METHOD AND PATCH FOR DEFECT REPAIR

Abstract

A patch (100) for repair of a structure (180) with a defect (182) having a topography, the patch (100) including: a patch body (102) that is at least partially metallic; a bonding surface (104) that is compatible with the topography of the defect (182); and a patch surface (106) opposite the bonding surface (104), wherein the patch (100) has a variable porosity and a set of material properties; and wherein at least one material property of the set of material properties varies as a result of the variable porosity.

Claims

1. A patch for repair of a structure with a defect having a topography, the patch including: a patch body that is at least partially metallic; a bonding surface that is compatible with the topography of the defect; and a patch surface opposite the bonding surface, wherein the patch has a variable porosity and a set of material properties; and wherein at least one material property of the set of material properties varies as a result of the variable porosity.

2. The patch of claim 1, wherein the patch body includes a first zone and a second zone, each zone having: a porosity; and a set of material properties, wherein the porosity of the first zone is different to the porosity of the second zone, and as a result, at least one material property of the first zone is different to a material property of the second zone.

3. The patch of claim 2, wherein the first zone includes a first patch layer and the second zone includes a second patch layer, the first and second patch layers being located between the bonding surface and the patch surface, wherein each patch layer is configured so as to be located, when the patch is applied to the structure, adjacent a corresponding structural layer of the structure, and wherein the porosity of each patch layer is predetermined so that: at least one material property of the first patch layer is more compatible with a first structural layer than a second structural layer; and at least one material property of the second patch layer is more compatible with the second structural layer than the first structural layer.

4. The patch of claim 2, wherein the first zone includes a first radial portion and the second zone includes a second radial portion, the first and second radial portions being located at different distances from a central axis of the patch.

5. The patch of claim 4, wherein the second radial portion is located further from the central axis than the first radial portion, and wherein the porosity of the second radial portion is higher than the porosity of the first radial portion.

6. The patch of claim 4, wherein the patch further includes a third radial portion intermediate the first and second radial portions, and wherein the porosity of the third radial portion is in a range between the porosity of the first radial portion and the porosity of the second radial portion.

7. The patch of claim 1, wherein the patch body includes: a doubler portion configured to, when the patch is applied to the structure, extend beyond the topography of the defect.

8. The patch of claim 7, wherein the doubler portion has a porosity and a set of material properties, and wherein at least one material property of the doubler portion is predetermined by the porosity.

9. The patch of claim 1, wherein the patch body includes a metallic cellular lattice material, the cellular lattice material having a plurality of voids and a metal lattice, the proportion of void volume to metal volume determining the porosity of the metallic cellular lattice material.

10. The patch of claim 9, wherein the void volume and/or the metal volume is predetermined to control the variable porosity.

11. The patch of claim 9, wherein the voids have a void axis that is transverse to the patch surface by a void angle.

12. The patch of claim 9, wherein a major cross-sectional dimension of a majority of voids in the plurality of voids has a magnitude of less than 1 mm.

13. The patch of claim 1, wherein the variable porosity is predetermined so as to vary as a function of distance from the central axis.

14. The patch of claim 1, wherein the bonding surface has a surface feature for increasing a surface area of the bonding surface to improve adhesion to an adhesive, wherein the surface feature is one of: a hook, or an extension with a hook-shaped cross-section, extending from the bonding surface; and a plurality of cones extending from the bonding surface.

15. A method for repair of a structure having a defect, the method including the steps of: acquiring a topography of the defect; forming a patch that is at least partially metallic and compatible with the topography of the defect, the patch including: a patch body having: a variable porosity; and a set of material properties; a bonding surface that is compatible with the topography of the defect; and a patch surface opposite the bonding surface, wherein the variable porosity is predetermined so that at least one material property of the set of material properties varies as a result of the variable porosity; and applying the patch to the defect using an adhesive layer.

16. The method of claim 15, wherein the structure is a composite structure having a structural first layer and a second structural layer, and the step of acquiring the topography also includes: acquiring information related to a set of material properties of the first and second structural layers, and wherein the patch body has a first zone and a second zone, each zone having: a porosity; and a set of material properties, wherein the first zone includes a first patch layer and the second zone includes a second patch layer, the first and second patch layers being located between the bonding surface and the patch surface, wherein each patch layer is configured so as to be located, after application of the patch, adjacent a corresponding structural layer of the structure, and wherein the porosity of each patch layer is predetermined so that: at least one material property of the first patch layer is more compatible with a first structural layer than a second structural layer; and at least one material property of the second patch layer is more compatible with the second structural layer than the first structural layer.

