Abstract: A method for analyzing a structure includes processing nondestructive inspection (NDI) data for a multi-layer structure to define areas of inconsistency at an internal layer or an interface between adjacent layers. The method includes mapping the areas of inconsistency to finite elements of a finite element model of a nominal of the structure. These finite elements are thereby identified as affected finite elements and include finite elements for the affected internal layer or interface. The method includes producing a reconstructed finite element model of the affected structure from the nominal finite element model, and a modified property or state value assigned to respective element datasets of the affected finite elements. The method includes performing a finite element method (FEM) failure analysis of the reconstructed finite element model under a load, which indicates an extent of residual integrity of the affected structure.

Abstract: A method for analyzing a structure includes processing nondestructive inspection (NDI) data for a multi-layer structure to define areas of inconsistency at an internal layer or an interface between adjacent layers. The method includes mapping the areas of inconsistency to finite elements of a finite element model of a nominal of the structure. These finite elements are thereby identified as affected finite elements and include finite elements for the affected internal layer or interface. The method includes producing a reconstructed finite element model of the affected structure from the nominal finite element model, and a modified property or state value assigned to respective element datasets of the affected finite elements. The method includes performing a finite element method (FEM) failure analysis of the reconstructed finite element model under a load, which indicates an extent of residual integrity of the affected structure.

Abstract: A method for analyzing a structure includes processing nondestructive inspection (NDI) data for a multi-layer structure to define areas of inconsistency at an internal layer or an interface between adjacent layers. The method includes mapping the areas of inconsistency to finite elements of a finite element model of a nominal of the structure. These finite elements are thereby identified as affected finite elements and include finite elements for the affected internal layer or interface. The method includes producing a reconstructed finite element model of the affected structure from the nominal finite element model, and a modified property or state value assigned to respective element datasets of the affected finite elements. The method includes performing a finite element method (FEM) failure analysis of the reconstructed finite element model under a load, which indicates an extent of residual integrity of the affected structure.

Abstract: A structural repair includes a tell-tale optical witness that allows the health of the repair to be visually monitored. The optical witness includes a stress sensitive fluorescent dye that shows changes in local strain/stress patterns when the repair is subjected to electromagnetic energy of a particular wavelength. The dyes fluoresce more or less strongly as a function of the local stress/strain.

Abstract: A patch for a structure has a rework area with an inconsistency formed therein. The patch comprises a patch body having at least two regions including a fail-safe region and a safe-life region encompassing the fail-safe region. The safe-life region has a mode I interlaminar fracture toughness that is less than the mode I interlaminar fracture toughness of the fail-safe region.

Abstract: A method for analyzing a structure includes processing nondestructive inspection (NDI) data for a multi-layer structure to define areas of inconsistency at an internal layer or an interface between adjacent layers. The method includes mapping the areas of inconsistency to finite elements of a finite element model of a nominal of the structure. These finite elements are thereby identified as affected finite elements and include finite elements for the affected internal layer or interface. The method includes producing a reconstructed finite element model of the affected structure from the nominal finite element model, and a modified property or state value assigned to respective element datasets of the affected finite elements. The method includes performing a finite element method (FEM) failure analysis of the reconstructed finite element model under a load, which indicates an extent of residual integrity of the affected structure.

Abstract: A rework system for a vehicle having an inconsistency on a component of the vehicle. A rework assessor is configured to examine a rework parameter array to ascertain whether a rework procedure is to be performed. The rework parameter array defines at least volumetric dimensions of the component, a type of the inconsistency, and location coordinates of the inconsistency with respect to the component or the vehicle. A rework interrogator is in communication with the rework assessor. The rework interrogator is configured to, when a rework is to be performed, identify a candidate for addressing the inconsistency. The candidate selected from the group that includes: a candidate part, a candidate rework procedure, and both the candidate part and the candidate rework procedure.

