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<p>This study investigates the effectiveness of bonded composite patches in enhancing the structural integrity of cracked aluminium plates through a combined numerical and statistical approach. A rigorous methodology was employed to systematically explore the influence of geometric parameters and the material properties on the stress intensity factor (SIF), considered here as the key indicator for the evaluation of the repair performance. A 3D finite element method was carried out using ANSYS APDL, with SIF extracted from the displacement field near the crack tip. Statistical regression models were established to represent the SIF response and were successfully validated by finite element results, demonstrating high predictive accuracy and model robustness. The study further examined the impact of plate thickness, revealing a reduction in the relative influence of geometric parameters as thickness increased. Optimization results showed that, the lowest values of SIF are achieved using the configuration of high-stiffness materials for both the patch and the adhesive with the maximum thickness levels. However, these optimal conditions must be balanced against practical constraints, particularly the recommended thickness limits, to ensure that the selected repair configurations remain compliant with experimental considerations.</p>

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Improving the performance of cracked aluminium structures using composite patch repairs: a numerical and statistical investigation

  • 期刊论文

  • 发表日期：

    2026年1月3日

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  • Mohammed A. Bouchelarm,
  • Mohammed Abdeldjalil Djehaf,
  • Abdelkader Boulenouar,
  • Meriem Chafi,
  • Noureddine Benseddiq

摘要

This study investigates the effectiveness of bonded composite patches in enhancing the structural integrity of cracked aluminium plates through a combined numerical and statistical approach. A rigorous methodology was employed to systematically explore the influence of geometric parameters and the material properties on the stress intensity factor (SIF), considered here as the key indicator for the evaluation of the repair performance. A 3D finite element method was carried out using ANSYS APDL, with SIF extracted from the displacement field near the crack tip. Statistical regression models were established to represent the SIF response and were successfully validated by finite element results, demonstrating high predictive accuracy and model robustness. The study further examined the impact of plate thickness, revealing a reduction in the relative influence of geometric parameters as thickness increased. Optimization results showed that, the lowest values of SIF are achieved using the configuration of high-stiffness materials for both the patch and the adhesive with the maximum thickness levels. However, these optimal conditions must be balanced against practical constraints, particularly the recommended thickness limits, to ensure that the selected repair configurations remain compliant with experimental considerations.