17. The method of claim 15, wherein the patch body includes a doubler portion and the step of applying the patch further includes: applying the patch such that the doubler portion extends beyond the topography of the defect.

18. The method of claim 15, wherein the step of forming the patch is at least partially performed using an additive layer manufacturing process and the additive layer manufacturing process deposits layers of material in a first plane, and wherein the patch body being formed extends in a second plane, the second plane being perpendicular to the first plane.

19. The method of claim 18, wherein the step of forming the patch includes: forming a plurality of patches in a single additive layer manufacturing process.

20. The method of claim 18, wherein the patch body is formed to include a metallic cellular lattice material, the cellular lattice material having a plurality of voids and a metal lattice, the proportion of void volume to metal volume determining the porosity of the metallic cellular lattice material.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0071] Preferred embodiments of the present invention will now be described, by way of examples only, with reference to the accompanying drawings:

[0072] FIG. 1 is a schematic perspective section view of a patch according to a preferred embodiment of the invention being applied to a structure.

[0073] FIG. 2 is a schematic side section view of the patch of FIG. 1.

[0074] FIG. 3 is a schematic view of a metallic cellular lattice material used in the manufacture of the patch of FIG. 1.

[0075] FIG. 4 is a schematic side section view of a patch according to another embodiment of the invention being applied to the structure.

[0076] FIG. 5 is a diagram showing the stiffness of the patch of FIG. 4 as a function of distance from a central axis.

[0077] FIG. 6 is a schematic side section view of a patch according to another embodiment of the invention being applied to the structure.

[0078] FIG. 7 is a diagram showing the stiffness of the patch of FIG. 6 as a function of distance from a central axis.

[0079] FIG. 8 is a schematic side section view of a patch according to another embodiment of the invention.

[0080] FIG. 9 is a schematic bottom view of the patch of FIG. 1.

[0081] FIG. 10 is a schematic side section view of the patch of FIG. 9.

[0082] FIG. 11 is a schematic bottom view of a patch according to another embodiment of the invention.

[0083] FIG. 12 is a schematic side section view of the patch of FIG. 11.

[0084] FIG. 13 is a flow diagram of a method according to a preferred embodiment of the invention.

[0085] FIG. 14 is a schematic side section view of a patch according to another embodiment of the invention.

[0086] FIG. 15 is a schematic isometric view of a patch according to another embodiment of the invention.

[0087] FIG. 16 is a schematic side section view of a patch according to another embodiment of the invention.

[0088] FIG. 17 is a schematic bottom view of a patch according to another embodiment of the invention.

[0089] FIG. 18 is a schematic perspective view of a base to which a plurality of patches of FIGS. 1 to 17 is connected.

DESCRIPTION OF EMBODIMENTS

[0090] Where reference is made in any one or more of the accompanying drawings to steps and/or features, which have the same reference numerals, those steps and/or features have for the purposes of this description the same function(s) or operation(s), unless the contrary intention appears.

[0091] It is to be noted that the discussions contained in the “Background” section and that above relating to prior art arrangements relate to discussions of documents or devices which form public knowledge through their respective publication and/or use. Such should not be interpreted as a representation by the present inventor(s) or the patent applicant that such documents or devices in any way form part of the common general knowledge in the art.

[0092] FIG. 1 shows a patch 100 according to a preferred embodiment of the invention being applied to a structure 180 having a defect 182, for example an airframe of an aircraft, or other aerospace applications. As shown in FIG. 2, the patch 100 includes a patch body 102. The patch body 102 includes a bonding surface 104 where, when applied, the patch body 102 interfaces with the structure 180, the structure 180 having, in some embodiments, at least a first structural layer 186 and a second structural layer 188, and a patch surface 106. The patch body 102 has a variable porosity and a set of material properties, wherein at least one material property, for example Young's Modulus, is controlled by the variable porosity.

[0093] The variable porosity may be varied continuously throughout the patch body 102, or according to predetermined portions, such as a first zone, in this case a first patch layer 108, and a second zone, in this case a second patch layer 110 located between the bonding surface 104 and the patch surface 106. As shown in FIG. 3, each layer 108, 110 includes a metallic cellular lattice material 130 manufactured at least partially using additive layer manufacturing from, for example Invar 36 or Ti-6Al-4V. Invar 36 is iron alloyed with 36 wt % nickel, while Ti-6Al-4V is titanium alloyed with 6 wt % Aluminium and 4 wt % Vanadium. In another embodiment, the cellular lattice material 130 is manufactured at least partially using Ti-6Al-4V ELI (Grade 23, or Extra Low Interstitials), which contains reduced levels of oxygen, nitrogen, carbon, and iron. The cellular lattice material 130 includes a metal lattice 134 surrounding a plurality of voids 132. As a result, each layer 108, 110 has a porosity determined by the volumetric proportion of the voids 132 compared to the volumetric proportion of the metal lattice 134. Each layer 108, 110 also has a set of material properties, such as Young's modulus, Poisson's ratio, yield strength, ultimate tensile strength, and coefficient of thermal expansion.

