Composite Structures 263 (2021) 113659

Contents lists available at ScienceDirect

Composite Structures
journal homepage: www.elsevier.com/locate/compstruct

Review

Review on the performance improvements and non-destructive testing

of patches repaired composites
Wei Zhou a,b,c,⇑, Xiao-long Ji a,b,c, Sa Yang a,b,c, Jia Liu a,b,c,⇑, Lian-hua Ma a,b,c,⇑
a
College of Quality and Technical Supervision, Hebei University, Baoding 071002, China
b
National & Local Joint Engineering Research Center of Metrology Instrument and System, Hebei University, Baoding 071002, China
c
Hebei Key Laboratory of Energy Metering and Safety Testing Technology, Hebei University, Baoding 071002, China

A R T I C L E I N F O A B S T R A C T

Keywords: The composites patch is an effective method to repair metal and composite parts while keeping the weight of
Patch repair performance repaired structures almost constant. This review focuses on the improvements of repair performance and the
Improvement methods applications of non‐destructive testing technologies on composites patch repair from four aspects such as opti-
NDT technologies mization design of patch, effects of adhesive on repair efficiency, improvements of repair methods and non‐
Detection and evaluation
destructive testing on repair evaluation. More importantly, this review discusses the applications of acoustic
emission, digital image correlation, infrared thermography technology and X‐ray micro‐computed tomography
in studying the mechanical performance and failure mechanism of repaired structures. Finally, some prospects
about the further developments of composites patch repair method and further development applications of
NDT technologies were proposed.

Contents

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Optimization design of patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1. Geometry optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1.1. Dimension parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1.2. Patch shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2. Patch hybridization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3. Additive effects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3. Effects of adhesive on repair efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1. Thickness and shear modulus effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2. Hygrothermal aging and debonding effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3. Additive effects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4. Improvements of repair methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1. Several crack stop methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2. Double-bonded patch repair and hybrid repair methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5. Non-destructive testing on composites patch repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1. AE monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2. DIC measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.3. IRT technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.4. Micro-CT observation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

⇑ Corresponding authors at: College of Quality and Technical Supervision, Hebei University, Baoding 071002, China.
E-mail addresses: zhouwei@hbu.edu.cn (W. Zhou), liujia@hbu.edu.cn (J. Liu), lhma@hbu.edu.cn (L.-h. Ma).

https://doi.org/10.1016/j.compstruct.2021.113659
Received 17 January 2021; Accepted 24 January 2021
Available online 3 February 2021
0263-8223/© 2021 Elsevier Ltd. All rights reserved.
W. Zhou et al. Composite Structures 263 (2021) 113659

Abbreviation

AE Acoustic emission PPT Pulsed phase thermography

CAI Compression after impact PCA Principle component analysis
CNT Carbon nanotubes QSI Quasi static indentation
CFRP Carbon fiber reinforced composites IRT Infrared thermography technology
COD Crack opening displacement SIF Stress intensity factor
DIC Digital image correlation SCF Stress concentration factor
EPCM Electrical potential change monitoring SEM Scanning electron microscope
FEA Finite element analysis SMA Shape memory alloy
FEM Finite element modeling TSR Thermographic signal reconstruction
LT Lock‐in thermography TT Transient thermography
micro‐CT X‐ray micro‐computed tomography UT Ultrasonic testing
NDT Non‐destructive testing
NDE Non‐destructive evaluation
OL Over loading

6. Conclusions and future prospects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

6.1. Future prospects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Declaration of Competing Interest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1. Introduction concentration factor (SCF), J integral at the defects, shear strain or

peel stress, and debonding, delamination, moisture absorption, etc.
Defects such as the opening hole, notch, crack, scratch and impact [6–9]. Thus, it is necessary to develop some methods to improve the
can arise during the service of structures. These defects will affect the repair performance of the patch. As shown in Fig. 2, aiming at the
structural integrity and significantly reduce the strength and stiffness enhancement of repair performance, optimization scheme for patch,
of materials [1]. Therefore, it is extremely important to repair defec- adhesive and repair methods have been investigated systematically
tive materials and restore their mechanical properties to some extent. by researchers in the past several decades. Various repair improvement
Compared with the mechanical repair method, bonded composites methods have been developed, and each of them has specific benefits.
patch repair technology has been extensively used in aerospace, wind The optimization of dimension parameters results in patches that have
power and other industrial fields due to the low price, flexible design better repair efficiency and extend the service life of repaired compos-
ability and lightweight [2]. Meanwhile, composites patch reduces the ites [10]. Optimizing the patch shape can reduce the SIF at the defect,
stress intensity factor (SIF), J integral, etc. at the defect and conse- and increase the safety‐cost ratio at the same time [11]. Comparing
quently stops the crack and increases the life [3,4]. Three common with common patches, hybrid patches consisting of different fibers
composite repair methods such as single‐bonded repair, double‐ or fiber orientations can better increase the performances of repaired
bonded repair and scarf repair are shown in Fig. 1. However, the composites under several loading conditions [12]. The optimization
results of composites repaired using the traditional single‐bonded of adhesive thickness and shear modulus can obtain a relatively supe-
repair methods and common patches are not adequate in some cases rior capacity of stress transfer and better connection effects [13].
[5]. The main reasons for the patch failure include increased SIF, stress Advanced hybrid methods prevent crack propagation successfully

Fig. 1. Three common composites repair methods, (a) Composites with a hole defect, (b) Single-bonded patch repair, (c) Double-bonded patch repair, (d) Scarf
repair.

2
W. Zhou et al. Composite Structures 263 (2021) 113659

Fig. 2. Directions of improvements on patch, adhesive and repair methods.

and prolong the life of structures significantly compared to single‐
bonded patch repair technology [14]. For the scarf repair and adhesive
joints technologies, the surfaces of repaired areas were treated manu-
ally, mechanically, or with a laser, which has a great influence on the
performance of repaired composites [15,16]. However, surface treat-
ment technologies have little influence on the performance of bonded
composites patch repair. Also, finite element analysis (FEA) and NDT
technologies were employed for the investigation of mechanical prop-
erties and failure modes of composites, the evaluation of repair effi-
ciency and the optimization of repair performance because of the
strong design function and ability of real‐time monitoring [17,18].
Specifically, the application of NDT technologies in the field of com-
posite patch repair has the following obvious advantages: (1) Non‐
contact detection and high safety: NDT technologies realize the detec-
tion of defects from inside structures without any destruction [19]. (2)
On‐line monitoring: Acoustic emission (AE), digital image correlation
(DIC) and infrared thermography technology (IRT) technologies mon-
itor the defect changes with time, load and other conditions, and real-

Fig. 3. Three optimized aspects of repair performance, (a) Geometry, (b) Additive, (c) Hybridization.

3
 W. Zhou et al. Composite Structures 263 (2021) 113659

References
ize simultaneous on‐line monitoring from the initial stage to the failure
stage [20]. (3) Wide range of applications: AE technology shows bril-

[10]

[26]

[25]
[28]

[29]

[30]
[27]

[13]
liant applicability for almost all types of materials and various types of

[4]
damage. [21]. Nevertheless, NDT technologies still have several insuf-
ficiencies in their application: (1) Due to the high sampling rate and
Optimized parameters

Length and thickness

Width and thickness

long sampling time, AE technology produces a large amount of data

Length, width and

during continuous monitoring. And it is sensitive to the noise around
the experimental environment [22]. (2) The limitations of DIC and
Thickness

Thickness

Thickness
thickness
IRT are discussed in section 5, thus the accurate recognition of failure
Length

Length

Length
modes and the analysis of failure mechanisms are infeasible some-
times. (3) Micro‐CT technology acquires 3D images of samples in a
non‐destructive way and can achieve the visualization of interior dam-
Aluminum plate

Aluminum plate
age. In this review, methods on performance improvements of patches

Carbon/epoxy
repaired composites were summarized, and the application of NDT

composite
Steel pipe

technologies for a repair evaluation and patch optimization over past

Matrix

decades were discussed.

The lowest limiting stress intensity K∞ ensures the transfer of load and the minimization of
The total strength increases with patch length and width; the increase of patch dimensions
The reduction of SIF ranges from 54% to 62% when the thickness of circular patch varies

2. Optimization design of patch

Minimize both strength ratio R* and dimensionless design parameter K help design the

Maximum skin stress reduced by 83–85%, load-carrying capacity increased by 42%.

