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CHAPTER 1 - INTRODUCTION
CHAPTER 2 - COMPOSITE MATERIAL FACILITY OPERATIONS
HAZARDOUS MATERIALS
Chronic Toxicity
Figure 2-1. Carbon Fiber and Human Hair Diameters Compared to Filtration Level of HEPA Filter
PERSONAL PROTECTIVE EQUIPMENT (PPE)
Figure 2-2. Removing Disposable Gloves
MATERIALS STORAGE
Laminating Resins and Paste Adhesives Storage
EMERGENCY AND FIRST AID PROCEDURES
COMPOSITE REPAIR ENVIRONMENTS
BONDING/LAYUP AREA
Figure 2-3. Temperature and Humidity Allowables for Bonding and Layup
Treatment Area
Table 2-1. - Personal Protective Equipment, Equipment/Facilities and Personal Hygiene for Working with Advanced Composite Materials
Table 2-1. - Personal Protective Equipment, Equipment/Facilities and Personal Hygiene for Working with Advanced Composite Materials - Continued
CHAPTER 3 - REPAIR EQUIPMENT, TOOLS AND SUPPLIES
Figure 3-1. Alternating Tooth Bandsaw Blade for Cutting Aramid Laminates
HANDHELD TOOLS
Figure 3-2. Heat Blanket Coniguration
Figure 3-3. Welded Thermocouple Wire
Figure 3-4. Twisted Thermocouple Wire
Ambient Temperature
Figure 3-5. Heat Lamp Temperature Affects (Sheet 1 of 2)
Figure 3-5. Heat Lamp Temperature Affects (Sheet 2 of 2)
Figure 3-6. Double Vacuum Debulk (DVD Tool Schematic)
Figure 3-7. Rigid Box Construction
CONSUMABLE MATERIALS
Table 3-2. - Material Temperature Capabilities
Table 3-2. - Material Temperature Capabilities - Continued
Patch and Fastener Installation
Figure 3-8. Blind Fastener Differences
Table 3-3. - Mechanical Fasteners
Figure 3-9. Hi-Lok Installation: Hand Tooling
Figure 3-11. Blind Fastener Grip Length Gauges (Sheet 1 of 2)
Figure 3-11. Blind Fastener Grip Length GaugesBlind Fastener Inspection (Sheet 2 of 2)
Table 3-5. - Composi-Lok II and IIa Installation Tooling
Table 3-6. - Visu-Lok Installation Tooling
Table 3-7. - Visu-Lok II Installation Tooling
Figure 3-12. Typical Drill Reamer
Figure 3-15. Spade Drill for Aramid Laminates
Figure 3-16. Brad Point Bit for Aramid or Fiberglass Laminates
Figure 3-18. Split Helix Router Bit for Trimming Aramid Composites
Figure 3-19. Countersink for Aramid Laminates
Figure 3-20. Coated Abrasive Disc
Figure 3-21. Hole Saw and Guide Bushing
Figure 3-22. Honeycomb Core Cutters
Figure 3-23. Industrial Hypodermic Syringe and Needles
Figure 3-25. Vacuum Cup
Figure 3-26. Moisture Indicator
Coolant
CHAPTER 4 - COMPOSITE MATERIALS
Figure 4-2. Sandwich Construction
Figure 4-3. Structural Property Comparison
Polyethylene
Figure 4-5. Warp vs. Fill Fibers in a Roll of Fabric
Figure 4-7. Twill Weave (2X2 Twill Shown)
Figure 4-8. Satin Weave (4 & 8 Harness Satin Shown)
Figure 4-9. Example Satin Weave Showing Alternating Warp and Fill Faces Used for Lamination
Figure 4-10. Braid
Stitched Multiaxial Fabrics
Figure 4-11. Weave and Stitch Process
Figure 4-12. Simultaneous Stitch Process
RESIN TYPES
SHELF LIFE
Table 4-2. - Shelf Life Data for Common Two-Part Epoxy Adhesives
ADHESIVES
Figure 4-13. Honeycomb Core Orientation and Nomenclature
Figure 4-15. Overexpanded Honeycomb Core
Cure In Place Core
LIGHTNING STRIKE PROTECTION, ELECTROMAGNETIC INTERFERENCE SHIELDING AND ELECTRICAL GROUNDING
CHAPTER 5 - TYPICAL DAMAGE AND ASSESSMENT
Tap Testing
Figure 5-1. Inspection Tap Hammer Details
Nondestructive Inspection Method (NDI)
Pulse-Echo Longitudinal Wave Ultrasonics
Figure 5-2. Pulse-Echo Ultrasonic Inspection with A-Scan Presentation (Sheet 1 of 3)
Figure 5-2. Pulse-Echo Ultrasonic Inspection with A-Scan Presentation (Sheet 2 of 3)
Figure 5-2. Pulse-Echo Ultrasonic Inspection with A-Scan Presentation (Sheet 3 of 3)
Figure 5-3. Through-Transmission Ultrasonic Inspection, A-Scan Presentation (Sheet 1 of 2)
Figure 5-3. Through-Transmission Ultrasonic Inspection, A-Scan Presentation (Sheet 2 of 2)