[0094] The layers 108, 110 of the patch body 102 may be dimensioned in thickness, so that the patch 100 conforms with the defect topography 184 of the defect 182. For example, as shown in FIGS. 7 and 8, the defect topography 184 may include distinct steps between a number of structural layers 186, 188, for example when the structure 180 is a composite structure. Thus, the layers 108, 110 of the patch 100 are dimensioned accordingly. Alternatively, the structure 180 may be of a homogenous material, for example a metallic material. In this case, the layers 108, 110 may be dimensioned to be very thin, and have tapered edges, as shown in FIGS. 9 and 10, to conform to the defect topography 184 of the defect 182 in the structure 180.

[0095] The use of the patch 100 may further includes the use of a doubler 190. The doubler 190 is not typically adapted to a particular defect 182 in a particular structure 180, but is a generic component applied over the tailored patch 100.

[0096] In another embodiment, as shown in FIG. 4, the first zone of the patch body 102 includes a first radial portion 112, and the second zone includes a second radial portion 114, each portion 112, 114 being located at a distance 116 from a central axis 118 of the patch 100. As can be seen in FIG. 4, the second radial portion 114 is located further from the central axis 118 than the first radial portion 112. As in the embodiment of FIG. 2, each portion 112, 114 is at least partially manufactured using additive layer manufacturing and includes the metallic cellular lattice material 130. Accordingly, each portion 112, 114 has a porosity and a set of material properties. In the preferred embodiment, the porosity of the second radial portion 114 is higher than the porosity of the first radial portion 112. In another preferred embodiment, the patch body 102 includes a third radial portion (not shown) having a higher porosity than both the first and second radial portions 112, 114.

[0097] Additionally, as shown in FIG. 5, in the preferred embodiment the variable porosity of the patch body 102 is predetermined so as to vary as a function of distance from the central axis 118. Specifically, in an example where the patch 100 is manufactured from Ti-6Al-4V, the porosity of the first portion 112 is predetermined such that Young's modulus of the first portion 112 varies from 113 GPa at the central axis 118 to 45 GPa at the furthest extent of the first portion 112. Similarly, the porosity of the second portion 114 is predetermined such that Young's modulus of the second portion 114 varies from 45 GPa to 23 GPa at the furthest extent of the second portion 114 from the central axis 118.

[0098] In another embodiment, as shown in FIG. 6, the patch body 102 includes a third radial portion 115 intermediate the first radial portion 112 and the second radial portion 114. Similarly to radial portions 112, 114, the third radial portion has a variable porosity that is predetermine, as shown in FIG. 7. Preferably, the porosity of the third radial portion 115 is predetermined such that the Young's modulus of the third radial portion 115 is in the range between the Young's modulus of the first portion 112 and the second portion 114. In a preferred embodiment, the Young's modulus of the second radial portion 114 and third radial portion 115 is 20% and 40% of the Young's modulus of the first radial portion 112, respectively.

[0099] In another embodiment, shown in FIG. 8, instead of using the doubler 190, the patch body 102 includes a doubler portion 120. The doubler portion 120 is also manufactured from the metallic cellular lattice material 130 and thus the doubler portion 120 may also have a porosity and a set of material properties, with at least one material property of the doubler portion being predetermined by the porosity.

[0100] In the embodiments of FIGS. 2, 4, 6, and 8 the patch surface 106 has a substantially smooth surface, compared to a higher surface porosity of the bonding surface 104 that is due to the manufacture of the patch body 102 from the metallic cellular lattice material 130. The patch surface 106 is smooth to match the surface quality of the surrounding structure 180.

[0101] In some embodiment, as shown in FIGS. 14 and 15, the bonding surface 104 has a surface feature 144 for increasing a surface area of the bonding surface 104 to improve adhesion to the adhesive layer 170. In one embodiment, shown in FIG. 14, the surface feature 144 includes a hook 144, or an extrusion or prism with a hook-shaped cross-section, extending from the bonding surface. In another embodiment, as shown in FIG. 15, the surface feature 144 includes a plurality of cones 144 extending from the bonding surface 104.

