Computational Analyses of Stepped-Lap Composite Repairs on a Full-Scale Wing Model

The use of carbon fiber-reinforced plastic (CFRP) components has increased significantly in civilian aviation, necessitating effective maintenance and repair strategies to ensure durability and performance. While prior studies have focused on composite repair methods, such as stepped scarf patch and bolted joint repairs, these were limited to specimen and panel levels without addressing full-scale wing models. This study bridges that gap by evaluating stepped-lap repairs on a full-scale composite wing model under realistic loading conditions and exploring various repair scenarios. To reduce computational cost, two-dimensional shell elements were employed to simulate repairs, with results validated using experimental tensile test data from stepped-lap repaired specimens. Numerical models were developed for single regions and two closely located repair regions. For single-region repairs, adding up to two extra layers enhanced mechanical strength, but three extra layers increased strain, diminishing performance. For two closely located repairs, additional layers improved strength, though less effectively than single-region repairs. Square-shaped repairs exhibited higher strain due to stress concentrations at the corners, while circular repairs showed more uniform stress and strain distribution. These findings emphasize the importance of optimizing repair geometry and layer configurations using numerical simulations to ensure optimal structural performance of CFRP components.