Mechanics of the composite scarf repair under tensile loading with and without overlay plies was examined for nontraditional patch ply orientations. Three-dimensional nonlinear analysis was performed for repair failure prediction and good baseline comparison for open-hole scarfed panels and panels repaired by using standard ply-by-ply replacement patch composition was achieved. Multidimensional optimization was performed to calculate the repair patch ply orientations which minimize the von Mises stresses in the adhesive. These optimal stacking sequences achieved significant reduction of the stress levels and resulted in predicted up to 75% and 85% strength restoration for flush and single ply thickness over-ply repair. These results are intended to illustrate additional design variables available for efficient composite repair design, namely the composition of the repair patch.

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