Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
art ic l e i nf o
a b s t r a c t
Article history:
Accepted 20 October 2014
Available online 4 November 2014
The present study focuses on experimental investigation of through the thickness displacement and
strain eld in thin adhesive layer in single sided (unsymmetrical) patch repaired CFRP (carbon ber
reinforced polymer) panel under tensile load. Digital image correlation (DIC) technique is employed to
acquire the displacement and strain (longitudinal, peel and shear) eld. Experimental determination of
shear transfer length based on shear strain eld obtained from DIC is introduced to estimate the
optimum overlap length which is an essential parameter in patch design for the repair of CFRP
structures. Further, DIC experiment with magnied optics is performed to get an insight into complex
and localized strain eld over thin adhesive layer especially at critical zones leading to damage initiation.
The failure mechanism, load displacement behavior, damage initiation and propagation are closely
monitored using DIC. The inuence of patch edge tapering on strain distribution in adhesive layer is also
investigated. The DIC successfully captures the global and localized strain eld at critical zones over thin
adhesive layer and further helps in monitoring the damage based on strain anomalies. Strains are found
to have maximum magnitude at the patch overlap edge and the shear strain level in adhesive layer is
higher than the peel strain. Normal tapering increases the peel strain and has negligible inuence on
shear strain level in adhesive layer. The recommended overlap length is found to be consistent with the
recommendation in the literature. Whole eld strain pattern and the overlap length obtained from
experiment are further compared with the nite element analysis results and they appear to be in good
coherence.
& 2014 Elsevier Ltd. All rights reserved.
Keywords:
Adhesive strain
Carbon/Epoxy composite
Digital image correlation
Debonding
Load transfer/shear transfer length
Longitudinal
Peel and shear strain
Repair
1. Introduction
Adhesively bonded composite patch repair is one of the most
prominent techniques to restore the structural integrity of damage
structures. This is because the adhesively bonded repair provides
lightweight, minimal source of stress concentrations and efcient
load transfer from one adherend to another [1] in comparison to
its counterpart and therefore it is being used in various applications especially in aerospace and marine industry. Since the load is
transferred between patch and panel through the adhesive layer,
adhesive plays a crucial role in load carrying capacity of repaired
panel. Adhesive layer being load transfer medium constitutes the
weakest link and failure usually initiates from such location in
adhesively bonded structures.
Several analytical, numerical and experimental works have
been carried out to understand the behavior of adhesively bonded
joints. Davis and Bond [2] have discussed the basic principles and
n
Corresponding author.
Tel.: 91 40 23 01 6078/ 91 40 23 01 6123; fax: 91 40 23 01 6032.
E-mail address: mdkashfuddoja@gmail.com (M. Kashfuddoja).
http://dx.doi.org/10.1016/j.ijadhadh.2014.10.005
0143-7496/& 2014 Elsevier Ltd. All rights reserved.
58
strain gauges [1012], moir interferometry [10,13], photoelasticity [14] and digital image correlation (DIC) [1525]. DIC has been
used extensively in recent years because of its advantages over the
other experimental technique [22,2628]. The DIC technique has
the advantage of being applied to any class of material, it requires
no heavy specimen surface preparation and the optics involved is
quite simple. No fringe analysis and phase unwrapping are needed
in this method and also there is no fringe density limitation which
makes the DIC measurement range much larger than the other
technique. Moreover, it is truly a non-contact by nature and
provides full eld data.
Colavito et al. have used the DIC technique to measure
displacement and strain eld within the adhesive layer of adhesively bonded double-lap joints [15,16]. They concluded that the
DIC can be employed to obtain the displacement eld within the
adhesive layer of a double lap joint and it is able to capture a
difference in behavior between the specimens with different
adhesive thicknesses. Moutrille et al. [17] have studied the shear
strain eld in an adhesive joint between composite patch and
aluminum. They concluded that the shear strain decreases with
increase in distance from the free edge and using these measurements they estimated the in-situ shear modulus of the adhesive.