Patch is one of the main factors which directly affects the perfor-
A minimum stress intensity factor K helps the patch optimization design of patch.

mance of repaired composites. The strength and life of repaired com-

posites are significantly related to the performance of patch.
Consequently, various studies of patch have been investigated and
The patch length affects the J integral or notch stress intensity factor.

designed to improve the repair efficiency and durability, finally

increasing the service life of repaired composites [23]. The effects of
patches on repair efficiency which are reflected in the variations of
SIF, SCF, mass gain and J integral at the defects are discussed in this
section, specific discussions are carried out from geometry, hybridiza-
The fatigue life increases with patch length increase.

tion and additive, as shown in Fig. 3. Particularly, the optimization of

patch dimension parameters and the corresponding effects are summa-
SIF significantly reduces with length increase.

rized in Table 1.

2.1. Geometry optimization

2.1.1. Dimension parameters

between 0.4 and 10 mm.

The FEA method is a useful tool for the design of performance eval-
reduces the J integral.

uation of dimension parameters in a simulation way, owing to its flex-

ibility in adjusting parameters. Consequently, many optimization
Main conclusions

optimal patch.

studies about patch dimension parameters have been conducted and

shear strain.

conceptual improvements on the evaluation of repair performance of

patch have been proposed. Most of the influential factors can be
obtained through the analyses of simulation results of FEA, and then
the optimization of patch is carried out by changing these factors.
Optimization of patch dimension parameters and corresponding effects.

Thereinto, the thickness and shear modulus of patch and adhesive

Central through

Central crack

are considered as four parameters that have the most significant on

Edge crack

the performance of patch. Most optimization work about these param-

Defects

Notch

Notch

Notch

eters were done by calculating SIF, mass gain and J integral. Salehi‐
crack
Hole

Khojin et al. [24] employed both analytical and experimental methods

to investigate the variations of SIF, potential energy (PE) and energy
release rate of the plates repaired with different patch layers.
Patch fabrication

Researches showed that the increase of patch layers positively or neg-

atively increased these parameters. Albedah et al. [25] studied the
processes

influences of patch thickness and adhesive shear modulus on the repair

Prepreg

efficiency through the comparison of calculated SIF and mass gain

variation based on the three‐dimensional finite element method. The
/

SIF at the tip of crack and the mass gain of patch decrease with the
Carbon

Carbon

increase of patch thickness. Higher adhesive shear modulus is benefi-

Fibers

Boron
fiber

fiber

fiber

cial to the increase of mass gain but will generate harmful shear stres-
ses. Besides, a dimensionless design parameter K integrating four
parameters (the thickness and shear modulus of patch and adhesive)
Tensile tests, FEA
Analysis methods

Fatigue loading

and a concept named strength ratio R* were proposed by Gong et al.

test, FEA

[26]. They illustrated that minimizing the value of R* could improve

the repair performance of patch and the optimal performance would
Table 1

FEA

be obtained when K = 1. In addition, the weights of four factors

(the shear modulus of adhesive, the Young module of patch and the

4
W. Zhou et al. Composite Structures 263 (2021) 113659

thickness of both adhesive and patch) and their interactions, as well

References
as the best combination were studied by Yala et al. [27]. Sufficient
comparison gives the lowest K 1 which is influenced by stiffness ratio

[11]
[31]

[39]

[35]

[37]

[34]

[36]

[32]

[33]
and shear strain, thereby an optimal patch can be obtained corre-
spondingly. The reduction degree of SIF ranges from 54% to 62%

position,circle patch,hexagonal patch on diagonal or

when the thickness of the circle patch varies between 0.4 mm and

Rectangular, trapezoidal, circular and elliptical

Circle, rectangle, square, ellipse, octagon, oval
10 mm, and the patch width also influences the evolution of SIF

Circle, rectangle, square, ellipse and octagon

[28]. Moreover, it is found that patches perform better when the

Rectangular patch on diagonal or positive

stiffness ratio ranges from 1.0 to 1.6 or the ratio of length to thick-
ness ranges in 80–100 [4]. Fekih et al. [29] stated that the J integral

Rectangular and trapezoidal shape

at the crack tip decreased with the increase of patch thickness but it
became almost independent on the patch thickness when the thick-
ness was greater than 1.2 mm. For the repaired aluminum plate with

“H” and “arrow” shape

Optimized parameters
a size of 152 mm × 152 mm × 2.3 mm, the best performance will
be obtained by the patch with dimensions of 110.44 mm × 77.5 m

positive position
Octagonal shape
Irregular shape
m × 1.69 mm. And Yala et al. found that a minimum stress intensity
factor K helps the patch optimization design of patch [13]. Further-
more, Albedah et al. [10] found that the fatigue life of repaired
plates was significantly reduced with the increase of patch length
because of the existence of secondary bending moment. Investiga-

Aluminum

Aluminum
tions showed that patch length also had significant influence on

composite

composite
Carbon/

Carbon/
the SIF and J integral at the defect and finally affected the life of

Matrix

epoxy

epoxy
Plate

plate

plate
repair materials [30]. Through the content above, it is known that
dimension parameters will influence the properties of repaired struc-

"H" or arrow shapes reduce the SIF and the mass of composite patches while increases the

5% reduction in SIF with the height 2c/3 compared to h = c, 7% reduction in SIF with the

Rectangular patch on positive position improves the ultimate tensile stress by 16.18%, the
The extended octagonal patch shape performs better in the case of mode I and mode II SIF
The rectangular shape is beneficial for repair durability but it presents a disadvantage for
repair efficiency. The elliptical patch is optimal whereas the trapezoidal patch gives high
tures from various aspects.

When the crack length is ranged from 5 to 20 mm (up to 40 mm), the trapezoidal shape
40–60% reduction in SIF with the optimal patch shape, the expected fatigue life can be
It is summarized that inappropriate (too large or too small) values
of dimension parameters, such as length, width and thickness will
reduce the durability and efficiency of patch which are reflected
by variations of SIF and J integral, etc. at the location of defect. Thus,
it is worth selecting the most suitable parameters of patch to improve
the repair performance and the life of composites.

2.1.2. Patch shapes

80% reduction in SCF with the optimum patch dimension.

Patch shape is also one of the important factors which affect the
performance of composites patch repair. The defects repaired with
50% reduction in SIF with the optimal shape patch.

different patch shapes have distinct effects on the repair perfor-

mance due to various degrees of stress concentrations, which are
reflected by the values of SIF. And the patch shapes can affect the
final damage mode and ultimate failure load as well as repair qual-
presents lower SIF at the crack tip.

ity. Thus, the optimization of patch shape is a good way to improve

height of c/3 compared to h = c.

ultimate tensile load by 73.66%.

the repair performance of composites repair. The FEA method is con-
venient to design complicated and irregular patch shapes as well as
shape parameters that can’t easily achieve in the experiment. There-
considerably improved.

fore, researchers are likely to employ it to design and choose the

Main conclusions

repair efficiency.

optimal patch. Brighenti et al. [11,31] combined the genetic algo-

values of SIF.

rithm with FEA method to design the optimum irregular patch

reduction.

shapes which aimed at fracture and fatigue improvements. And

Ramji et al. used a three‐dimensional finite element method to ana-
lyze the effects of different patch shapes (circle, rectangle, square,
ellipse and octagon) on the efficiency of composites patch repair suc-
Inclined
Summary of patch shapes optimization and effects.

cessfully [32]. FEA method has made great contributions to the

Central

Central
Defects

center
Edge/

crack

crack

crack

crack
Edge
Hole

Hole

development of more efficient patches in terms of experimental

research and field application.
In the past decades, patch shapes have been developed from the
fabrication
processes

traditional patch shapes to the extended patch shapes aiming at the

Prepreg
Patch

reduction of cost and the increase of repair efficiency and safety.