Abstract: A peel-resistant mechanism includes a body and a plurality of arms extending from the body such that a recess is defined between each pair of adjacent arms. At least one of the arms is positionable to facilitate restricting an edge disbond from spreading across the body of the patch.

Abstract: A composite rework patch and method. The composite rework patch comprises a trapezoidal shape, a first region, and a second region. The trapezoidal has a first base and a second base, the first base parallel to the second base. The first region comprises a first composite material portion and a first adhesive portion. The second region comprises a second composite material portion and a second adhesive portion.

Abstract: A structural repair includes a tell-tale optical witness that allows the health of the repair to be visually monitored. The optical witness includes a stress sensitive fluorescent dye that shows changes in local strain/stress patterns when the repair is subjected to electromagnetic energy of a particular wavelength. The dyes fluoresce more or less strongly as a function of the local stress/strain.

Abstract: A structural repair includes a tell-tale optical witness that allows the health of the repair to be visually monitored. The optical witness includes a stress sensitive fluorescent dye that shows changes in local strain/stress patterns when the repair is subjected to electromagnetic energy of a particular wavelength. The dyes fluoresce more or less strongly as a function of the local stress/strain.

Abstract: Disclosed are systems and methods of creating altered adhesive bonded joints between metal or composite substrates, including bonds that are weaker in strength than selected reference bonds. One method of creating an altered adhesive bond includes providing a first substrate and a second substrate, selecting a manufacturing process having a plurality of steps designed to produce a desired, or reference, adhesive bond having a desired strength, and selectively altering at least one of the plurality of steps during performance of the manufacturing process to produce an altered bond between the first substrate and the second substrate, the altered bond having an altered strength that is weaker than the strength of the desired adhesive bond. The systems may include systems that may be utilized to create the altered adhesive bonds and/or test standards.

Abstract: A peel-resistant mechanism includes a body and a plurality of arms extending from the body such that a recess is defined between each pair of adjacent arms. At least one of the arms is positionable to facilitate restricting an edge disbond from spreading across the body of the patch.

Abstract: A peel-resistant mechanism includes a body and a plurality of arms extending from the body such that a recess is defined between each pair of adjacent arms. At least one of the arms is positionable to facilitate restricting an edge disbond from spreading across the body of the patch.

Abstract: A patch for a structure has a rework area with an inconsistency formed therein. The patch comprises a patch body having at least two regions including a fail-safe region and a safe-life region encompassing the fail-safe region. The safe-life region has a mode I interlaminar fracture toughness that is less than the mode I interlaminar fracture toughness of the fail-safe region.

Abstract: A patch for a structure has a rework area with an inconsistency formed therein. The patch comprises a patch body having at least two regions including a fail-safe region and a safe-life region encompassing the fail-safe region. The safe-life region has a mode I interlaminar fracture toughness that is less than the mode I interlaminar fracture toughness of the fail-safe region.

Abstract: A peel-resistant mechanism includes a body and a plurality of arms extending from the body such that a recess is defined between each pair of adjacent arms. At least one of the arms is positionable to facilitate restricting an edge disbond from spreading across the body of the patch.

Abstract: A rework system for a vehicle having an inconsistency on a component of the vehicle. A rework assessor is configured to examine a rework parameter array to ascertain whether a rework procedure is to be performed. The rework parameter array defines at least volumetric dimensions of the component, a type of the inconsistency, and location coordinates of the inconsistency with respect to the component or the vehicle. A rework interrogator is in communication with the rework assessor. The rework interrogator is configured to, when a rework is to be performed, identify a candidate for addressing the inconsistency. The candidate selected from the group that includes: a candidate part, a candidate rework procedure, and both the candidate part and the candidate rework procedure.

Abstract: A patch for a structure has a rework area with an inconsistency formed therein. The patch comprises a patch body having at least two regions including a fail-safe region and a safe-life region encompassing the fail-safe region. The safe-life region has a mode I interlaminar fracture toughness that is less than the mode I interlaminar fracture toughness of the fail-safe region.