Wang et al. [18] have presented the results of a combined
experimental and nite element investigation on strain/stress
distributions around the overlap ends of laminated composite
single-lap joints. They concluded that the spew llets with high
rectangular segments and composite bulges at the overlap ends
have impacts on the load carrying ability and stresses peak at the
overlap end. Haghani et al. [19] have investigated the effect of
geometrical modications like laminate end tapering or adding
adhesive ller on strain distribution in adhesive joint between
CFRP laminate and steel using the DIC technique. They concluded
that the normal tapering of the laminate did not affect the shear
and principal strain components, but it increased the maximum
peeling strain in the joint and therefore no improvement in joint
strength is observed. Guo et al. [20] used the DIC technique to
evaluate the shear modulus of adhesive layer between aluminum
and aluminum adherend. Ruiz et al. [21] conducted experimental
and numerical study to assess the strain distribution in adhesive
layer of epoxy bonded aluminumaluminum and aluminumCFRP
double lap shear joints under tensile loading. They compared their
experimental results with the numerical predictions and found
that there is a good match between the FEA and DIC results in case
of aluminumaluminum double lap joint as compared to the
aluminumCFRP joint conguration. Comer et al. [22] have used
both 2D and 3D DIC technique to evaluate the evolution of
deformation and strain in composite single lap bonded joints prior
to failure. They concluded that the 3D DIC measurements may be
useful in detecting subcritical damage. Katnam et al. [23] have
used high magnication 2D DIC to analyze strain distributions
near the adhesive llet regions of adhesively bonded composite
single lap joints. They studied the inuence of adhesive ductility
on joint strength and strain distribution at the overlap ends and
concluded that the adhesive with relatively low tensile strength
and high ductility provides a higher joint strength. Crammond
et al. [24] have used full-eld measurement techniques to analyze
the complex stress and strain distributions in adhesively bonded
composite joints using thermoelastic stress analysis (TSA) and DIC.
The experimental stress and strain data in their study is manipulated to give the same output for the purpose of comparison and a
reasonable agreement between the two independent measurement techniques is achieved. Kumar et al. [25] have presented an
experimental approach of measuring peel and shear strains in the
adhesive bondline of composite single-lap joints using DIC. They
compared their experimental results with the theoretical ones and
achieved a similar trend between experimental and numerical
59
Fig. 1. Specimen geometry of single sided patch repaired (SSPR) panel: (a) front view and (b) side view.
dimensions using a special diamond-coated end mill (JS520100D3S.0Z6-SIRA) supplied by SECO Jabro Tools. Backing plates are used
to avoid the edge delamination. Before machining, careful marking is
done over the laminate parallel to 01 bers and due care is taken such
that the bers are machined parallel to the marking. The typical
model of the repaired panel is shown in Fig. 1. Both patch and panel
are made of same unidirectional Carbon/Epoxy composite laminate.
The length (L), width (W) and the thickness (t) of the panel are
250 mm, 50 mm and 1.6 mm respectively. The stacking sequence in
the panel is [01]4 and bers are oriented along the loading direction. A
circular hole of 10 mm diameter (d) is drilled at the center of the panel
by using a diamond coated drill bit supplied by SECO-Jabro Tools. The
hole is drilled to simulate the effect of damage removal as it happens
in the case of low velocity impact damage. The panel with open hole
is repaired with adhesively bonded single sided rectangular patch
having stacking sequence of [01]3. The length (Lp), width (Wp) and
thickness (tP) of the patch are 60 mm, 50 mm and 1.2 mm respectively. The bonding surface of the specimens is roughened using 200grit sandpaper and then cleaned with isopropyl alcohol to remove any
foreign particle or grit paper residue. Proper marking parallel to the
bers is done over the panel and then the patch is bonded over the
panel along the marking with due care such that the bers in patch
and panel are parallel to each other. Patch is bonded over the
damaged area of the panel using an adhesive. A uniform weight is
then placed over the bonded patch and the squeezed out excess
adhesive from all the sides is cleaned with a surgical blade before
complete curing to avoid the adhesive bulge at the patch overlap edge.
The excess adhesive at the hole is also removed in all the specimens
and then the bonded panel is left for complete curing at room
temperature for 7 days (same curing time is also used for adhesive
samples for evaluating their properties). Beveled aluminum tabs of
dimension 50 mm 50 mm 2 mm are bonded at each end of the
Table 1
Material properties of CFRP laminate and adhesive obtained using the DIC
technique.