Summary of patch shape optimization and effects on repair perfor-
/

mance are shown in Table 2. Many researchers investigated the

with the

Carbon

Carbon

effects of traditional patch shapes such as regular polygon and circle,

Fibers

Boron
Same

plate

fiber

fiber

fiber

the influences of some extended patch shapes such as rectangular,

trapezoidal and elliptical were also investigated. It was found that
an extended octagonal patch shape made of carbon fiber reinforced
tensile tests
algorithm

Quasi-static
and FEA

and FEA

composites (CFRP) with maximum allowable size seemed to be a bet-

methods
Analysis

Genetic

ter choice in the case of repair of the inclined cracked panel [32]. Li
Table 2

FEA

et al. [33] compared the effects of specimens repaired with five dif-
ferent patch shapes through numerical simulation and experimental

5
W. Zhou et al.
Fig. 4. “H” patch shape and arrow patch shape [37].
Fig. 5. Four specific hybridization patterns. (a) Intra-ply hybrid patch, (b) Inter-ply hybrid patch, (c) Composites-metal hybrid patch, (d) Smart patch (the shape
memory alloy embedded between the layers).
study based on the three‐dimensional progressive damage theory.
Results showed that rectangular patches on positive positions exhib-
ited the highest improvement of load‐carrying capability. Kaddouri
et al. [34] found that the octagonal patch could reduce the SIF at
the repaired crack and improve the fatigue life. The height‐width ratio
h/c of patch affects the degree of reduction of SIF. When compared to
the case of h = c, h = c/3 has a better performance about a 7% reduc-
tion of SIF. The parameter h is the height of octagonal patch and the
parameter c is the width of octagonal patch. Meanwhile, it is found
that the rectangular patch is beneficial for repair durability but it isn’t
the optimal choice (the lowest safety‐cost ratio) in some cases. Com-
pared with the rectangular shape patch, composites repaired with
trapezoidal shape patch presented lower SIF at the crack tip when
the edge crack length ranged from 5 mm to 20 mm [35]. In compar-
ison to rectangular and trapezoidal patches, elliptic patch has the best
performance when repairing the central cracked panel, while trape-
6
Composite Structures 263 (2021) 113659
zoidal patch has higher SIF values at the crack tip tends to result in
bonding failure [36]. In addition, some more advanced shapes were
likewise developed for the composites patch repair. Instead of a rect-
angle patch, Rachid et al. [37] designed patches in “H” or arrow shape,
as shown in Fig. 4, to reduce the SIF at the tips of cracks and finally
improve the repair efficiency of patch. The values of SIF increases with
the increase of c/W and h/H, and the values of SIF decreases with the
increase of d/W. Thereinto, the parameters c, h, d, W and H correspond
to the width, height and distance of the “H” shape foot as well as the
width and height of rectangular patch. To improve load‐carrying
capacity, Arikan et al. [38] employed different additional plies to
repair sandwich composites, and four different ways were used: con-
ventional patch repair (CPR), extra fiber‐reinforced repair (PT1), split
fill foam repair (PT2) and internally reinforced repair (PT3). Kashfud-
doja et al. [39] found that the composites repaired with optimum
patch dimension and adhesive thickness could obtain an 80% reduc-
W. Zhou et al. Composite Structures 263 (2021) 113659

tion in SCF. From the above literature, the experiment and simulation

References
results of studies almost correspondingly show that optimizing patch
shapes is a convenient and effective means to improve the efficiency

[44]

[46]
[45]
[47]

[12]

[49]

[48]

[54]

[53]
and durability of repair. Patch shape is an important factor for the
improvement of repair performance. It is necessary and significant to

The intra-ply hybrid patches reduced the impact of energy absorption by 10.17% at a higher impact

The ultimate load of specimen repaired with the intra-ply hybrid patch was 24.53% higher than the

The super hybrid patches with aluminum on the skin had lower absorbed energy at an impact energy

Anchored specimens improve the compressive strength by 25% under non-impacted conditions and
choose appropriate patch shapes for different kinds of defects in the
field of composites patch repair. Finally, the summary of patch shapes

50G 50 K showed the highest retention of load-carrying capability and restored the ultimate

restoring it by 88%, 77%, 29%, and 28% at the impact velocity of 70, 85, 95, and 105 m/s,
optimization and effects on repair performance are listed in Table 2.

2.2. Patch hybridization

Many studies showed that hybrid composites made of kinds of fiber

fabrics have better mechanical properties which have been proved
from the perspective of experiment and micromechanics [40–42].

The reduction factor of SIF was in the order of 91.60% to 87.77%.

The smart composite patches showed better mechanical behavior.

Hence, it is feasible to improve the mechanical properties of patch con-
taining different kinds of fiber fabrics. In recent decades, to improve

50G 50 K presented a more favorable indentation response.

the repair efficiency, carbon, glass and Kevlar fibers patches and their

50G 50 K restored the ultimate tensile load by 84.73%.

comparisons of repair performance are studied besides the boron fiber

of 8 J. It had optimum stiffness and tensile response.

patch [43]. Then, the hybrid patches consisting of many kinds of fibers
are invented with the development of repair technology. Several
hybrid patches were developed to combine the superior properties of
different fibers in a single patch using a logical manner. And some
studies have proved that they have better repair effects for damaged
composites compared with the common patches under different load-

compressive load by 92.17%.

ing conditions. At present, four hybridization patterns: intra‐ply hybrid
patch, inter‐ply hybrid patch, composites‐metal hybrid patch and
smart patch are the primary application forms shows in Fig. 5. In
recent years, patch hybridization schemes and their effects have been
Main conclusions

virgin specimen.
energy of 8 J.
summarized in Table 3.

respectively.
Hybridizations of carbon fiber with glass fiber or Kevlar fiber with
Summary of patch hybridization and effects (C, G, K and M represent carbon fiber, glass fiber, Kevlar fiber and matrix).

glass fiber are usually used to make hybrid patches. Makwana et al.
[44] found that the hybridization of carbon fiber with some amount
of glass fibers would improve the ultimate strain of repaired compos-

notched
Defects

ites. Andrew et al. [45–47] investigated the intra‐ply hybrid patch

Edge-
crack
Edge

Hole

Hole
made of glass and Kevlar fibers, effects of different ratios of these
two fibers on the compression behavior and tensile behavior were ana-
and post-impact tensile

and quasi-static tensile

lyzed. It was found that external patches containing equal volume frac-

Tensile, bending, and

Low-velocity impact

Low-velocity impact

Ballistic impact and

tion of glass and Kevlar fibers presented a more favorable indentation
Analysis methods

compression test

response and ultimate tensile load. In addition, the effects of intra‐ply

Cyclic QSI test

Cyclic QSI test

impact tests
Quasi-static
Tensile test

and inter‐ply hybrid patches on energy absorption and indentation

behavior were studied [48]. Results showed that the stacking sequence
of patch considerably influenced the load‐carrying capability and local
FEA

CAI
test

bending response. Specimens repaired with intra‐ply hybrid patches

showed better impact properties and damage tolerance capability than
Aluminum

Steel plate
composite

composite

composite

composite
that of specimens repaired with other patches [12]. Because hybridiza-
Matrix

Glass/

Glass/

Glass/

Glass/
epoxy

epoxy

epoxy

epoxy
plate

tion patterns strongly restricted the interlaminar delamination at the

interface between parent matrix and external patch, as a result of
the combination of advantages of both glass and Kevlar fibers [49].
Hand layup
fabrication

In addition to the stacking sequence, the orientations of fibers are also

processes

infusion
process
Patch

Resin

an important factor that must be considered. The orientations of par-

ent laminates and patches have significant influences on the residual
/

strength of repaired specimens [50]. The overall strength after repair

M 0.4 vol fraction, C and G

G and K (100/0,75/25,50/

and the failure between laminates layers are dependent on the orien-
(0.45/0.15, 0.3/0.3, 0.15/

tations of the fibers [51]. And the ply sequences of patch influenced
G, K and 50G/50 K

the stresses in adhesive layer, it would be more profitable and efficient

50, 25/75,0/100)

Aluminum and G

when cross‐ply patches were in contact with the adhesive layer [52].
G, K and SMA

Consequently, the orientation of internal layer in contact with the

G and SMA

matrix and adhesive is an important parameter for composites patch

Fibers

0.45)

repair. Proper configurations of patches are beneficial for repair per-

formance improvement in the cases of laminates with different orien-
tations that need to be repaired.
Intra-ply and

In summary, patch orientations and stacking sequences are two

Hybridization

Intra-ply and

Smart patch,

Smart patch
Inter-ply

Inter-ply

main factors that significantly affect the repair performance of patch.

