On the Certification of Bonded Repairs to Primary Composite Aircraft Components

Airworthiness certification is required when bonded repairs are made to primary composite structure in situations where damage has reduced or has the potential to reduce residual strength to below the design ultimate strength. Generally, certification of bonded primary structure poses many difficulties. As most repairs are one-off events meeting these certification requirements is especially challenging since demonstration by testing will generally not be possible or cost-effective. This paper discusses options for addressing the two key issues relating to certification: (a) how to validate initial and enduring bond strength of adhesive bonds, mainly given the inability of conventional non-destructive inspection to provide this assurance and (b) how to develop acceptable generic design allowables for bonded repairs which represent actual failure modes - especially for cyclic loading, since validation by testing of simulated repairs will generally be infeasible. It is concluded that proof testing of bonded repair coupons is a promising approach for validating bond strength and fatigue testing of representative bond joint specimen can provide generic allowables for patch design. For hidden structure or very high value repairs structural health monitoring of repairs based on a strain-transfer approach offers considerable promise.