Advantages and Application Challenges of Composite Material Repair Methods Used in Aircraft

Emre Lekesizcan; Bekir Güney

doi:10.29130/dubited.1762499

Review

Advantages and Application Challenges of Composite Material Repair Methods Used in Aircraft

Year 2026, Volume: 14 Issue: 1, 299 - 311, 21.01.2026

Emre Lekesizcan , Bekir Güney

https://doi.org/10.29130/dubited.1762499

Abstract

With the development of fiber-reinforced composite materials, composites have become indispensable in modern aircraft structures. Aircraft receive damages from impacts or environmental conditions throughout their service life. Since replacing a damaged composite with a new one is an economically costly task, appropriate repair techniques are keeping its importance. It is possible to restore structural integrity by repairing the damaged part. In addition, since composites are difficult to recycle, their repair contributes to sustainability by reducing the amount of waste material. Although systematic repair methodologies have been well established for thermoset matrix composites, a clear and standardized roadmap for thermoplastic composites has yet to be developed. In this article, damages in composite materials used in today's aircraft, their detection, evaluation and repair methods have been examined. In addition, studies from the literature on ultrasonic, resistance and induction welding methods, which are among the welded repair methods of thermoplastic matrix composites, which have been used increasingly in recent years, have been presented. The advantages of repair methods and the difficulties encountered in application have been evaluated.

Keywords

Composite repair , Repair , Fusion bonding , Thermoplastic composite , Aircraft

Ethical Statement

This is not a study that requires ethical committee approval.

Supporting Institution

No financial support was used.

Thanks

The authors would like to thank Karamanoğlu Mehmetbey University.

References

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Hava Araçlarında Kullanılan Kompozit Malzemelerin Onarımı

Year 2026, Volume: 14 Issue: 1, 299 - 311, 21.01.2026

Emre Lekesizcan , Bekir Güney

https://doi.org/10.29130/dubited.1762499

Abstract

Fiber takviyeli kompozit malzemelerin gelişmesiyle kompozitler hava araçlarının vazgeçilmez malzemesi haline gelmiştir. Hava araçları hizmet ömürleri boyunca darbelerden veya çevresel koşullardan kaynaklanan hasarlar alır. Hasarlı kompozitin yenisi ile değişimi ekonomik olarak külfetli bir iş olması nedeniyle uygun onarım teknikleri önem arz etmektedir. Hasarlı parçanın onarılmasıyla yapı bütünlüğünün geri kazanılması mümkündür. Ayrıca kompozitler geri dönüşümleri zor malzemeler olduğu için onarılmaları, atık malzeme miktarını azaltarak sürdürülebilirliğe katkı sağlamaktadır. Bu makalede günümüz hava araçlarında kullanılan kompozit malzemelerde oluşan hasarlar, hasarların tespiti, değerlendirilmesi ve tamir yöntemleri incelenmiştir. Özellikle son yıllarda kullanımı artan termoplastik matrisli kompozitlerin kaynaklı onarım yöntemlerinden ultrasonik, direnç ve indüksiyon kaynağı yöntemleri ile ilgili literatürdeki çalışmalar sunulmuştur. Onarım yöntemlerinin avantajları ve uygulamadaki karşılaşılan güçlükler değerlendirilmiştir.

