Additive metal solutions to corroded wing skins in operational aircraft

This report presents the results of a detailed three dimensional non-linear a finite element study into SPD repairs to corrosion damage in P3C upper wing planks. This analysis, which allowed for both large deformation and material non-linearity (yielding), first reveals that the effect of skin corrosion on the load carrying capacity of rib stiffened wing planks on compression surfaces can't be assessed by comparing the linear buckling loads and that a fully non-linear analysis allowing for both material and geometric nonlinearities is needed. It then highlights how SPD can be an effective means for repairing skin corrosion. Recommendations for the design of SPD repairs are also presented.