Novel Repair Procedure for CFRP Components Instead of EOL

Area of Science:

• Materials Science
• Polymer Chemistry
• Composite Materials Engineering

Background:

• Carbon fiber reinforced plastic (CFRP) components are widely used in demanding environments.
• Existing repair methods for damaged CFRPs are often ineffective, especially with dry fiber materials.
• High costs and limited lifespans of CFRPs necessitate advanced repair solutions.

Purpose of the Study:

• To develop an innovative and efficient repair procedure for damaged CFRP components.
• To address the challenge of restoring mechanical properties in safety-critical CFRP structures.
• To provide a cost-effective alternative to component replacement.

Main Methods:

• Utilizing an oxide semiconductor activated by ultraviolet (UV) irradiation to depolymerize the thermoset matrix.
• Locally removing the damaged matrix and physically extracting compromised fibers.
• Applying a load-adjusted, tailored fiber reinforcement patch.
• Consolidating the repaired area through local thermoset re-infiltration.

Main Results:

• Successful local repair of damaged CFRP structures using new carbon fiber (CF).
• Restoration of mechanical properties in repaired CFRP components.
• Achieved an approximately original surface finish on repaired areas.
• Demonstrated a more efficient repair process compared to current state-of-the-art methods.

Conclusions:

• The developed UV-activated depolymerization and re-infiltration method offers an effective solution for CFRP repair.
• This innovative procedure can significantly extend the service life of CFRP components.
• The repair technique provides a promising alternative to costly component replacement in safety-critical applications.