Abstract
In this study, the three-dimensional finite element method is used to analyze the effects of the thermal residual stresses due to the adhesive curing on the efficiency of bonded composite repair of cracked aluminum panels. The variation of the stress intensity factor at the crack tip is used for evaluating the repair performances. The effects of the geometrical and the mechanical properties of the composite patch and the adhesive on the repair efficiency were highlighted. The obtained results show that the thermal residual stresses significantly increase the stress intensity factor at the crack tip which reduces the repair efficiency.