CFRP composite laminate
Longitudinal modulus, Exx (GPa)
Transverse modulus, Eyy Ezz (GPa)
Shear moduli, Gxy Gxz (GPa)
Shear modulus, Gyz (GPa)a
Poisson's ratio (xy xz)
Poisson's ratio (yz)a
Araldite 2011 adhesive
Young's modulus E (GPa)
Poisson's ratio ()
a
84.16
7.12
3.30
2.47
0.31
0.43
1.86
0.38
Out of plane properties are evaluated using the procedure given in Ref. [47].
60
elements and patch with three elements. The model is built with
20-noded solid 186 brick element. The patch is bonded on to the
panel over the hole using adhesive layer. Multipoint constraint
(MPC) algorithm is employed for ensuring a perfect bonding
between patch/panel and panel/adhesive interface. The material
properties presented in Table 1 are used in FEA. Fibers in the panel
and patch are aligned parallel to the loading direction. The panel is
xed at bottom face and an in-plane tensile load is applied at the
top face along x-direction so as to simulate the experimental
boundary conditions. The results obtained from FEA are compared
with the experimental data for the same load. The zoomed view of
nite element model of the panel repaired with straight edge
patch is shown in Fig. 3.
61
Fig. 4. Displacement (mm) contours in SSPR panel at 38.5 kN: (a) longitudinal
displacement (u) and (b) transverse displacement (w).
diagonal and their angle varies along the panel length from
beginning of the adhesive joint at patch overlap edge till the
cutout zone. This observation implies that a differential deformation mechanism is happening in repaired conguration. The large
angles at and near the patch overlap edge infer that a large
amount of load is being transferred from panel to patch around
this zone through the adhesive layer by the shear deformation
mechanism. The band almost becomes horizontal showing near
zero angles just around the cutout zone which indicates that this
zone has no signicant inuence on load transfer. The present
nding is consistent with the results reported in Ref. [36] which
were presented for double strap joint using the Moir technique.
The results in this section are especially presented in pseudorandom contours to facilitate a qualitative comparison with results
reported using the Moir technique [36]. On qualitative comparison between the two results it is found that the diagonal bands in
the present single sided patch repaired panel case have got more
angles in comparison with double strap joint. This nding seems
obvious since there is a slight shift in neutral axis of singe sided
repair conguration and the load acts through an eccentricity
which causes bending effect in addition to applied in-plane tensile
load. To better understand this phenomenon, the transverse
displacement (w) of a point P located in center of the panel is
traced with increasing load using DIC and it is shown in Fig. 5. It is
found that the transverse displacement of considered point varies
linearly up to a certain load which signies the inuence of
bending phenomena in SSPR panel conguration. The variation
remains constant with further increase in load once the neutral
axis coincided with the loading axis. The bending phenomenon in
SSPR panel conguration is elaborately explained in Ref. [37] and
also reported by Hosseini-Toudeshky et al. [38].
62
Fig. 6. Through the thickness strain distribution in single sided patch repair conguration at 56% of failure load: (a) xx (b) zz and (c) xz.
Fig. 7. Longitudinal strain variation in the CFRP panel under single sided patch
at 56% and 68% of failure load.
Fig. 8. Shear strain variation in the adhesive layer under single sided patch at 56%
and 68% of failure load.
over this small zone from the overlap edge. This zone is referred as
shear transfer zone and the corresponding length as shear transfer
length (Ls). Shear transfer length is also known as overlap length in
bonded patch repair domain. The overlap length is an essential
63
determination of overlap length and it is found to be approximately 12 mm. The discrepancy between the two approaches
could be attributed to the scatters present in the experimental
data. Therefore, it can be concluded that the minimum overlap
length should be approximately 1.52 times the cutout or hole
diameter. Through a parametric study involving FEA, several
authors [4044] have reported the optimum overlap length using
the shear stress distribution and they also fall in the above
recommended range.
64
Fig. 11. Failure surface corresponding the debonded patch and failed panel.
