Application of Cohesive Zone Modeling to Composite Bonded Repairs

Cohesive zone models can play an important role in the definition of repair strategies. These models allow the prediction of damage initiation and propagation. They are based on a softening relationship between stresses and relative displacements between crack faces, thus simulating a gradual degradation of material properties. Typically, stress-based and energetic fracture mechanics criteria are used to simulate damage initiation and growth, respectively. Those elements are placed at the planes where damage is prone to occur which, in the case of bonded repairs, is usually easy to identify a priori. Taking this into consideration, cohesive mixed-mode damage models based on interface finite elements were used with the objective of optimizing the repair efficiency. The determination of the cohesive pure mode softening laws is a key aspect of these models, and the direct method is the most accurate process to do it. The models were validated and applied to two different cases involving repairs. Several geometrical aspects influencing the single-strap repair strength were analyzed as well as the evolution of the maximum load and alteration of damage mechanism as a function of the angle used in scarf joints. It was verified that CZM are able to predict with accuracy the damage mechanisms and strength of composite bonded repairs, thus constituting a powerful tool in its design.