Method of metal work repair in hybrid composite blades

A method of repairing a composite blade comprising a composite part, a metal work, and an adhesive layer bonding the metal work to the composite part, the metal work comprising a bullet forming a leading edge of the composite blade, a first wing extending from the bullet, and a second wing extending from the bullet and opposing the first wing, the method comprising the steps of:

• determining a locally damaged portion of the metal work;
• removing a bullet portion corresponding to the locally damaged portion from a rest of the bullet;
• detaching a first wing portion corresponding to the locally damaged portion from a rest of the first wing;
• detaching a second wing portion corresponding to the locally damaged portion from a rest of the second wing;
• debonding and removing the first wing portion from the composite part to obtain a first exposed surface portion of the composite part;
• debonding and removing the second wing portion from the composite part to obtain a second exposed surface portion of the composite part;
• reconditioning the first exposed surface portion of the composite part to obtain a first reconditioned surface portion of the composite part;
• reconditioning the second exposed surface portion of the composite part to obtain a second reconditioned surface portion of the composite part;
• applying a first adhesive layer to the first reconditioned surface portion;
• applying a second adhesive layer to the second reconditioned surface portion;
• and
• bonding a metal work patch to the first adhesive layer and the second adhesive layer, wherein the metal work patch comprises a bullet part corresponding to the bullet portion, a first wing part corresponding to the first wing portion, and a second wing part corresponding to the second wing portion.