65
Fig. 12. Localized whole eld strain distribution in adhesive layer for a panel repaired with straight edge patch at a tensile load of 23.9 kN: (a) xx, (b) zz and (c) xz.
Fig. 13. Damage monitoring in adhesive layer with increasing load based on peel strainzz. (For interpretation of the references to color in this gure, the reader is referred
to the web version of this article.)
66
Fig. 15. Actual joint depicting the angle made to achieve the tapered patch edge
(zoomed up view).
Fig. 17. Comparative plot of strain variation in adhesive layer for the panel repaired
with tapered edge patch obtained from DIC at a tensile load of 23.9 kN.
Fig. 16. Localized whole eld strain distribution in adhesive layer for a panel repaired with tapered edge patch at a tensile load of 23.9 kN: (a) xx (b) zz and (c) xz.
6. Numerical results
In this section the results obtained from FEA for a panel
repaired with tapered edge patch bonded with Araldite 2011
adhesive are presented and further compared with DIC results.
Finite element results are presented by assuming linear elastic
Fig. 18. Comparative plot of peel strain variation in adhesive layer between panels
repaired with straight and tapered edge patch obtained from DIC at a tensile load of
23.9 kN.
67
Fig. 19. Whole eld strain distribution in adhesive layer at a tensile load of 23.9 kN obtained from FEA: (a) peel strainzz and (b) shear strainxz.
68
Fig. 20. Shear strain variation along adhesive length of a panel repaired with
straight edge patch at 46.8 kN: DIC vs. FEA.
7. Conclusions
In the present work, critical strain analysis in thin adhesive
layer of a single sided patch repaired CFRP panel under tensile load
is carried out using the DIC technique. A methodology is presented
to successfully demonstrate the full eld through the thickness
strain measurement in such a thin adhesive layer by employing
the DIC technique. Both global and local analysis approaches are
executed for analyzing longitudinal, peel and shear strains over
the adhesive layer and they are found to be maximum near the
root of adhesive joint at panel/adhesive interface. Shear strain in
adhesive layer is found to be signicantly high compared to peel
strain. Based on global strain analysis it is found that only a small
zone near the patch edge facilitates the load transfer from panel to
patch through the adhesive layer by the shear deformation
mechanism. The shear transfer length which is an essential
parameter in arriving at an appropriate overlap length in patch
design is estimated based on the shear strain eld in adhesive
layer and it matches closely with the FEA prediction. It is
recommended to have minimum/optimum overlap length in the
range of 1.52 times the cutout diameter, which is found consistent with the data available in the literature on comparison.
Conventional DIC along with magnied optics is capable of exactly
capturing the localized complex strain eld at the root of adhesive
References
[1] Baker AA, Rose LRF, Jones R. Advances in the bonded composite repair of
metallic aircraft structure. Killington: Elsevier Publications; 2002.
[2] Davis M, Bond D. Principles and practices of adhesive bonded structural joints
and repairs. Int J Adhes Adhes 1999;19(23):91105.
[3] Whittingham B, Bakerb AA, Harman A, Bitton D. Micrographic studies on
adhesively bonded scarf repairs to thick composite aircraft structure. Compos
Part A: Appl Sci Manuf 2009;40(9):141932.
[4] Katnam KB, Da Silva LFM, Young TM. Bonded repair of composite aircraft
structures: a review of scientic challenges and opportunities. Prog Aerosp Sci
2013;61:2641.
[5] Banea MD, da Silva LFM. Adhesively bonded joints in composite materials: an
overview. Proc Inst Mech Eng Part L: J Mater Des Appl 2009;223:1. http://dx.
doi.org/10.1243/14644207jmda219.
[6] da Silva LFM, das Neves PJC, Adams RD, Spelt JK. Analytical models of
adhesively bonded joints Part I: literature survey. Int J Adhes Adhes
2009;29:31930.
[7] da Silva LFM, das Neves PJC, Adams RD, Wang A, Spelt JK. Analytical models of
adhesively bonded joints Part II: comparative study. Int J Adhes Adhes
2009;29:33141.