[0102] As seen in FIG. 16, each void 132 has a void axis 136. In one embodiment, the void axis 136 is transverse to the patch surface 106 by a void angle 138, preferably the void angle is about 3°. In another embodiment the void angle 138 varies as a function of the distance 116 from the central axis 118, for example the void angle 138 varies linearly from 0° adjacent the central axis 118 to 3° at a maximum of the distance 116 from the central axis 118.

[0103] In one embodiment, the metal lattice 134 includes a honeycomb structure 140, as seen in FIG. 17. The honeycomb structure 140 may be an arrangement of six adjacent voids 132 surrounding each void 132 (forming a hexagonal honeycomb structure 140), or an arrangement of 4 adjacent voids 132 surrounding each void 132 (forming a rectangular honeycomb structure 140). In preferred embodiments, a major cross-sectional dimension 142 which, as shown in FIG. 16, is the largest cross-sectional dimension of a void 132 in a plane of the patch surface does not exceed 1 mm.

[0104] Use of the patch 100 will now be discussed.

[0105] As shown in FIG. 13, a method 101 for defect repair according to a preferred embodiment of the present invention starts at step S101 by acquiring the defect topography 184. Acquisition of the defect topography 184 may be performed by methods such as laser scanning, air-coupled ultrasound, gel-coupled ultrasound, visual inspection, X-ray, and the like. For clarification, the defect 182 and the defect topography 184 refer to the defect 182 in the state where the defect 182 is ready to receive the patch 100. The method 101 is agnostic of whether removal of material has occurred or not, provided that the defect topography 184 is such that the patch 100 can be applied. In the preferred embodiment, step S101 also includes acquiring information related to a set of material properties of a first structural layer 186 and a second structural layer 188, shown in FIG. 2.

[0106] The method 101 continues, at step S103, forming the patch 100 from, for example, Invar 36 or Ti-6Al-4V. Step S103 is preferably performed using Selective Laser Melting and Laser Metal Deposition additive layer manufacturing methods to create the cellular lattice material 130 having the metal lattice 134 surrounding a plurality of voids 132. During the execution of step S103, at step S105, the porosity of the cellular lattice material 130 is adjusted by adjusting the control parameters of the additive layer manufacturing methods to change dimensional parameters, such as the size and/or shape of the voids 132 and the size and/or shape of the metal lattice 134 of the metallic cellular lattice material, to increase or decrease the volume of the metal lattice 134 compared to the plurality of voids 132. Thereby the variable porosity and thus a material property of the current zone of the patch 100 being formed is adjusted, thereby creating the first zone, such as the first patch layer 108 or the first radial portion 112, and the second zone, such as the second patch layer 110 or the second radial portion 114, each zone having a set of material properties wherein at least one material property is different between the first zone and the second zone.

[0107] In a preferred embodiment, the porosity of the first patch layer 108 is adjusted such that at least one material property of the first patch layer 108 is more compatible with the first structural layer 186 than the second structural layer 188. Similarly, the porosity of the second patch layer 110 is adjusted such that at least one material property of the second patch layer 110 is more compatible with the second structural layer 188 than the first structural layer 186. For example, it may be desirable to match the anisotropic Young's modulus of each layer in a carbon fibre reinforced plastic (CFRP), or its anisotropic yield properties.

[0108] More preferably, the porosity of the first patch layer 108 is adjusted such that at least one material property of the first patch layer 108 is substantially similar to the same material property of the first structural layer 186. Similarly, the porosity of the second patch layer 110 is adjusted such that at least one material property of the second patch layer 110 is substantially similar to the same material property of the second structural layer 188.

[0109] In a preferred embodiment step S103 includes forming a plurality of patches 100 in a single additive layer manufacturing process, using a base 150 to which each patch 100 is connected, as shown in FIG. 18. The additive layer manufacturing process deposits layers of material in a first plane 146 (and subsequent like parallel planes). The patch body 102 being formed extends substantially in a second plane 148, the second plane 148 being substantially perpendicular to the first plane 146.

