Reinforced Composite Repair Method

The increased use of composite materials on both military and commercial aircraft must be accompanied by a more efficient means of in-service repair techniques. Composite fuselage, wing and engine components are subjected to Foreign Object Debris (FOD) which can result in many types of repairable damage. Current repair techniques can be expensive and fail to restore complete structural integrity of the component. Foster-Miller proposes new repair technology to reduce costs and enhance the structural performance of composite repairs. The proposed process utilizes a proprietary process developed by Foster-Miller, Z-fiber reinforcement. This proven process can be adapted to reinforce cured composite structures through the thickness to prevent growth of delaminations without the need for removal of the damaged material. When severe damage is encountered, this process can serve to mechanically fasten composite patches and provide a smooth aerodynamic surface. Phase I will demonstrate the feasibility of this process to repair complex shaped structures such as engine blades and vanes. Three common types of damage are to be addressed in this program: internal delaminations, edge delaminations, and material losses. General Electric Aircraft Engines is our partner in the Phase I effort to insure approaches developed are relevant to future aircraft engine components. This proposed process is of particular interest to GEAE for repair of CF6-80CZ guide vanes and GE90 fan blades.