[8] da Silva LFM, Campilho RDSG. Advances in numerical modeling of adhesive
joints. Berlin, Heidelberg: Springer; 2012.
[9] He X. A review of nite element analysis of adhesively bonded joints. Int J
Adhes Adhes 2011;31:24864.
[10] Tsai MY, Morton J. An experimental investigation of nonlinear deformations in
single lap joints. Mech Mater 1995;20(3):18394.
[11] Shenoy V, Ashcroft IA, Critchlow GW, Crocombe AD, Wahab MMA. An
investigation into the crack initiation and propagation behaviour of bonded
single-lap joints using backface strain. Int J Adhes Adhes 2009;29(4):36171.
[12] Derewonko A, Godzimirski J, Kosiuczenko K, Niezgoda T, Kiczko A. Strength
assessment of adhesive-bonded joints. Comput Mater Sci 2008;43(1):15764.
[13] Asundi A. Deformation in adhesive joints using moir interferometry. Int J
Adhes Adhes 1987;7(1):3942.
[14] Schroeder JA. Photoelastic stress analysis of bonded lap shear joints having
thermoplastic adherends. J Adhes 1990;32:23.
[15] Colavito KW, Das M, Hahs D, Gorman J, Madenci E, Smeltzer S. Digital image
correlation technique to extract adhesive strains in lap joints. In: Proceedings
of the 49th AIAA/ASME/ASCE/AHS/ASC structures, structural dynamics, and
materials conference; 2008.
[16] Colavito KW, Gorman J, Madenci E, Smeltzer S. Renements in digital image
correlation technique to extract adhesive strains in lap joints. In: Proceedings
of the 50th AIAA/ASME/ASCE/AHS/ASC structures, structural dynamics, and
materials conference; 2009.
[17] Moutrille MP, Derrien K, Baptiste D, Balandraud X, Grdiac M. Throughthickness strain eld measurement in a composite/aluminium adhesive joint.
Compos Part A 2009;40:98596.
[18] Wang ZY, Wang L, Guo W, Deng H, Tong JW, Aymerich F. An investigation on
strain/stress distribution around the overlap end of laminated composite
single lap joints. Compos Struct 2009;89(4):58995.
[19] Haghani R, Al-Emrani M and Kliger R. Effects of geometrical modications on
behaviour of adhesive joints used to bond CFRP laminates to steel members
experimental investigation. In: Proceedings of the Nordic steel construction
conference (NSCC). Malmo (Sweden); 2009.
[20] Guo BQ, Xie HM, Zhu JG, Wang HX. Study on the mechanical behavior of
adhesive interface by digital image correlation. Sci China: Phys Mech Astron
2011;54(4):57480.
[21] Ruiz PD, Jumbo F, Huntley JM, Ashcroft IA, Swallowe GM. Experimental and
numerical investigation of strain distributions within the adhesive layer in
bonded joints. J Strain 2011;47:88104.
[22] Comer AJ, Katnam KB, Stanley WF, Young TM. Characterising the behaviour of
composite single lap bonded joints using digital image correlation. Int J Adhes
Adhes 2013;40:21523.
[23] Katnam KB, Dhte JX, Young TM. Experimental analysis of the bondline stress
concentrations to characterize the inuence of adhesive ductility on the
composite single lap joint strength. J Adhes 2013;89:6.
[24] Crammond G, Boyd SW, Dulieu-Barton JM. Through-thickness load transfer in
adhesively bonded composite joints. Conf Proc Soc Exp Mech Ser 2013:1114.
[25] Kumar RLV, Bhat MR, Murthy CRL. Experimental analysis of composite single-lap
joints using digital image correlation and comparison with theoretical models. J
Reinf Plast Compos 2013. http://dx.doi.org/10.1177/0731684413500859.
[26] Sutton MA, Orteu JJ, Schreier H. Image correlation for deformation and shape
measurements. New York: Springer; 2009.
[27] Cognard JY, Creachcadec R, da Silva LFM, Teixeira FG, Davies P, Peleau M.
Experimental analysis of the inuence of hydrostatic stress on the behaviour
of an adhesive using a pressure vessel. J Adhes 2011;87:80425.
