An integrated bonded repair system: A reliable means of giving new life to aging airframes

The application of bonded composite repairs to restore cracked or corroded metallic airframes has seen rapid expansion recently, following twenty years of technology development. However, the lack of standardized bonded repair methods and certification concepts impedes wider application of the technique. Existing bonded repair technologies are maturing rapidly, but several specialities (design and analysis, surface preparation, installation, inspection, training and certification) must be integrated into a seamless package before civil and military airworthiness authorities will embrace bonded 'crack patching.' This paper outlines efforts by the United States Air Force to develop an integrated system to allow aircraft maintenance engineers to cover the complete life cycle of a bonded repair. The successful construction of this integrated system will speed the widespread acceptance of the technology and help to assure the continued airworthiness of the aging aircraft fleet.