Intra-ply

Inter-ply
patterns

According to different parent materials and loading conditions, the

Table 3

appropriate patch configurations can markedly improve the repair effi-

ciency. However, the composites‐composites hybrid patches cannot

7
W. Zhou et al.
provide enough transfer stiffness under high loads sometimes. Hence,
composites‐metal hybrid patches were developed by some researchers.
Specimens repaired by composites‐metal hybrid patches exhibit better
impact properties and damage tolerance capability than those repaired
with common patches [48]. More advanced, hybrid patches embedded
with shape memory alloy, named smart patches, were studied by Kha-
lili and Verma et al. [53,54]. They found that the composites repaired
with smart patches showed better performances under various
mechanical tests, especially the capacity of energy absorption. More
specifically, the configurations of shape memory alloy (straight wired,
meshed and anchored) embedded inside the patch influenced the
repair performance. It can be seen from the above works of literature
that patch hybridization is a better choice for repair performance
improvement and both the stacking sequence and patch orientation
are considerable factors that can’t be forgotten. And to improve the
repair efficiency of patch, the configurations of patch hybridization
need to be selected according to the different work environments
and mechanical requirements.
2.3. Additive effects
Adding nano‐particles to reinforce mechanical property has been
quickly developed as an effective approach in the field of composites.
However, few works are studied on the addition of nano‐particles to
composites patch. Ahmed et al. [55] made CNT sensing skins based
on a smart patch proposed by Chang and Ihn [56]. The combination
of patch and sensing layer which is made of CNT and nonwoven ara-
mid veil is utilized to realize the crack propagation monitoring owing
to the superior electrical property of CNT [55,57]. However, the effect
of CNT on mechanical properties was not fully discussed in these stud-
ies. Few studies focused on the improvement of repair efficiency of
Fig. 6. Influencing factors of adhesive performance.
8
Composite Structures 263 (2021) 113659
patch by adding nano‐particles. Besides, the addition of nano‐
particle also has been applied in adhesive joints, and more details
can be seen in section 3.3. The application of nano reinforced adhesive
and patch in composites patch repair is still necessary to be studied
systematically and deeply.
3. Effects of adhesive on repair efficiency
Generally, the properties of adhesive play an important role in the
stress transfer and better connection of patch and matrix. In the last
decades, the necessity of optimization of adhesive has been discussed
all the time. Fig. 6 shows some factors that influence the performance
of adhesive. Many researchers have proved that adhesive optimization
is beneficial for the improvement of repair performance. It is a signif-
icant factor that should be considered during the process of composites
patch repair.
3.1. Thickness and shear modulus effects
Although the effects of adhesive on repair performance are lower
than patch, it is also an important influencing factor in the field of
composites patch repair. Typically, the effects of thickness and shear
modulus of adhesive on the repair efficiency are studied by FEA
method [13,25–27]. The high thickness of adhesive results in the early
separation of a patch from parent composites, the low thickness of
adhesive exhibits the poor transfer of load between the patch and
cracked composites. A good adhesive bond can be produced only in
a small range of thickness 0.124–0.249 mm, thus it is important to
optimize the adhesive thickness [4,28]. Besides, the adhesive proper-
ties are significant for the performance of composites patch repair as
well. Compared to general adhesive, the high shear modulus of
W. Zhou et al.
adhesive provides excellent transfer of load, however, it cannot ensure
the connection between these two structures patch and matrix well. To
solve this problem, the effects of different adhesive systems on the
repaired composites are investigated. Fekirini and Bouladjra et al.
[58,59] studied the performances of composites repaired with two dif-
ferent adhesive bands. Two configurations of adhesive (two adhesive
bands with the same shear modulus and different thicknesses or two
adhesive bands with the same thickness and different shear modulus)
were proposed. The results showed that the SIF and energy release rate
at the crack tip were highly reduced by the difference of properties
between two adhesive bands especially the second configuration.
The fracture life of composites repaired with the second configuration
increased compared with other specimens. And the effect of thickness
of adhesive band used on the crack region for SIF and energy release
rate wasn’t significant. Although it costs more time than that of com-
posites repaired with a common single adhesive, it’s safety‐cost ratio
is relatively high. Safety is more important than cost especially in
the aerospace field which needs higher security. During the repair pro-
cess, the selection of different adhesive is a considerable factor.
3.2. Hygrothermal aging and debonding effects
In addition to thickness and shear modulus, some factors such as
debonding, aging and humidity absorption of adhesive also affect
the repair performance of composites patch repair. The damage of
adhesive will affect the transfer of load and reduce the efficiency
and durability of composites patch repair [60]. It happens when the
ratio of the damage zone/adhesive zone exceeds the value of 0.22.
Then debonding occurs between the patch and parent composites as
a result of damage development. Noteworthy, the debonding of patch
and adhesive is the main factor that results in the reduction of carrying
capacity. Aggelopoulos et al. [61] considered two debonding condi-
tions (patch end debonding and crack mouth debonding) on the per-
formance of repaired composites. They found that the debonding
length significantly corresponded to the values of stress magnification
factor Y (up to 60% of patch length) and strain energy release rate G at
the crack tip. Bouiadjra and Albedah et al. [62,63] stated that the
propagation of adhesive disband vertically to the crack had enormous
negative effects on the repair efficiency. It was found that the fatigue
load and the thermal residual stresses due to the curing process of
adhesive are two main reasons which result in the adhesive disbond
[63]. Furthermore, the repair efficiency of patch is related to disbond
width [64]. And the degree of reduction of SIF increases with the
increase of patch thickness when the disbond width higher than crack
length, by a contrary, an opposite behavior will occur when the crack
length higher than disbond width. Moreover, the location of debond-
ing is an influencing factor too. For the debonding defects, researchers
tried to use NDT technologies (AE, DIC and IRT) to conduct a further
study. It is presented and discussed clearly in Section 5. In addition to
the debonding, hygrothermal aging of adhesive is also a factor affect-
ing the repair efficiency. Because moisture increases the plasticity of
adhesive and reduces the stiffness [8]. And the efficiency and durabil-
ity of composites patch repair are highly affected by the humidity
absorption of adhesive because it increases the SIF and J integral at
the tip of repaired cracks [65,66]. Moreover, hygrothermal aging of
the adhesive has a significant effect on the load transfer, then causes
a rapid crack propagation and reduction of fatigue life [67,68]. Hence,
it is important to prevent humidity absorption of adhesive during the
using and curing process. However, it is also challenging to solve this
problem for repaired composites due to the effects of servicing envi-
ronment, weather and other reasons.
3.3. Additive effects
Previous work had shown the influences of thickness, shear modu-
lus, debonding and humidity absorption on the repair efficiency of
9
Composite Structures 263 (2021) 113659
composites patch repair. In recent decades, the polymer composites
reinforced with nano‐particles were quickly developed as a promising
approach in the field of composites. Many researchers were encour-
aged to enhance the mechanical properties of composites by adding
several nano‐additive such as carbon nanotubes (CNT), graphene, sil-
ica nanofillers and ZnO whiskers, etc. As a result, the stiffness and frac-
ture toughness of epoxy composites are improved by adding a certain
amount of carbon nanotubes [69–71]. For nano reinforced composites,
hybrid and hierarchical nano reinforced polymer composites are two
main means for fatigue performance improvement, and the second
way can better increase the fatigue life of composites. In addition,
the CNTs also have been embedded in fibers within composites for
structural health monitoring because of their superior electrical prop-
erties [72,73]. Similarly, the composites reinforced with graphene and
silica nanofillers are studied by researchers as well [74–76]. The
results showed that the mechanical properties of composites adding
graphene and silica nanofillers better than that of original composites.
However, previous works only studied the nano reinforced polymer
composites, but few works of nano‐particle reinforced adhesive or
patch had been done in the field of composites patch repair. Thereinto,
it was found that the fracture toughness and shear properties improve-
ments after repair were owed to the nano‐structuring (CNT) within the
toughened resin system [77]. Charles et al. [78] pointed out that the
toughened resin system with carbon triblock copolymer could be used
for the repair of composites. And the adhesive adding CNT was
employed to make a good connection effect of adhesive joints and
composites. Besides, ZnO whiskers were firstly added in the adhesive
to improve repair quality by Wang et al. [79]. It stated that the glass
fiber epoxy composites repaired by common patch and adhesive
embedded with ZnO whiskers had higher failure load and matrix
strength by using AE and DIC. ZnO whiskers collaborate with resin
matrix to resist external loads, there is thus, the stiffness and resistance
ability to deformation of repaired composites are improved. It shows
the possibility of application of nanoreinforced adhesive for the com-
posites patch repair. The repair efficiency of patch was indeed
improved. Presently, most studies about nano‐particle reinforced
adhesive are mainly focused on the adhesive joints in the field of com-
posites repair. Researchers aimed to improve the performance of adhe-
sive joints by adding some nano‐particles. Micro‐CT becomes a
contributory tool in the investigations of these studies. For observing
the micro performance of nano‐particle reinforced adhesive, the pro-
portion and disperstiveness of CNT and graphene in adhesive joints
as well the effects of pores can be investigated by micro‐CT. But, there
are few works using micro‐CT technology in the field of composites
patch repair, it is noteworthy and promising based on lots of works
about nano reinforced polymer composites and adhesive joints. More-
over, it is significant for applying nano‐particle in the application of
composites patch repair.
4. Improvements of repair methods
4.1. Several crack stop methods
Cracks are the most common and severe defects that may cause
property damage and casualties during the service life of composites.
Thus, in the last few decades, crack stop methods such as stop‐
drilled holes, overload peaks, bolt clamping and indentation method
were studied in the materials field. Wu and FU et al. [80,81] found
that the stop‐hole method influenced the crack propagation and fati-
gue life of cracked structures. Drilling a hole at or close to the crack
tip resulted in the reduction of stress concentration [82]. In addition,
the effects of flank holes and additional holes were studied by FU and
Murdani et al. [81,82], Fanni et al. [83] even considered the stop hole
shape on the performance of crack inhibition. Furthermore, other
crack stop methods are investigated too. The impact indentation tech-
nique could replace the drilling hole method to prevent crack propaga-
W. Zhou et al.
tion under some specific conditions [84]. Moreover, Dai et al. [85]
found that loading variables (load ratio, overload extent and overload
number) had influences on the overload retardation of crack. The over-
loading slowed down fatigue crack growth in an overload ratio but the
underloading had no significant effects on crack growth rate [86,87].
Albedah et al. [14] studied the repair performance of cracked plates at
two stress ratios: R = 0 and R = 0.1. Increasing the fatigue load
amplitude after patch repair successfully stops a certain extent of crack
retardation. However, some harmful phenomena may occur after using
these crack stop methods, thereby influencing the repair performance.
Thus, some improvement methods are developed according to the
block diagram process shown in Fig. 7 based on these crack stop meth-
ods and composites patch repair technology. Summary of repaired
methods optimization and effects are shown in Table 4.
4.2. Double-bonded patch repair and hybrid repair methods
Composites patch repair is a basic method to restore the properties
of cracked materials. It is divided into two means, single‐bonded patch
repair and double‐bonded patch repair. And many studies have shown
that double‐bonded repair has better performance on crack repair
compared with the single‐bonded repair. Numerical analysis results
showed that the SIF of composites repaired with double patch reduced
distinctly compared to single patch [88]. And it has better perfor-
mance of the gain of patch thickness in mode I and mixed‐mode. How-
ever, the mechanical and geometrical properties of adhesive can affect
the mass gain of a double patch, optimizing these properties can
improve the repair performance indirectly [89,90]. Moreover,
Meriem‐Benziane et al. [91] found that the pipeline repaired with a
double‐bonded patch extremely increased the repair performances
for a common crack which length ranged from 10 mm to 20 mm.
Niu et al. [92] confirmed that the adhesive interface stiffness (R)
and the ratio of patch stiffness/plate stiffness (S) could be designed
for the better fracture load of cracked metallic plate repaired with
double‐bonded patch by Line Spring Model. Thus, compared to the
Fig. 7. Block diagram of repair methods improvement.
10
Composite Structures 263 (2021) 113659
single‐bonded repair, double‐bonded patch repair technology should
be considered for preferable repair performance if the repair condi-
tions permit. Additionally, based on composites patch repair and
crack‐stop methods, hybrid repair technology (the combination of
two repair methods) was developed by researchers. Bouzitouna et al.
[9] studied the effects of the location of drilling holes on the notch
stress intensity factor and plastic zone sizes combined with composites
patch repair. The results showed that drilling a hole at the point of
crack could increase the service life of composites visibly. Hybrid
repair method (a combination with stop hole and composites patch)
showed better performance than other configurations. Furthermore,
Maleki et al. [93] combined composites patch and bolt clamping as
a hybrid method to repair cracked structures. This hybrid method
had better performance on the crack repair in mode I, mode II and
mix modes, but the bolt clamping method showed a better perfor-
mance compared to mere composites patch in pure mode II.
Mohammed et al. [94] investigated the effects of overload peaks on
the retardation in crack growth for composites patch repair. It showed
that combining the two technologies better increased the fatigue life of
repaired specimens compared to applying mere overload peaks, and
overload peaks applied before the composites patch repair had a more
favorable performance on fatigue life. From the above results of liter-
ature, three hybrid methods shown in Fig. 8 are effect on the repair
performance improvement. A good bond of several crack‐preventing
technologies performs well for composites repair. To increase the
repair efficiency, it is necessary to consider and design some more pro-
gressive hybrid repair methods.
5. Non-destructive testing on composites patch repair
To obtain the repair efficiency of composites patch, it is essential to
know the damage mechanisms of repaired composites. Thus, various
characterization techniques have been used to improve the under-
standing of the damage evolution in patch and adhesive layer. There-
into, NDT technologies are frequently utilized to help analyze damage
W. Zhou et al. Composite Structures 263 (2021) 113659

