post-repair mechanical behaviour. It is found that the damage initiates at the adhesive interface between the scarf patch and the base composite. The resulting debonding and damage to the base composite leads to the failure of the repaired section.