COMPOSITES 2025

Finite Element Modelling of Alternative Repair Methods for Damaged Honeycomb Sandwich Beams

  • Wiegmink, Arjan (Royal Netherlands Aerospace Centre (NLR))
  • Vroon, Jos (Royal Netherlands Aerospace Centre (NLR))
  • Post, Melvin (Royal Netherlands Aerospace Centre (NLR))

In session: CT - Structures

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This paper presents a numerical investigation into the effectiveness of alternative repair methods for damaged honeycomb sandwich beams, with a focus on restoring their original strength. The study specifically addresses damages in the form of holes in the top layer, which is a common type of damage that can significantly compromise the structural integrity of these components. Conventional repair methods often require extensive material removal and are time-consuming [1], making them less desirable for fast in-field repairs. In this study, an alternative repair method is investigated, which involves applying a patch over the damaged area, thereby eliminating the need for material removal. This patch-based repair approach has the potential to significantly reduce repair time and complexity. A three-dimensional finite element model is developed to simulate the deformation patterns of repaired beams during a 4-point bending test. With this model, a prediction is made of the failure and deformations before the damage, with damage and after repair of the sandwich structure. The results of the repair patch method are compared to the conventional methods. The influence of repair size on the structural integrity of the repaired beams is also investigated, providing valuable insights into the optimal repair design. The results of this study is to demonstrate the potential of alternative repair methods to efficiently restore damaged honeycomb sandwich beams to almost original strength, enabling fast and reliable in-field repairs that can minimize downtime and reduce maintenance costs.