Investigation of the Bonding Mechanism between Overlapping Textile Layers for FRP Repair Based on Dry Textile Patches

Lots of damaged fiber-reinforced plastic (FRP) components are replaced by new components instead of repairing. Furthermore, only very labor-intensive repair methods are available on the market to fully restore the integrity of the structure. This requires a high level of experience or, alternatively, very cost-intensive technology, such as the use of computer tomography and robotics. The high costs and CO(2) emissions caused by the manufacture of FRP components then bear no relation to their service life. The research project IGF-21985 BR “FRP-Repair” aims to solve the named challenges. Using semiconductor oxide catalysts, the matrix can be locally depolymerized by ultraviolet (UV) radiation, and thus removed from the damaged area of the FRP component. Subsequently, the damaged fibers in this area can be detached. By using customized textile repair patches and local thermoset reinfiltration, the repair area is restored. With this process, the fiber structure can be repaired locally with new fibers on the textile level. The repair is similar to the original production of a fiber composite in an infusion process. No additional adhesive material is used. As a result, repaired FRP structures with restored mechanics and a near-original surface can be realized. This article provides an insight into the actual steps of the development of the FRP component repair process using dry textile patches. The empirical investigation of overlapped rovings and UD material showed the expected results. Residual fracture forces of up to 86% could be achieved. The most interesting approach on the roving level was splicing the overlapping fibers. The free ends of the fibers of the patch and part are mechanically bonded. This bond at the textile level is further strengthened by infusion with matrix.