Effect of bondline thickness on the mechanical performance of CFRP laminate with asymmetric damage repaired by double-sided adhesive patch

•Repair of CFRP with asymmetric damage through double-sided adhesive patch.•Investigation on the mechanical performance of the repaired CFRP with different bondline thicknesses.•A numerical damage model was constructed using FEM, aiding the analysis of damage evolution and failure mode in the repaired CFRP with different bondline thicknesses. As a common CFRP repair method, double-sided adhesive patch has been widely used in the automotive and aeronautic industry. More specific research is thus needed to help better understanding the effect of repairing parameters on the mechanical performance of CFRP structures after patch bonding. In this paper, experimental and Finite Element Modelling (FEM) efforts were made on the adhesive repaired CFRP laminate with different bondline thicknesses. Artificial damage was prefabricated in the centre of the CFRP laminate, which was then repaired through double-sided adhesive patch. Quasi-static tensile tests were conducted on the repaired specimen up to failure, to obtain the load-displacement curves. With a bondline thickness of 0.5 mm, the repaired CFRP structure reached its maximum peak load, increased by 25.3% and 26.4% compared to 0.2 mm and 1.0 mm bondline thicknesses, respectively. SEM observations were used to analyse the influence of adhesive thickness on the fracture modes. Combined with Cohesive Zone Model (CZM) for the adhesive layer and Hashin damage criterion for the CFRP, the FE model of the CFRP laminate repaired with double-sided adhesive patch subjected to tensile loading was established. Finally, the damage evolution as well as the failure modes in the parent laminate and adhesive layer with different bondline thicknesses were compared and analysed. It was revealed that bondline thickness can effectively affect the mechanical performance of CFRP laminate after adhesive patch repair.