The increasing demand for life extension of both military and civil aircrafts led to significant
advances in repair technology of cracked metallic structures. Consequently, bonded
composite repairs of metallic structures became a rapidly growing technology in the field of
aerospace. Given the specific characteristics of a bonded composite repair and the differences
in the materials used in each case (metal, composite & adhesive), the applicability of a
number of Non Destructive Testing methods to trace crack propagation under a composite
patch repair of a cracked metallic structure is examined, following mechanical testing in
fatigue. In this paper, the main NDT methods examined include the eddy current method
applied over a bonded composite repair (i.e. without removing the repair) as well as Bragg
grating optical sensors embedded into composite patches. The capability and the reliability of
the eddy-current method to detect cracks under a composite obstacle of significant thickness
were checked for several patch thickness. The eddy-current method was found to be fully
capable of tracing the crack propagation under the composite patch, requiring only proper
calibration of the generator. Small differences in the crack lengths between the patched and
the unpatched side of the specimen which were examined were explained by their nonsymmetric
configuration, which induced different stress intensity factors at the patched and
the unpatched sides, as finite element analysis has clearly shown. On the other hand, Bragg
grating sensors were proven capable of tracing crack propagation with high accuracy, through
interpretation of the differences caused in the strain field over the crack, after comparison
with finite element analysis results.