Table 4
Summary of repaired methods optimization and effects.

Repair methods improvement Analysis methods Study objects Main conclusions References

Double-bonded patch repair
Composites patch repair and
crack-stop methods
Composite patch repair and
bolt clamping
Composite patch repair and
overload peaks
FEA SIF A considerable reduction of SIF at the crack tip. [25,88,89,91,92]
FEA and tensile test SIF and peel stress The COD parameter, the size of the plasticized zone and maximum peel [9]
stress are reduced.
FEA and fatigue test Retardation cycles Retards the crack growth,Applied OL first has a higher retardation cycle [93]
number number.
FEA, fatigue test and SIF and geometry/ 49% increase in tensile strength under the pure tensile mode,28% increase [94]
tensile test loading factor in fracture strength under pure shear mode.

modes of composites because of the advantages of real‐time and no‐
contact capabilities. In the field of composites repair, several NDT
methods such as AE, DIC, IRT, scanning electron microscope (SEM),
X‐ray radiography, Ultrasonic C‐scanning, Ultrasonic guided waves
(Lamb waves), etc. are always used for damage monitoring and analy-
sis. Researchers evaluate the repair efficiency of patch and design the
optimal patch for different damage types by the results of these NDT
technologies. In this section, the applications of NDT technologies on
the design and optimization of composites patch are reviewed as a pro-
cess which is shown in Fig. 9. The advantages and functions of four
commonly used nondestructive testing methods on composites patch
repair are summarized, and the promising research direction about
micro‐CT on the bonded failure between patch and parent composites
is tried to propose.
5.1. AE monitoring
The status of AE technology in fiber‐reinforced composites is signif-
icantly important based on detecting stress waves. Hence, the analysis
of damage mechanisms for composites is frequently realized by this
technology. Fig. 10 shows the schematic diagram and workflow dia-
gram of classical AE detection. Due to the ability of damage identifica-
tion of AE technology, subsurface damage modes in composites such as
matrix‐cracking, fiber/matrix debonding, fiber‐breakage and delami-
nation can be divided with the AE signals frequency or amplitude by
clustering analysis [95]. Besides, other AE parameters, such as AE
hit rate, amplitude, energy and duration have been applied to the
study of various damage modes. Moreover, AE technology is also
employed in the estimation of repair efficiency of patch in the field
of composites patch repair. The AE signals of composites repaired with
different patches size, thickness and shape are different, and the opti-
mal parameters can be selected through the analysis of these signals. In
this part, the effects of AE on the patch parameters optimization are
summarized according to the former literature.
AE technology is found to have the capacities of damage modes res-
olution and parameter optimization. Lots of work about damage
modes identification based on the AE signals frequency and amplitude
have been done. Thereinto, the AE characteristics of repaired speci-
mens were divided into various fracture processes such as resin crack-
ing, Al cracking, fiber breakage and delamination between patch fiber
and aluminum plate by Gu et al. [96]. They thought that the damage
process of repaired composites could be divided into four stages:
matrix cracking, debonding, delamination and fiber breakage
[96,97]. Most classifications of damage processes are almost the same.
The detailed damage modes identification based on the AE signals are
summarized in Table 5. For the parameter optimization, different peak
frequency distributions and amplitude characteristics as well the signal
waveforms can help researchers to choose the appropriate value for

Fig. 8. Several repair methods. (a) Composites patch repair, (b) Composites repair with opening holes, (c) Composites repair with bolt clamping, (d) Composites
repair with overload peaks.

11
W. Zhou et al. Composite Structures 263 (2021) 113659

Fig. 9. Application of NDT technologies on the composites patch repair.

Fig. 10. Schematic diagram and workflow diagram of acoustic emission detection.

