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Bonded composite patch repair technology has gained widespread adoption across industries such aerospace, wind energy, and various industrial sectors due to its cost-effectiveness, versatile design, and lightweight characteristics. This technique effectively reduces the stress intensity factor SIF at the crack tip, thereby inhibiting crack propagation and prolonging the structural lifetime. However, the application of composite patches without optimization of their shape, size and properties can result suboptimal repairs, compromising the structural integrity and safety. In this study, we investigate the influence of the dimensions of a rectangular composite patch on the SIF the crack tip, an essential parameter for assessing the repair's effectiveness. Using the finite element method FEM analysis, we developed a model that integrates FEM with bio-inspired optimization technique, specifically a genetic algorithm GA, to optimize the length and the width of the composite patch for SIF reduction. The results demonstrate that the model employing the GA effectively identifies the optimal dimensions for composite patch repairs, enhancing their efficiency.
