Investigation on bonding behavior between CFRP patch and corrosion-damaged steel associated with surface preparation techniques

To assess the impact of corrosion on steel and the effectiveness of surface preparation techniques on the bonding behavior between carbon fiber reinforced polymer (CFRP) and steel, thirty bonded joint specimens were examined. These specimens were based on three distinct corrosion levels of steel and three conventional surface preparation techniques. Furthermore, various evaluation methods were employed to understand the steel surface characteristics, encompassing macro and microscale observations, analysis of topographical structures, and quantification of surface evaluation indices. These were performed to determine their correlations with the interfacial stress behavior. The findings revealed that when the target for repair shifted from a new steel substrate to a corroded one, the synergistic performance at the steel-adhesive interface decreased. This led to a decrease in the maximum shear stress at the plate end, and there was also an undesirable shift in the mode of failure. Both test parameters (i.e., the corrosion level and surface preparation), synergistically determined the surface cleanliness, topography, and bonding defects, all three of which directly influenced the bonding behavior. Finally, an improved model for predicting the debonding capacity of CFRP-corroded steel bonded joints was introduced, incorporating surface damage (k₁) and surface topography (k₂) coefficients. This model's applicability was also verified by collecting other test data from available literature.