Predicting filling efficiency of composite resin injection repair

We propose to develop a two-dimensional reduced-order reconstruction, simulation and injection strategy to model resin injection repair which is scalable and practical for use with available equipment. The proposed method involves reconstructing a damaged composite laminate using ultrasonic C-scans to determine the damage zone geometry and porosity. The damage zone permeability is calculated via semi-empirical constitutive equations, and used as input data for the CFD simulation of a resin injection process through the composite. The ultimate aim is to guide repair operators by identifying suitable injection configurations in order to improve cavity filling and thus repair efficiency. After establishing the methodology basis, we verify simulations through comparison to a proposed and analytically solved problem. Validation results show a 70+% simulation accuracy. Finally, we create a case study where cavity filling is improved by applying knowledge of the damage zone. This method's ability to predict filling efficacy offers a viable, quantitative and more consistent alternative to existing intuition-based practices for resin injection repair.