12
 Table 5

W. Zhou et al.
Summary of damage identification and monitoring based on AE characteristic signals.

Combining AE characteristic signals Signal processing Damage identification and monitoring (frequency, energy, amplitude and duration range) Major functions References
methods

SEM, ultrasonic AE energy rate, hit rate, peak Characteristic parameters, Resin cracking (110–270 kHz), Al cracking (120–270 kHz), delamination (140–260 kHz), fiber Patch thickness optimization [96]
C- frequency, amplitude signal waveforms, and breakage (>270 kHz),
scanImaging clustering analysis
and FEA
Ultrasonic A-scan Peak frequency, cumulative Characteristic parameters and Matrix cracking (85–135 kHz), debonding (135–180 kHz), delamination (180–250 kHz), fiber Evaluate the repair quality of [97]
counts, amplitude and duration, clustering analysis fracture (250–300 kHz). two repair methods
events location
SEM Cumulative AE energy, peak Characteristic parameters and Al cracking (AE signals with the energy less than 8 aJ), adhesive layer failure (AE signals with the Patch thickness and layup [98]
frequency clustering analysis energy higher than 8 aJ). optimization
/ AE cumulative counts, amplitude Characteristic parameters and Matrix or resin cracking (45–61 dB), fiber/matrix debonding (62–78 dB), fiber micro-buckling Evaluate the effects of various [47]
and duration, event location K-means ++ cluster analysis (79–100 dB). patch hybridization and stacking
versus time sequences
Peak frequency and time Characteristic parameters and Matrix cracking (114–120 kHz), debonding (137–145 kHz), delamination (160–170 kHz), fiber Evaluate the efficiency of the [99]
K-means ++ cluster analysis micro breakage (249–254 kHz). repair procedure
DIC Amplitude and duration Characteristic parameters and Matrix or resin cracking (45–56 dB), fiber/matrix debonding (56–72 dB), fiber micro-buckling Evaluate the repair efficiency of [100]
K-means ++ cluster analysis (69–100 dB). three filling materials
Neural network AE events, amplitude and Characteristic parameters and The crack propagation signals can be differentiated from signals due to matrix cracking, fiber Monitor the crack initiation and [101]
frequency AE waveforms analysis, FFT breakage, and shear of composites patch. propagation, predict the crack
length
EPCM and LT Cumulative AE events and Characteristic parameters The onset of damage marked (Stage I) – the increase in damage rate marked (Stage II) (40% of Monitor the debonding process [57]
techniques duration fatigue lifetime), the increase in damage rate marked (Stage II) - accelerates until failure (Stage
III) (60% of fatigue lifetime).
/ AE cumulative counts, AE event Characteristic parameters and Matrix or resin cracking (45–61 dB; 0–561 μs), fiber/matrix debonding (58–78 dB; 0–5940μs), Evaluate the effects of various [45]
location and time, amplitude and K-means ++ cluster analysis fiber micro-buckling (78–100 dB;983–10420 μs). patch hybridization and stacking
duration sequences
13

AE cumulative counts, AE event
location and time, amplitude and
duration
DIC and SEM AE relative energy and time,
cumulative hits, amplitude
Characteristic parameters and
K-means ++ cluster analysis
Characteristic parameters and
K-means ++ cluster analysis
Matrix or resin failure (short duration and low amplitude), fiber/matrix debonding/delamination Evaluate the effects of various [46,49]
(low to moderate amplitude and short to medium duration), fiber breakage (high amplitude and patch hybridization patterns
duration).
Identify failure mode such as matrix cracking and delamination damage between patch and Evaluate the repair efficiency of [79]
motherboard during the process of fracture failure. different types of adhesive

Composite Structures 263 (2021) 113659

W. Zhou et al.
repair performance improvements in the case of specimens repaired
with patches having various conditions. Asokan et al. [97] evaluated
repair quality obtained from composites repaired with different repair
methods under different impact loads by AE. The AE characteristic sig-
nals of scarf‐repaired composite laminates at different depths (repair
length 50 mm) and lap‐repaired composite laminates at different
lengths were analyzed. The results helped understand which failure
mode was primary in each case and possibly proposed the most advan-
tageous repair method for composites. Maleki et al. [98] monitored
the effects of thickness and layup of patches on the failure behavior
by the AE. It was found that the AE signals of aluminum cracking
and adhesive layer failure could be accurately distinguished, then
the point of patch separation from repaired specimens would be pre-
dicted. Subsequently, it can evaluate the repair efficiency of each kind
of patch and choose the optimal one for different repaired materials.
Andrew et al. [45–47,49] studied the repair properties of hybrid
patches made of different fibers on the tensile and compression behav-
ior by AE. Different stacking sequences and patch orientations corre-
sponded to different characteristic signals. Through the
differentiation of AE signals, it can obtain the optimal patch configura-
tion, patch orientation and adhesive thickness for the highest repair
efficiency and superior properties. In addition, the repair perfor-
mances of three repair materials consisting of an epoxy matrix rein-
forced with micro‐sized particulate fibers, chopped short fibers and
continuous fibers were studied [99,100]. The AE signals of different
damage modes were distinct; it was following the variation of stress
waves generated by different repair systems. The specimens repaired
with chopped short fibers showed a better effect on the stress transfer
and the inhibition of crack growth. In the previous work of AE technol-
ogy, the parameters such as patch thickness, length, size and repair
methods as well as the adhesive thickness and shear modulus are
investigated through the analysis of AE signals. By contrast from differ-
ent AE signals, the optimum parameters can be selected and the opti-
mization patch can be designed. It is an interesting research direction
that is worthy of further study.
As a useful NDT technology, AE technology has influences on mon-
itoring the debonding process and predicting the propagation of crack
in real‐time [101]. Even, it shows a better effect in combination with
other technologies, such as IRT and DIC technologies [57,79,100]. The
AE characteristic signals can be well correlated with the results
acquired from other technologies. Then it can better explain the failure
mechanism of materials by combining the advantages of several NDT
technologies. In the previous work of this paper, the influencing fac-
tors of repair performance about patch are summarized from patch
geometry, hybridization and additive. It is found that parameters
affecting the repair efficiency of patch can be significantly analyzed
and studied by AE. And the literature [96–98] allows researchers to
understand the role of AE technology in monitoring and evaluating
the repair efficiency of patches. Summarizing, the influencing factors
can easily be analyzed with the help of AE technology, then the opti-
mum configuration of patch will obtain. However, it is sensitive to the
test environment that may produce lots of noise. The study of AE tech-
nology on the composites patch repair is still incomplete, in particular,
the adhesive adding nano‐particles is also a promising approach in the
field of composites patch repair [79]. Furthermore, nano reinforced
patches as well the combination with AE technology and micro‐CT
on the analysis of bonded failure also need to have further study.
5.2. DIC measurement
The DIC technology was first recommended to the experimental
mechanics by Peters et al. in the 1980s [102]. It is used for acquiring
both the global and local full‐field strain, owing to obtaining the lon-
gitudinal, peel, and shear strain distribution over the composites layer
[103]. Two‐dimensional (2D) and three‐dimensional (3D) DIC are the
main application forms for measuring surface displacement and strain
14
Composite Structures 263 (2021) 113659
field of composites [104]. With the rapid development of bonded
patch repair technology, DIC technology is gradually employed for bet-
ter repair assessment and damage monitoring except for the AE tech-
nology. Observing the strain distribution over the adhesive layer
between patch and parent composites during loading tests, corre-
spondingly, damage status of repaired composites can be accurately
obtained. The schematic diagram of DIC is shown in Fig. 11.
As a full‐field and non‐contact technique, DIC technology has been
applied in the previous work to evaluate and monitor the damage pro-
cess in laminated composites and adhesive layer, but few works are
studied on the evolution and analysis of patch. Limited studies are
focusing on the performance of repaired configurations of patch. Com-
monly, DIC technology assesses the repair efficiency of patch by the
variations of strain and displacement obtained from repaired areas.
Make a comparison between these different repaired specimens, then,
the best configuration will be decided. Bhatia et al. [50,51] studied the
effects of influencing parameters stacking sequence and fiber orienta-
tion on repair efficiency by DIC technology and FEA method. Through
the observation of strain and displacement within the different patch
configurations, the best one for repair performance can be distin-
guished under different loading conditions. Except for the stacking
sequence, other influencing factors such as dimension, shape and
hybridization also can be analyzed by DIC. At present, the application
of DIC technology is still concentrated on damage detection and mon-
itoring. Caminero et al. [104] successfully used the DIC technology
and Lamb waves to detect surface strain and damage evolution in com-
posites patch repair. It showed preferable detecting results. Further-
more, damage monitoring and repair performance of bonded patches
under loading were investigated by using two‐dimensional (2D) and
three‐dimensional (3D) DIC full‐field strain measurements [105].
The results of DIC full‐field strain measurements were in good agree-
ment with the analytical results. They also assessed the performance
of both bonded repair methods (external patch repair and scarf repair)
applied to CFRP composite laminates under uniaxial tensile loading in
combination with different monitoring technologies (DIC, C‐scanning
and X‐rays) [106]. C‐scanning and X‐rays technologies helped identify
the damage in patch for a better performance assessment. Kashfuddoja
et al. [107,108] presented an experimental study method that includes
whole‐field strain analysis of damaged CFRP laminates and external
patch repaired (both single‐ and double‐sided) CFRP laminates by
using 3D‐DIC technology. Moreover, the 3D finite‐element‐based pro-
gressive damage model showed a considerably good agreement with
the experimental results that acquiring from DIC technology for CFRP
laminates repaired with both single‐ and double‐bonded external
patch [109]. Almost the results of experimental and numerical analysis
showed consistency with DIC results. Hence, the DIC technology is
revealed to be an efficient, successful and simple means to study dam-
age in composites patch repair. The present work has shown that the
DIC technology is maturely used on the damage monitoring and assess-
ment. However, most studies analyzed the repair performance of
repair methods (single and double external patch repair and scarf
repair) by DIC technology, the further study of other influencing
parameters should be more investigated.
However, employing single DIC technology cannot accurately
obtain the complex damage modes due to certain limitations some-
times. Consequently, researchers always use DIC technology in combi-
nation with other technologies such as X‐ray radiography [105,106],
Lamb waves [104,105], and Magnified optics [106,108], etc. In com-
bination with several NDT technologies or numerical analysis meth-
ods, the characteristics of failure modes and failure mechanisms can
be analyzed more accurately. For example, owing to a challenge to
accurately identify internal damage in the form of resin cracking,
fiber/matrix interface failure, delamination and fiber micro buckling
by DIC technology, there is thus, the AE technology is frequently com-
bined with it to solve this problem aiming at analyzing the damage
modes. Wang et al. [79] used AE and DIC technologies to investigate
W. Zhou et al. Composite Structures 263 (2021) 113659