[0110] At step S107, after the patch 100 has been successfully formed, the patch 100 is applied to the defect 182 in the structure 180. As shown in FIGS. 2, 4, and 6, a variety of functional designs are possible for the patch 100. Generally, it is possible to apply the patch 100 according to FIGS. 2 and 4, with a doubler 190, or to apply the patch 100 according to FIG. 8, in which case the patch 100 has a doubling portion 120. In the case of FIGS. 2 and 4, a first adhesive layer 170 is applied so as to be located between the patch 100 and the defect topography 184. In a preferred embodiment, prior to application of the first adhesive layer 170, the bonding surface 104 is treated by grit-blasting with dry nitrogen, and a silane surface treatment. Depending on the adhesive compound used in the adhesive layer 170, the adhesive layer 170 may be cured, or the doubler 190 may be applied immediately after. The application of the doubler 190 includes application of a second adhesive layer 172 such that it is located between the doubler 190 and the structure 180, as well as the patch surface 106. The adhesive of the second adhesive layer 172 is then cured. In the case of FIG. 8, the first adhesive layer 170 is applied so as to be located between the patch 100 and the defect topography, as well as between the doubler portion 120 of the patch 100 and the structure 180. The adhesive of the first adhesive layer 170 is then cured.

[0111] Advantages of the patch 100 will now be discussed.

[0112] Because the porosity of the first zone and the second zone can be controlled such that at least one material property is different between the first zone and the second zone, the patch 100 can accommodate materials with anisotropic properties and/or create locally compliant portions to smoothly transfer loads and decrease the risk of adhesive failure between the portion 100 and the structure 180.

[0113] When embodied as the first and second patch layers 108, 110, the zones allow improved compatibility between the material properties of the structure 180 and the patch 100.

[0114] When embodied as the first and second radial portions 112, 114, the zones allow smooth transfer of out-of-plane loads between the structure 180 and the patch 100, decreasing the risk of local adhesive failure, and thus potential for a snowball-effect of a decreased load-transfer surface, akin to thread-failure in threaded connections. Thus, it is desirable to create a more compliant material at the radially outward portion, and a less compliant material for the remainder of the patch 100 to maintain dimensional stability.

[0115] When a third radial portion 115 is formed between the first and second portions 112, 114, the material properties of the patch 100 can be varied more smoothly between the design requirements at a perimeter of the patch 100, compared to close to the central axis 118.

[0116] Because the material properties of the patch 100 are controlled using the porosity of the metallic cellular lattice material 130, it is possible to change the material properties at much faster rates, compared to, for example, heat treatments. In the preferred embodiment, for example, Young's modulus may be varied at a rate up to 17 GPa mm.sup.−1.

[0117] The bonding surface 104 also has a porosity, due to the patch body 102 being manufactured from the metallic cellular lattice material 130. The porosity of the bonding surface 104 may be specifically controlled so as to improve the adhesive bond between the patch 100 and the structure 180.

[0118] Forming the patch 100 from Invar 36 or Ti-6Al-4V allows closer matching of thermal expansion coefficients with CFRP materials, while allowing use of these materials at relatively low part density, due to the inclusion of voids 132 in the material. Thus, while Invar 36 and Ti-6Al-4V both have relatively high bulk material density, the inclusion of the voids 132 allows manufacture of parts with relatively low effective density, which is desirable for aerospace applications. The use of Extra Low Interstitial Ti-6Al-4V (Grade 23) provides improved ductility and fracture toughness, which is advantageous in aerospace applications.

[0119] The voids 132 having a void angle 138 is beneficial for additive layer manufacturing of cavities, and may also improve stress paths in the patch 100. Variation of the void angle 138 as a function of a distance from a centre of the patch body 102 may also improve stress paths in the patch 100.

[0120] The metal lattice 134 having a form of a honeycomb 140 or a gyroid 140 structure improves the structural performance of the metal lattice 134 while using a low amount of metal material, compared to other structural configurations of a metal lattice.

[0121] The use of voids 132 with a major cross-sectional dimension being less than 1 mm allows better and detailed control of the porosity, and thereby the material properties, of the patch body 102.

[0122] The use of surface features 144, such as the hooks or the cones, improves the adhesion between the adhesive layer 170 and the bonding surface 104.

[0123] The additive manufacturing of the patch 100 such that it extends substantially perpendicularly to the first plane 146 reduces bending of the patch 100 as it is formed. This allows formation of voids 132 with cleaner, more controllable, surfaces, and thereby improved control of porosity and material properties.

REFERENCE NUMERALS

[0124]

TABLE-US-00001 100 patch 101 method 102 patch body 104 bonding surface 106 patch surface 108 first patch layer 110 second patch layer 112 first radial portion 114 second radial portion 116 distance 118 central axis 120 doubler portion 130 metallic cellular lattice material 132 voids 134 metal lattice 136 void axis 138 void angle 140 honeycomb structure 142 major cross-sectional dimension 144 surface feature 146 first plane 148 second plane 150 base 170 first adhesive layer 172 second adhesive layer 180 structure 182 defect 184 defect topography 186 first structural layer 188 second structural layer 190 doubler