Development and validation of nondestructive inspection techniques for composite doubler repairs on commercial aircraft

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Composite doublers, or repair patches, provide an innovative repair technique which can enhance the way aircraft are maintained. Instead of riveting multiple steel or aluminum plates to facilitate an aircraft repair, it is possible to bond a single boron-epoxy composite doubler to the damaged structure. In order for the use of composite doublers to achieve widespread use in the civil aviation industry, it is imperative that methods be developed which can quickly and reliably assess the integrity of the doubler. In this study, a specific composite application was chosen on an L-1011 aircraft in order to focus the tasks on … continued below

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170 p.

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Roach, D. & Walkington, P. May 1, 1998.

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This report is part of the collection entitled: Office of Scientific & Technical Information Technical Reports and was provided by the UNT Libraries Government Documents Department to the UNT Digital Library, a digital repository hosted by the UNT Libraries. It has been viewed 350 times. More information about this report can be viewed below.

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  • Sandia National Laboratories
    Publisher Info: Sandia National Labs., Albuquerque, NM (United States)
    Place of Publication: Albuquerque, New Mexico

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Composite doublers, or repair patches, provide an innovative repair technique which can enhance the way aircraft are maintained. Instead of riveting multiple steel or aluminum plates to facilitate an aircraft repair, it is possible to bond a single boron-epoxy composite doubler to the damaged structure. In order for the use of composite doublers to achieve widespread use in the civil aviation industry, it is imperative that methods be developed which can quickly and reliably assess the integrity of the doubler. In this study, a specific composite application was chosen on an L-1011 aircraft in order to focus the tasks on application and operation issues. Primary among inspection requirements for these doublers is the identification of disbonds, between the composite laminate and aluminum parent material, and delaminations in the composite laminate. Surveillance of cracks or corrosion in the parent aluminum material beneath the doubler is also a concern. No single nondestructive inspection (NDI) method can inspect for every flaw type, therefore it is important to be aware of available NDI techniques and to properly address their capabilities and limitations. A series of NDI tests were conducted on laboratory test structures and on full-scale aircraft fuselage sections. Specific challenges, unique to bonded composite doubler applications, were highlighted. An array of conventional and advanced NDI techniques were evaluated. Flaw detection sensitivity studies were conducted on applicable eddy current, ultrasonic, X-ray and thermography based devices. The application of these NDI techniques to composite doublers and the results from test specimens, which were loaded to provide a changing flaw profile, are presented in this report. It was found that a team of these techniques can identify flaws in composite doubler installations well before they reach critical size.

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170 p.

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OSTI as DE98005803

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  • Other Information: PBD: May 1998

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  • May 1, 1998

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  • Sept. 12, 2015, 6:31 a.m.

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  • May 5, 2016, 8:27 p.m.

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Roach, D. & Walkington, P. Development and validation of nondestructive inspection techniques for composite doubler repairs on commercial aircraft, report, May 1, 1998; Albuquerque, New Mexico. (https://digital.library.unt.edu/ark:/67531/metadc704411/: accessed April 24, 2024), University of North Texas Libraries, UNT Digital Library, https://digital.library.unt.edu; crediting UNT Libraries Government Documents Department.

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