Fig.11. Typical schematic diagram of DIC.

Table 6
Summary of the effects of DIC technology on composites patch repair.

Rationale Measuring surface displacement and global and local-strain field of repaired
structures
Objects Combining methods Purposes References

The repair effects of two methods (external bonded patches and scarf repair). FEA, ultrasonic C-scanning and Damage detection, [106]
X-ray radiographs monitoring and assessment
The damage process of (open hole) specimens under uniaxial tensile loading. X-ray radiographs [105]
Damage initiation and propagation and patch debonding in repaired panel by single/double-side FEA [107,108]
repair.
Critical strain field in thin adhesive layer of double-side (symmetrical) patch-repaired carbon fiber FEA [109]
reinforced polymer composite panel under tensile load.
The performance of repaired composites with different types of adhesive. AE and SEM Repair efficiency evaluation [79]
The performance of repaired composites with three filling materials. AE [100]

the failure behavior of glass fiber epoxy composites repaired by patch
and adhesive embedded with ZnO whiskers. The results showed that
the adhesive added ZnO whiskers perform better performance and
the AE signals have corresponded to the field strain acquired from
DIC technology. The real‐time monitoring of damage modes was real-
ized successfully. Andrew et al. [100] utilized AE and DIC technologies
to study the effects of different types of fiber reinforcements on resid-
ual compression properties of repaired glass/epoxy composite lami-
nates, and the qualitative and quantitative evaluations of damage
progression were developed. DIC technology is a flexible NDT technol-
ogy, various NDT technologies including IRT thermography and
micro‐CT also can be used together except the AE technology. To
obtain the optimal patch, the application of DIC technology in combi-
nation with some NDT technologies need to be developed for acquir-
ing the accurate damage and failure modes of patches. Through the
variations of global and local strain of patch, repair parameters can
be analyzed. By selecting the optimal parameters, the repair perfor-
mance of patch is improved and the optimization patch is designed.
The application of DIC technology on the composites patch repair
are summarized in Table 6.
5.3. IRT technology
The purpose of thermography method is to catch the real‐time tran-
sient thermal images of composites by thermal waves generated from
input heat energy or own heat energy [110]. The schematic diagram of
IRT technology is shown in Fig. 12. It can be divided into active ther-
mography and passive thermography. Thereinto, the transient and
lock‐in thermography using a halogen lamp thermal wave source are
two leading non‐contact thermal NDT technologies in the field of com-
posites which belong to active thermography. Thermography enables
the whole area of composites to be detected, and the subsurface dam-
age can be quantified in terms of depth and size [111]. Hence, it is
widely used in damage detection of composite structures. Moreover,
it can be employed to inspect and identify the damage of composites
patches which has been proved by researchers. Nonetheless, the suc-

15
W. Zhou et al. Composite Structures 263 (2021) 113659

Fig.12. Typical schematic diagram of IRT.

Table 7
Summary of the effects of IRT on damage detection.

Rationale Capturing the real-time transient thermal images of the composites by thermal waves

Advantages Quantitative measurements, time-saving and large area monitoring

Inspectability of defects Using technologies Influencing factors References

Crack, fatigue damage TT Defect depth and size [112]

Subsurface features and defects
Disbond
Disbond and delamination
Delamination and disbond
Edge debonding
Edge debonding
Fatigue damage (debonding)
Wrinkles, porosity, weak bond
areas and disbonds
Delamination and disbond
TT and PPT [113]
PT, PPT, TSR, ultrasonic pulse-echo c-scan The repair geometry and variations in its thermal properties [115]
Step heating thermography, PCA, TSR, PPT Post-process technique [116]
Step heating thermography, FEM. The variation in dimension and depth of defects [117]
Thermography technique, FEM A thin air layer (air gap) between the aluminum and the epoxy resin adhesive [118]
and some small debonding defects
Step heating thermography, FEM The edge effect [6]
LT / [119]
IRT, TSR [120]
Thermography technique, UT C-scan, The inspection of multilayers structures [121]
image fusion algorithms

cess of thermography is highly dependent on defect depth, size, etc.
and it shows less sensitivity to subsurface defects in thicker laminates.
Table 7 summarized the abilities of IRT technology on damage detec-
tion and some subsistent limitations.
Lots of work have been done for disbond growth monitoring of
composites repair with non‐destructive evaluation (NDE) technolo-
gies. Avdelidis et al. [112,113] had proved that it’s efficient to detect
various defects of aircraft repaired with composites patches that con-
sisting of different plies carbon or boron fibers by using thermography.
The separation and the loss of load‐bearing capability of composites
patch will lead to a reduction of fatigue life or even an earlier disas-
trous failure of repaired structures. Haj‐Ali et al. [114] studied the
damage initiation and progression of adhesive by a full‐field thermoe-
lastic stress analysis infrared method successfully. Genest et al. [115]
proposed an infrared NDE technology (Pulsed phase thermography
(PPT) in combination with thermographic signal reconstruction
(TSR)) which could be used for the detection of disbond as well as
the monitoring of disbond growth in composites patch repair. They
found that the changes of repair geometry and adhesive or patch thick-
ness would fatally result in some variations in the thermal images that
could be misinterpreted by the untrained person. Daryabor et al. [116]
compared the effectiveness of three common post‐processing technolo-
gies of thermography (principal component analysis (PCA), pulse
phase thermography (PPT) and thermal signal reconstruction (TSR))
on defect detecting of delamination of various sizes and locations as
well as some disbond. The results showed that the TSR exhibited a
more accurate size of defect than other two processing methods. Addi-
tionally, the effects of defect modes (delamination and disbond) and
the detection ability of defect size and depth in the test using step heat-
ing thermography were evaluated [117]. It was shown that the varia-
tion of defect size and depth near the surface led to the significant
change of temperature peak. The changes in each parameter (dimen-
sion or depth) resulted in a smaller variation in temperature as the
defect depths exceeded 1 mm. It is a remarkable fact that the efficiency
of thermography inspection can be affected due to a thin air layer
embedded between matrix and adhesive in the case of real debonding