Keywords

Kompozit onarım , Onarım , Füzyon Yapıştırma , Termoplastik kompozit , Uçak

References

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Becker, S., & Mitschang, P. (2022). Process improvement of continuous induction welding of carbon fiber-reinforced polymer composites. Journal of Materials Engineering and Performance, 31(9), 7049–7060. https://doi.org/10.1007/s11665-022-06842-0
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Budhe, S., Banea, M. D., & de Barros, S. (2018). Bonded repair of composite structures in aerospace application: a review on environmental issues. Applied Adhesion Science, 6(1), Article 3. https://doi.org/10.1186/s40563-018-0104-5
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Cambaz, A. (2024). Kompozit kanat yapıları üzerinde tamir modellemesi ve sonlu elemanlar analizi [Master's thesis, TOBB University of Economics and Technology].
Çetinkaya, Ş. (2017). Investigation of circular damage repairing by using adhesive in laminate composite materials experimentaly [Doctoral thesis, Firat University].
Chen, C., Fan, C., Cai, X., Lin, S., Yang, C., & Zhuo, Y. (2020). Microstructure and mechanical properties of Q235 steel welded joint in pulsed and un-pulsed ultrasonic assisted gas tungsten arc welding. Journal of Materials Processing Technology, 275, Article 116335. https://doi.org/10.1016/j.jmatprotec.2019.116335
Choi, B.-K., Kang, C.-S., Yoo, M.-H., & Seo, M.-K. (2023). Effect of processing parameters on bonding performance of a carbon fiber/polyetheretherketone thermoplastic composite prepared by induction welding. Materials, 16(11), Article 3954. https://doi.org/10.3390/ma16113954
Collombet, F., Grunevald, Y.-H., Crouzeix, L., Douchin, B., Zitoune, R., Davila, Y., Cerisier, A., & Thévenin, R. (2015). Repairing composites. In P. Boisse (Ed.), Advances in Composites Manufacturing and Process Design (pp. 197–227). Woodhead Publishing. https://doi.org/10.1016/B978-1-78242-307-2.00010-5
Darwish, F. H., & Shivakumar, K. N. (2014). Experimental and analytical modeling of scarf repaired composite panels. Mechanics of Advanced Materials and Structures, 21(3), 207–212. https://doi.org/10.1080/15376494.2013.834096
Dindar, B., & Ağır, İ. (2021). Charpy impact response of notched aluminum 5754-H111 of repaired with carbon/epoxy and e-glass/epoxy. European Journal of Science and Technology, (22), 352–356. https://doi.org/10.31590/ejosat.844824
Du, B., Chen, L., Liu, H., He, Q., Qin, W., & Li, W. (2020). Resistance welding of glass fiber reinforced thermoplastic composite: Experimental investigation and process parameter optimization. Chinese Journal of Aeronautics, 33(12), 3469–3478. https://doi.org/10.1016/j.cja.2020.02.018
Dubinskii, S., Feygenbaum, Y., Senik, V., & Metelkin, E. (2019). A study of accidental impact scenarios for composite wing damage tolerance evaluation. The Aeronautical Journal, 123(1268), 1724–1739. https://doi.org/10.1017/aer.2018.152
Erdem, A. T. (2024). İçerisinde çatlak bulunan pim bağlantılı kompozitlerin yama ile tamiri ve tamir sonrası mukavemetinin incelenmesi [Master's thesis, Firat University].
Eveno, E. C., & Gillespie, J. W. (1988). Resistance welding of graphite polyetheretherketone composites: an experimental investigation. Journal of Thermoplastic Composite Materials, 1(4), 322–338. https://doi.org/10.1177/089270578800100402
Evren, M. (2024). Hava araçlarında kullanılan kompozit yapısalların onarım yöntemlerinde uygulanan yapıştırma bağlantılarının optimizasyonu [Master's thesis, Yildiz Technical University].
Gong, X.-J., Cheng, P., Aivazzadeh, S., & Xiao, X. (2015). Design and optimization of bonded patch repairs of laminated composite structures. Composite Structures, 123, 292–300. https://doi.org/10.1016/j.compstruct.2014.12.048
Gouin O’Shaughnessey, P., Dubé, M., & Fernandez Villegas, I. (2016). Modeling and experimental investigation of induction welding of thermoplastic composites and comparison with other welding processes. Journal of Composite Materials, 50(21), 2895–2910. https://doi.org/10.1177/0021998315614991
Hale, J. (2014, December). Boeing 787 from the ground up. Boeing Aero Magazine, 56. https://skybrary.aero/sites/default/files/bookshelf/3815.pdf
Kaman, M. O., & Cetişli, F. (2011). Yama ile tamir edilmiş kenar çatlak içeren kompozit levha probleminin sayısal analizi. Prooceedings of 9th International Fracture Conference, (pp. 232–243). http://www.endil.yildiz.edu.tr/proceedings9/24.pdf
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Details

Primary Language	English
Subjects	Resource Technologies, Material Design and Behaviors
Journal Section	Review
Authors	Emre Lekesizcan 0000-0002-0612-6742 Bekir Güney 0000-0001-9764-9313
Submission Date	August 13, 2025
Acceptance Date	December 10, 2025
Publication Date	January 21, 2026
Published in Issue	Year 2026 Volume: 14 Issue: 1

Cite

APA	Lekesizcan, E., & Güney, B. (2026). Advantages and Application Challenges of Composite Material Repair Methods Used in Aircraft. Duzce University Journal of Science and Technology, 14(1), 299-311. https://doi.org/10.29130/dubited.1762499
AMA	Lekesizcan E, Güney B. Advantages and Application Challenges of Composite Material Repair Methods Used in Aircraft. DUBİTED. January 2026;14(1):299-311. doi:10.29130/dubited.1762499
Chicago	Lekesizcan, Emre, and Bekir Güney. “Advantages and Application Challenges of Composite Material Repair Methods Used in Aircraft”. Duzce University Journal of Science and Technology 14, no. 1 (January 2026): 299-311. https://doi.org/10.29130/dubited.1762499.
EndNote	Lekesizcan E, Güney B (January 1, 2026) Advantages and Application Challenges of Composite Material Repair Methods Used in Aircraft. Duzce University Journal of Science and Technology 14 1 299–311.
IEEE	E. Lekesizcan and B. Güney, “Advantages and Application Challenges of Composite Material Repair Methods Used in Aircraft”, DUBİTED, vol. 14, no. 1, pp. 299–311, 2026, doi: 10.29130/dubited.1762499.
ISNAD	Lekesizcan, Emre - Güney, Bekir. “Advantages and Application Challenges of Composite Material Repair Methods Used in Aircraft”. Duzce University Journal of Science and Technology 14/1 (January2026), 299-311. https://doi.org/10.29130/dubited.1762499.
JAMA	Lekesizcan E, Güney B. Advantages and Application Challenges of Composite Material Repair Methods Used in Aircraft. DUBİTED. 2026;14:299–311.
MLA	Lekesizcan, Emre and Bekir Güney. “Advantages and Application Challenges of Composite Material Repair Methods Used in Aircraft”. Duzce University Journal of Science and Technology, vol. 14, no. 1, 2026, pp. 299-11, doi:10.29130/dubited.1762499.
Vancouver	Lekesizcan E, Güney B. Advantages and Application Challenges of Composite Material Repair Methods Used in Aircraft. DUBİTED. 2026;14(1):299-311.

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