Summary: Composite Repair Design

2 Literature review

The edge repair design project has three objectives, starting with a literature study on composite repair methods applicable to a Boeing aircraft component. Thereafter, writing a new repair method and performing the repair on composite samples whereof the material properties have identical properties as the Boeing aircraft component. Finally, testing the composite samples on quality items and when test results show compliance, validating the repair method.

The literature study starts with a look into the role of composites in aircraft (2.1). Continuing with relevant repair methods for this project (2.2). Thereafter, the relevant testing methods for this project (2.3). Then the evaluation of the repair design and its production

These advanced composites, also called laminates, are more expensive and have specific properties to achieve a specific objective in a structure. Aircraft composite structures are made using precisely positioned plies of carbon fibre and polyester resin composition.

Large components of commercial airliners, such as the Boeing 787 Dreamliner, are an example of application of composites in aircraft structures. Refer to Figure 2 for the application of composites in the Boeing 787 Dreamliner.

As presented in Figure 2 the aircraft consists of more than 50% of advanced composites. The use of advanced composites in aircraft has a number of advantages, also disadvantages. These are listed as follows:

- Advantages of advanced composites in aircraft are:

- High strength and stiffness-to-weight ratio.

- Optimized structures.

- Metal fatigue is not an issue.

- Composites do not

These chapters provide crucial information and steps to perform repairs on structures and composites. The SRM is a useful and reliable reference to use as a guideline for creating an edge repair design. These SRM Chapters are elaborated in Chapter (3) Permitted repair methods by Boeing for the Outer Barrel.

2.5.2 Inlet Cowl Outer Barrel Skin

The GE CF6-80C2 engine as illustrated in Figure 5 consists of several components. The Inlet Cowl is one of these components and is referred to as Detail I.

The Inlet Cowl is located in the front section of the engine. The Inlet Cowl serves as a casing for the engine system and the air enters the engine through here.

Refer to Figure 6 for a front view and refer to Figure 7 for a back view of the Inlet Cowl. The Inlet Cowl consists of several parts. These parts are numbered in the illustrations as items. Refer to Table 1 for a description of these items.

Table 1 - List of items of an Inlet Cowl

ITEM DESCRIPTION

1 Engine Inlet Cowl

2 Outer Barrel

3 Inner Barrel

4 Lip