Composite Repairs That Restore Strength and Performance

Impact

Fibre reinforced composite damage is usually the result of heavy impact. High and low impact can result in significantly different damage patterns for any given composite component. The bumper pictured to the left is an example of a severe impact, and then what it would look like on completion of all repairs.

We are equipped to do all forms of composite repair, but the Bumper shown on the left is made out of carbon fibre.

De-Lamination

In monolithic laminates the underlying damage can extend to a much larger area than the visible evidence on the surface. Composite components and structures can also suffer from sub surface de-lamination which is not visible from the surface. These de-laminations can be detected using NDT ultra-sonic methods allowing the full extent of the de-lamination to be mapped and repaired.

Using ultrasonic equipment we assess how deep the de-laminations are. Then we drill very small holes to the depth of the de-lamination allowing us to accurately resin-inject the area. This area is then re-inspected using ultrasonic methods to confirm that the repair has been carried out successfully.

Punctures/Heat Damage/Fretting

In sandwich structures, impact results in dents of various sizes, and depending on the energy levels puncture damage is not unusual. In the case shown on the left, external and internal skins may be damaged. Other common damage types include heat damage and local damage to mechanical fixture areas. The heat damage is caused by the exposure to high temperatures which can cause blistering and bubbling which de-laminates the local area, for example around exhaust exits. The mechanical fixture area damage is cause by stresses at the contact surfaces of the composite structure with a bolt or rivet. This could result in elongation of a hole, the laminate to split, or fretting to the upper plies.

Contamination

Damage can also be caused through contamination, when composite materials come into contact with lubricants, fuel, hydraulic fluids, battery acid, and numerous other chemicals. The presence of these fluids may result in further deterioration of the mechanical performance and structural integrity of the component/structure. You can see from the picture displayed to the right that contamination is usually on clearly visable.