Aerodynamic Impact of Repair Patches on NACA 0012 and NACA 2412 Airfoils: A Computational Study

Aircraft structures are frequently exposed to damage from environmental factors and operational wear, leading to the development of surface imperfections such as cracks. These imperfections can increase aerodynamic drag, a phenomenon known as excrescence drag. To mitigate these effects and quickly restore structural integrity, repair patches, often made from aluminium alloys and tailored to the damage, are applied following guidelines set out in the Aircraft Battle Damage Repair (ABDR) manuals. This paper investigates the aerodynamic performance impacts of applying such patches to two prominent airfoil models: the symmetric NACA 0012 and the cambered NACA 2412. Utilizing advanced computational tools including CATIA V5 for 3D modelling and CFD++ for fluid dynamics simulation, this study examines changes in aerodynamic characteristics such as lift, drag, and pressure distribution under various flow conditions. The research particularly focuses on quantifying the aerodynamic changes introduced by the patches through detailed analyses of lift curves, drag polars, and pressure coefficient (Cp) plots. Our findings aim to provide insights into the trade-offs involved in patch repairs, exploring how different patch configurations influence airfoil performance. This contributes to the development of optimized repair strategies that ensure minimal aerodynamic disruption while extending the operational lifespan of aircraft components.