Direct Resistive Heating Simulation Tool for the Repair of Aerospace Structures through Composite Patches

Bonded composite patches are very appropriate for aircraft structural repair, showing very good properties when compared with traditional mechanical fastening of metal sheets. The curing process of the composite patch must be done “onsite” and a direct resistive heating method has been proposed. The heat produced by the electric current through the Joule effect when crossing the patch carbon fibre bundles has been modelled with a Finite Element Program code, developed for the electric current equation. The heat conduction equation has also been modelled in the program, as well as the kinetics of the curing reaction of the composite resin. The electric resistivity of the materials is function of the temperature, so a nonlinear coupled system has been developed. Therefore, a complete simulation tool able to study different configurations, current intensities, materials, etc. for the composite patches is presented. A study case has been run with the developed code and results have been compared with experimental values. Good agreement is found.