Methods and apparatus for performing repair operations using an unmanned aerial vehicle (UAV). A UAV carries a repair patch ensemble containing all repair materials (including a repair patch, a heating blanket and other ensemble materials) in a prepackaged form to the repair area. During flight of the UAV, the repair patch is vacuum adhered to the heating blanket. Vacuum pressure is also used to hold the repair patch ensemble in position on the composite surface of the structure. Then the hot bond process is enacted to bond the repair patch to the repair area. In accordance with one embodiment, the hot bond process involves heating the repair patch to adhesively bond the repair patch while applying vacuum pressure to consolidate the composite material. Then the repair patch is released from the ensemble and residual ensemble materials (heating blanket, bleeder material, and release films) are removed by the UAV.

Disclosed herein are a repair apparatus, system, and method for structurally reinforcing an abnormal composite structural member. The repair is suited for reinforcing a cured composite structure that defines a strength tolerance and has an abnormality that reduces the structural strength relative to the strength tolerance of the cured composite. The structural reinforcement repairs the abnormality in the cured composite and provides the repair strength so that the repaired composite has a structural strength that meets or exceeds the strength tolerance. The structural reinforcement has a composite patch that is coupled to the cured composite over the abnormality and is covered by pressure-sensitive tape.

Disclosed herein are a repair apparatus, system, and method for structurally reinforcing an abnormal composite structural member. The repair is suited for reinforcing a cured composite structure that defines a strength tolerance and has an abnormality that reduces the structural strength relative to the strength tolerance of the cured composite. The structural reinforcement repairs the abnormality in the cured composite and provides the repair strength so that the repaired composite has a structural strength that meets or exceeds the strength tolerance. The structural reinforcement has a composite patch that is coupled to the cured composite over the abnormality and is covered by pressure-sensitive tape.

Disclosed herein are a repair apparatus, system, and method for a composite sandwich structure. The repair is suited for reinforcing a sandwich panel having a first sheet and a second sheet opposite the first sheet. A core is interposed between and coupled to the first sheet and the second sheet. The repair uses a potting compound packed into an abnormality of the core and located on the outer surface of the first sheet. A patch is coupled to the outer surface of the first sheet over the abnormality of the core and cured. The cured potting compound is interposed between and bonded to the patch and the abnormality of the core and bonded to the patch and the outer surface of the first sheet to form a structural reinforcement.

Disclosed herein are a repair apparatus, system, and method for a composite sandwich structure. The repair is suited for reinforcing a sandwich panel having a first sheet and a second sheet opposite the first sheet. A core is interposed between and coupled to the first sheet and the second sheet. The repair uses a potting compound packed into an abnormality of the core and located on the outer surface of the first sheet. A patch is coupled to the outer surface of the first sheet over the abnormality of the core and cured. The cured potting compound is interposed between and bonded to the patch and the abnormality of the core and bonded to the patch and the outer surface of the first sheet to form a structural reinforcement.

A self-stressing shape memory alloy (SMA)/fiber reinforced polymer (FRP) composite patch is disclosed that can be used to repair cracked steel members or other civil infrastructures. Prestressed carbon FRP (CFRP) patches have emerged as a promising alternative to traditional methods of repair. However, prestressing these patches typically requires heavy and complex fixtures, which is impractical in many applications. This disclosure describes a new approach in which the prestressing force is applied by restraining the shape memory effect of nickel titanium niobium alloy (NiTiNb) SMA wires. The wires are subsequently embedded in an FRP overlay patch. This method overcomes the practical challenges associated with conventional prestressing.

A self-stressing shape memory alloy (SMA)/fiber reinforced polymer (FRP) composite patch is disclosed that can be used to repair cracked steel members or other civil infrastructures. Prestressed carbon FRP (CFRP) patches have emerged as a promising alternative to traditional methods of repair. However, prestressing these patches typically requires heavy and complex fixtures, which is impractical in many applications. This disclosure describes a new approach in which the prestressing force is applied by restraining the shape memory effect of nickel titanium niobium alloy (NiTiNb) SMA wires. The wires are subsequently embedded in an FRP overlay patch. This method overcomes the practical challenges associated with conventional prestressing.

A method including receiving a model of a composite structure having an inconsistency. The model includes a pre-calculated heating model that specifies areas of the inconsistency for which corresponding different amounts of heating are applied to an uncured composite material that is applied to the inconsistency. A design for heating elements of varying density across the areas is generated from the model. The design is configured to cause the heating elements in a first sub-area of a heat blanket system to generate a first amount of heat in a third area in the areas, and to cause the heating elements in a second sub-area of the heat blanket system to generate a second, different amount of heat in a fourth area of the areas. The heating elements are printed according to the design on a blanket to manufacture the heat blanket system.

A method including receiving a model of a composite structure having an inconsistency. The model includes a pre-calculated heating model that specifies areas of the inconsistency for which corresponding different amounts of heating are applied to an uncured composite material that is applied to the inconsistency. A design for heating elements of varying density across the areas is generated from the model. The design is configured to cause the heating elements in a first sub-area of a heat blanket system to generate a first amount of heat in a third area in the areas, and to cause the heating elements in a second sub-area of the heat blanket system to generate a second, different amount of heat in a fourth area of the areas. The heating elements are printed according to the design on a blanket to manufacture the heat blanket system.

A kit for repairing material includes an external packaging defining an interior cavity and a repair packet inside the interior cavity. The repair packet includes a delivery layer, a frame positioned on the delivery layer, the frame being more rigid than the delivery layer and a repair material adhesively located on a first surface of the delivery substrate. A sacrificial layer is juxtaposed with the repair material such that the repair material is sandwiched between the delivery layer and the applicator layer.