Figure 5-4. Types of Defects
Heat/Burn Damage
DAMAGE ASSESSMENT METHODOLOGY
Figure 5-5. Defect Mapping of Damage Extent from NDI
Figure 5-6. Damage Work Lines Drawn on Part Surface
Figure 5-7. Typical Orientation Markings
Figure 5-8. Ply and Ply Fiber Direction
Figure 5-9. Fiber Orientations
Figure 5-11. Stacking Sequence Effects
Figure 5-12. Patch Drawing Example and Typical Scarf Repair Stackup (Sheet 1 of 2)
Figure 5-13. Scab Patch Ply Arrangement
Figure 5-14. Repair Ply Cutting Template (Example) (Sheet 1 of 3)
Figure 5-14. Repair Ply Cutting Template (Example) (Sheet 3 of 3)
Figure 5-15. ASTM Standard for Measuring Ply Angles
Figure 5-17. Example for Positive and Negative Angles
Figure 5-20. Example Odd Symmetric Laminate
Figure 5-23. Example Sets for Non-Symmetric Laminates
Figure 5-24. Excerpt from CMH-17F
Figure 6-1. Paint Removal Zone
PAINT REMOVAL PROCEDURE
Figure 6-2. Damage Outlining
Table 6-1. - Ranking of Damaged Material Removal Techniques
Figure 6-3. Router Template Fabrication
Figure 6-4. Partial Thickness Damage Removal
Figure 6-5. Core Cell Axis Orientation
Figure 6-6. Removal of Core With Core Knife
Figure 6-8. Typical Router Setup With Template
CLEANING PROCESS
Wiping Process
DRYING PROCESS
Figure 6-9. Average Drying Time for Advanced Composite Laminates
Heat Blanket/Vacuum Technique.
Removal of Water From Honeycomb Core
Heat Blanket, Oven or Hot Air Module Method
Figure 6-10. Patch Edge Taper Dimensions
Figure 6-11. In-Plane Versus Out-Of-Plane Cutting Forces
Fiberglass
General Air Tool Safety
Partial Thickness Damage Removal
KEVLAR-EPOXY REPAIRS PROCESS
Removal of Fuzzing by Back Sanding
FIBERGLASS-THERMOSETTING RESIN REPAIRS
HONEYCOMB CORE REPAIR PROCESS
Figure 6-12. Spoiling and Potting Core
Figure 6-13. Basic Repair Joints
Figure 6-14. Basic Repair Joints (General)
Figure 6-16. Basic Repair Joints (Bolted)
Multiple Row Fastener Patterns
Figure 6-17. Ply Overlap Chart
Figure 6-18. Dimensions of a Scarf Repair
Figure 6-20. Scarf Joint Outline Layout
Figure 6-21. Scarf Joint Machining
Figure 6-22. Laminate Fiber Orientation (Sheet 1 of 2)
Figure 6-22. Laminate Fiber Orientation (Sheet 2 of 2)
Figure 6-23. Scarf Joint Inspection Requirements
Figure 6-24. Step Joint Outline Layout
WET LAYUP METHOD
WET LAYUP METHOD - Continued
WET LAYUP METHOD - Continued
Figure 6-26. Ply Layup Log
Tools, Equipment, and Materials Required
Figure 6-27. Vacuum Assist Impregnation Process (Sheet 1 of 2)
Tools, Equipment, and Materials Required - Continued
Tools, Equipment, and Materials Required - Continued
RESIN PREPARATION AND USE
Figure 6-28. Two Part Adhesives and Filler Compounds Formula
Figure 6-29. Examples for Preparing Two Part Adhesives and Filler Compounds
Table 6-2. - Filler Guidelines
Liquid Shimming
VACUUM BAGGING THEORY AND TECHNIQUES
Figure 6-30. Vacuum Bagging Arrangement
Table 6-3. - Vacuum Pressure Conversion Chart
Single Side Vacuum Bag Procedure
Envelope Bagging Procedure
Figure 6-31. Envelope Bagging a Part on a Worktable
Facilities, Equipment, and Materials
Two-Side Access Seal Technique
One-Side Access Backside Seal Technique
Figure 6-33. Component Sizes and Slotted Disc Geometry for Single-Side Access Seal
Method 1, One-Side Access Backside Seal Procedure
Facilities, Equipment and Materials
Facilities, Equipment and Materials - Continued
Vacuum Integrity Test
Solving for Vacuum Leaks
Thermal Survey Considerations
Figure 6-35. Heat Blanket Placement and Temperature Variations in Repair Area
Figure 6-36. Typical Thermal Survey Setup
CURING ADVANCED COMPOSITES
Figure 6-37. Typical Cure Cycle
Figure 6-38. Typical Vacuum-Bagged Cure Cycle
Cure Temperature
Table 6-4. - Maximum Cure Temperatures on Aircraft
Placement
Figure 6-39. Typical Thermocouple Placement
Temperature Control
Heat Blanket.
