Fatigue Life Analysis of a Plate with a Repair Node Subjected to Uniform Shear

Aircraft structures are highly susceptible to fatigue damage, particularly in thin-walled aluminum alloy components such as skin panels. Damage in the form of holes or material loss drastically reduces fatigue life and compromises structural safety, which makes effective repair strategies essential. This study presents an experimental investigation into the fatigue performance of EN AW-2024-T3 aluminum alloy plates with central openings subjected to uniform shear. Repair nodes were applied using two approaches: conventional riveted metal patches and adhesively bonded composite patches. Variants of patch geometry, thickness, and diameter were evaluated to determine their influence on load transfer, buckling response, and fatigue life. The results show that central holes significantly shorten fatigue life, with a 20 mm hole causing a 67% reduction and a 50 mm hole causing a 95% reduction when compared with undamaged plates. Riveted metal patches restored only part of the lost performance, as stress concentrators introduced by fastener holes initiated new fatigue cracks. In contrast, adhesively bonded composite patches provided a substantial improvement, extending fatigue life beyond that of the riveted solutions, improving buckling shape, and delaying crack initiation. Larger patches, particularly those combined with metallic inserts, proved most effective in restoring structural functionality. The findings confirm the effectiveness of bonded composite repairs as a lightweight and reliable method for extending fatigue life and enhancing the safety of damaged aircraft structures. The study highlights the importance of patch geometry and stiffness in the design of repair nodes.