16
W. Zhou et al.
detection. Hence, Moradi et al. [118] studied the effect of air gaps for
the simulation of debonding defect at the edge of composite patch
under thermography inspection. They proposed that using the polyur-
ethane sheet instead of Teflon sheet could obtain more realistic simu-
lation of debonding defect within composites patch. Besides, the
disbond at the edge of composites patch was also investigated using
step heating thermography method by Moradi et al. [6]. The three
dimensional wavelet transform was firstly used to optimize the results
in terms of the ratio of signal to noise and time processing, it exhibited
the major advantage for enhancement of infrared images. Further-
more, Grammatikos et al. [119] stated that the lock‐in thermography
(LT) could provide qualitative and quantitative information about
the patch repair efficiency and debonding monitoring process under
the fatigue loading. Consequently, IRT technology is an effective
way of debonding detection.
In addition to disbond, the wrinkles and porosity of patches can be
identified by infrared thermography as well [120]. However, due to
the variations of defect depth, size [112,113] and repair geometry
[115] as well as the effects of adhesive or patch thickness [115] and
edge effects [6], some probable missing small debonding defects
[118], thus it shows some limitations of thermography testing.
Whereas, different NDT technologies can be used to overcome these
limitations by combining the advantages of each inspection technol-
ogy. The combination of AE technology and thermography realized a
better real‐time debonding monitoring of composite repaired materials
[57], the combination of ultrasonic testing (UT) C‐scan and thermog-
raphy remarkably improved the precision of defect characterization
and the reliability of inspection results [121]. Currently, there are
few works of studying the influencing factors mentioned above on
the repair efficiency by using IRT technology in the field of composites
patch repair. Whereas the advantages of time‐saving and large area
monitoring, it will make a large contribution to the repair improve-
ments of composites patch. For the IRT technology, the ability of crack,
delamination and disbond monitoring has been proved. However,
most studies utilize the Teflon sheet that is put in the adhesive layer
in advance as a delamination or disbond defect. It has several uncer-
tain influencing factors for the observation of real defect extension
in a good bond condition. In addition, the fiber reinforced composites
repaired with patches have more complicated damage modes such as
the fiber pull out and fiber breakage compared to the repaired metal
matrix. The existence of fibers makes the delamination or disbond
within repaired composites more complex that cannot be observed
easily and clearly. Thus, it is necessary to integrate other NDT tech-
nologies for the better damage monitoring.
5.4. Micro-CT observation
In the past few decades, micro‐CT technology has become a com-
mon method due to its ability to identify the occurrence/evolution
and distribution characteristics of internal damage in composites.
Micro‐CT technology provides the means for acquiring the 3D images
of specimens in a non‐destructive way and achieving the visualization
of interior progressive damage [122]. And researchers have investi-
gated the effects of influencing factors such as fiber orientation, delam-
ination, debonding, water aging, cracks and pores on the mesoscopic
and microstructure characteristics of composites. The effects of various
processing parameters of cure procedures on the generation of the
voids within composites can be analyzed through the use of micro‐
CT, FEM and CFD software [123]. It makes a great contribution to
the analysis of the interior structure. However, in the field of compos-
ites patch repair, there are few works of micro‐CT for analyzing com-
posites patch especially the failure modes of adhesive between patch
and parent composites. Thus, it is a crucial and promising issue in
the existence of composites patch repair.
In the previous works, in contrast to the micro‐CT technology,
researchers frequently studied the damage mechanism and influencing
17
Composite Structures 263 (2021) 113659
factors of patch by SEM [53,79,80,93,94]. Through a combination
with several NDT technologies, such as AE, DIC or IRT, it provides
more accurate detection and evaluation results of internal damage ini-
tiation/extension. In addition, X‐ray radiograph is also employed to
improve the accuracy of defect detection and damage mode identifica-
tion [33,105,106]. For instance, Li et al. [33] studied the effects of
patch shapes on the repair performance of specimens by FEA and X‐
ray radiographs aiming at selecting the best patch. Generally, for the
adhesive joints, the microstructure characteristics of composites and
3D visualization of internal damage can be obtained with micro‐CT.
Dumont et al. [124,125] studied the effect of the applied load on the
numbers of pores or their volumetric ratio inside the joint by in‐situ
X‐ray microtomography. The results showed that the damage was
caused by the increase in the size of existing pores or the generation
of new voids, while the cohesion of these pores/voids resulted in the
bonded failure. The application of mechanical stress on the adhesive
bonds had a significant influence on the pores, there is thus, the coa-
lescence phenomena (an abrupt decrease in the number of pores)
would be triggered once certain stress was reached. Then it resulted
in the occurrence of adhesive failure. Zhang et al. [126] studied the
static compressive mechanical behaviors of CFRP single‐lap bolted
joints. It was found that the squeezing damage of composite holes
increased bearing failure, the delamination and valleys were the main
failure mechanisms of squeezing damage regions. The micro‐CT tech-
nology significantly expanded the ability to characterize the compres-
sive damage of CFRP single‐lap bolted joints. However, literature
[124–126] focused on the failure analysis of adhesive joints, barely
studies on the composites patch repair had done. Besides, it was found
that the accuracy of evaluation of barely visible impact damage could
be improved by a combination of UT and micro‐CT methods [127]. For
the composites patch, impact damage is also an important factor that
results in bonded failure [128]. The precise recognition of impact dam-
age is beneficial for the better estimation of repair performance. And
Wingham et al. [129] stated that micro‐CT could characterize porosity
and the dispersion of additives in the Laser Sintering specimens. For
the damaged composites repaired with composites patch assisted with
a laser ablation process, the effects of the laser ablation process on the
repair quality can be studied by micro‐CT as well [130,131]. Besides,
Sabuncuoglu et al. [132] found that the vascular channels caused an
adverse effect in the fibers around the channel region using micro‐
CT. It reduced the local stiffness by up to 19%. In the field of compos-
ites patch repair, the smart patch embedded SMA had shown better
performance compared to common patches. However, the effects of
SMA on the disturbance of local stiffness within composites patch
are still not studied. It is possible to realize the understanding of the
influencing process by micro‐CT. The previous work had shown a
potential ability of the 3D visualization of damage using in the field
of composites patch repair. It has absolute reliability for the study of
damage between patch and parent materials. Moreover, this technol-
ogy also can use to study the effects of different sizes, thicknesses,
shapes and braided fibers, etc. on the composites patch repair. Even,
in combination with micro‐CT and other NDT technologies can make
the failure mode and damage detecting/evaluation more accurate.
Therefore, it is of great significance to develop a detecting technology
that integrates the AE technology or other technologies with micro‐CT
to study the interface damage of adhesive.
6. Conclusions and future prospects
Although the composites patch repair technology is globally
employed at a high rate, it is also essential to develop more efficient
repair technologies by contrast to commonly composites patch repair
(traditional patch shape, materials and layup way). First, this paper
has attempted to have a comprehensive review of three key groups,
specifically, patch optimization, adhesive effects and repair methods
W. Zhou et al.
improvements. It presents an in‐depth understanding of the methods,
which can improve the repair performance of composites patch. The
results of these improvement methods showed an obvious increase
in repair efficiency. Optimizing patch, adhesive and repair methods
are the most direct and effective way to obtain better repair quality.
Finally, the application progress of NDT technologies on the repair
improvements of composites patch is reviewed. Various characteriza-
tion technologies (AE, DIC, IRT and micro‐CT, etc.) were used to
obtain the accurate damage modes of composites patch and then
improve the understanding of the damage mechanisms in composites
successfully. They are beneficial for repair evaluation and repair opti-
mization. Furthermore, micro‐CT technology is an emerging research
area in this field, it is potential for real‐time monitoring and meso-
scopic or microstructure characteristics detection of composites patch
to enhance structural maintenance and repair.
6.1. Future prospects
In the previous work, there were many studies had done on the
improvements of repair performance. Various patch shapes (tradi-
tional and irregular) and hybridization patterns (inter‐ply, intra‐ply
and composites‐metal hybridization) as well the nano reinforced adhe-
sive are designed. By reviewing the development of improved methods
on the repair performance from three aspects, patch, adhesive and
repair methods, future prospects are mainly concentrated in the fol-
lowing four aspects: (1) The development of smart patch especially
in the aerospace field, (2) The patch and adhesive reinforcement by
employing the superior mechanical properties of nano‐additive such
as CNTs, graphene and so on, (3) Real‐time monitoring of defects by
using the superior electrical properties of nano‐particles, (4) The
development of more efficient hybrid repair methods. In addition, by
reviewing the development of NDT technologies in the field of com-
posites patch repair, development trends are mainly concentrated in
the following two aspects: (1) A combination of several NDT or NDE
technologies on the damage detection of patch, (2) The development
of micro‐CT technology in the field of composites patch repair.
Declaration of Competing Interest
The authors declare that they have no known competing financial
interests or personal relationships that could have appeared to influ-
ence the work reported in this paper.
Acknowledgments
The authors gratefully acknowledge the financial support of the
National Natural Science Foundation of China (grant no. 11502064
and 11572109) and Science Foundation for Returned Scholars of He-
bei Province of China (Grant no. C20190318) and Post‐graduate’s
Innovation Fund Project of Hebei University (HBU2021ss080).
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