[28] Kashfuddoja M, Ramji M. Whole-eld strain analysis and damage assessment
of adhesively bonded patch repair of CFRP laminates using 3D-DIC and FEA.
Compos Part B 2013;53:4661.
[29] Caminero MA, Pavlopoulou S, Lopez-Pedrosa M, Nicolaisson BG, Pinna C,
Soutis C. Analysis of adhesively bonded repairs in composites: damage
detection and prognosis. Compos Struct 2013;95:50017.
[30] Caminero MA, Lopez-Pedrosa M, Pinna C, Soutis C. Damage monitoring and
analysis of composite laminates with an open hole and adhesively bonded
repairs using digital image correlation. Compos Part B: Eng 2013;53:7691.
[31] Kashfuddoja M, Ramji M. Adhesive strain measurement in patch repaired
CFRP laminate using 2D DIC. In: Proceedings of the 19th international
conference on composite materials (ICCM - 19). Montreal (Canada); July 28
August 2, 2013.
[32] Kashfuddoja M, Ramji M. Critical analysis of adhesive layer behaviour in patch
repaired CFRP panel involving digital image correlation. J Compos Mater 2014,
http://dxdoi.org/10.1177/0021998314541312.
[33] Ubaid J, Kashfuddoja M, Ramji M. Strength prediction and progressive failure
analysis of carbon ber reinforced polymer laminate with multiple interacting
[34]
[35]
[36]
[37]
[38]
[39]
[40]
[41]
[42]
[43]
[44]
[45]
[46]
[47]
69
holes involving three dimensional nite element analysis and digital image
correlation. Int J Damage Mech 2013. http://dx.doi.org/10.1177/1056789513504123.
Bhise VS, Kashfuddoja M, Ramji M. Optimization of circular composite patch
reinforcement on damaged carbon ber reinforced polymer laminate involving both mechanics-based and genetic algorithm in conjunction with 3D
nite element analysis. J Compos Mater 2013. http://dx.doi.org/10.1177/
0021998313501922.
Kashfuddoja M, Ramji M. An experimental and numerical investigation of
progressive damage analysis in bonded patch repaired CFRP laminates. J
Compos Mater 2014. http://dx.doi.org/10.1177/0021998314521058.
Tsai MY, Morton J. An investigation into the stresses in double-lap adhesive
joints with laminated composite adherends. Int J Solids Struct 2010;47:
331725.
Duong CN, Wang CH. Composite repair, theory and design. 1st ed.. The
Netherlands: Elsevier Publications; 2007.
Hosseini-Toudeshky H, Saber M, Mohammadi B. Mixed-mode 3-D crack
propagation of repaired thin aluminium panels using single-side composite
patches. J Fract Mech 2008;153:10516.
Rose LRF. Theoretical analysis of crack patching. In: Baker AA, Jones R, editors.
Bonded repair of aircraft structure. Dordrecht, The Netherlands: Martinus
Nijhoff Publishers; 1988. p. 77105.
Soutis C, Hu FZ. Design and performance of bonded patch repairs of composite
structure. Proc Inst Mech Eng Part G 1997:211.
Campilho RDSG, de Moura MFSF, Domingues JJMS. Modelling single and
double-lap repairs on composites materials. Compos Sci Technol 2005;65:
194858.
Hu FZ, Soutis C. Strength prediction of patch-repaired CFRP laminates loaded
in compression. Compos Sci Technol 2000;60:110314.
Soutis C, Duan DM, Goutas P. Compressive behaviour of CFRP laminates
repaired with adhesively bonded external patches. Compos Struct 1999;45:
289301.
Liu X, Wang G. Progressive failure analysis of bonded composite repairs.
Compos Struct 2007;81:33140.
da Silva LFM, Adams RD. Techniques to reduce peel stresses in adhesive joints
with composites. Int J Adhes Adhes 2007;27:22735.
Kumar S, Mittal KL. Advances in modeling and design of adhesively bonded
systems. New York, United States: Wiley-Scrivener; 2013.
Mallick P. Fiber reinforced composites: materials, manufacturing, and design.
3rd ed. New York, United States: CRC Press; 2007.