Figure 6-40. Thermocouple Placement in Repair Area
Heat Lamp
Table 6-5. - Typical Heat Lamp Performance Chart
Figure 6-41. Pressure Levels Produced Using Various Pressure Methods (Sheet 1 of 4)
Figure 6-41. Pressure Levels Produced Using Various Pressure Methods (Sheet 2 of 4)
Figure 6-41. Pressure Levels Produced Using Various Pressure Methods (Sheet 3 of 4)
Figure 6-41. Pressure Levels Produced Using Various Pressure Methods (Sheet 4 of 4)
Figure 6-42. Methods for Applying Positive Pressure
Figure 6-43. C-Clamp Sequence and Placement
Figure 6-44. Typical Two Part Adhesive Heat Cure Cycle
Two Part Adhesive Room Temperature Cure Cycle Method.
Figure 6-45. Inspection of Adhesive Squeeze Out Following Cure
GALVANIC CORROSION OF CARBON COMPOSITES
CHAPTER 7 - REPAIR PROCEDURES
Table 7-1. - General Description of Different Repair Types
Table 7-1. - General Description of Different Repair Types - Continued
Table 7-1. - General Description of Different Repair Types - Continued
Table 7-1. - General Description of Different Repair Types - Continued
Table 7-1. - General Description of Different Repair Types - Continued
Figure 7-1. Process Flow Diagram for Surface Damage
Figure 7-2. Process Flow Diagram For Partial Thickness Damage
Bonded Repair Procedure.
Figure 7-3. Partial Thickness Bonded Repair
Figure 7-5. Layup of Stacked Patches and Adhesive
Partial Thickness Scarf Repair
PENETRATION DAMAGE REPAIR
Figure 7-7. Process Flow Diagram for Penetration Damage Repair
Full Thickness Scab Repair
Full thickness Scab Repair Procedure.
Figure 7-8. Cross Section of Typical Stepped Repair
Full Thickness Step Repair Procedure.
Moisture Ingression
Figure 7-9. Core Replacement Methods
Figure 7-10. Replacement Core Fit
Figure 7-11. Weight Versus Hole Diameter for Two Core Replacement Methods
Figure 7-13. Procedure for Core Replacement Using the Core Potting Method
Honeycomb Core Repair Procedure.
Figure 7-14. Process Flow Diagram for Core Repair, Paste Adhesive Method
Paste Adhesive Method Procedure.
Paste Adhesive Method Procedure. - Continued
Figure 7-15. Procedure for Core Replacement Using the Paste Adhesive Method
Rapid Densiication
Figure 7-16. Process Flow Diagram for Rapid Densiication
Adhesive Bonded Joints Procedure.
Figure 7-17. Layup of Stacked Patches and Adhesive
MECHANICALLY FASTENED JOINTS
Figure 7-18. Basic Repair Joints (Bolted)
Multiple Row Fastener Patterns
Table 7-2. - Blind Fastener Inspection Requirements (VISU--LOK)
Table 7-3. - Blind Fastener Inspection Requirements (COMPOSI-LOK)
Figure 7-19. Hi-Lok Removal
Figure 7-20. Removal of Tightly Clamped Blind Fasteners
Figure 7-21. Removal of Loose Blind Fasteners
Figure 7-22. Hole Finder
Blind Hole Transfer Punches
Figure 7-23. Blind Hole Transfer Punch
Figure 7-24. Measuring and Scaling Method of Transferring Blind Holes
Figure 7-25. Mold Method of Transferring Blind Holes
Mold Method
Figure 7-26. Arc Method of Locating Blind Fastener Holes (Sheet 1 of 3)
Figure 7-26. Arc Method of Locating Blind Fastener Holes (Sheet 2 of 3)
Figure 7-26. Arc Method of Locating Blind Fastener Holes (Sheet 3 of 3)
Example Procedure For A Bolted Repair.
Figure 7-27. Process Flow Diagram for Penetration Damage Bolted Repair, External Patch
Figure 7-28. Sump Removal and Installation
Facilities, Equipment and Materials.
Figure 7-29. Sealing Bolted Repairs
Figure 7-30. Process Flow Diagram for Partial Thickness Bolted Repair
Partial Thickness Bolted Repair Procedure
Figure 7-31. Types of Delaminations
Figure 7-32. Impact Damage Injection Repair
Figure 7-34. Process Flow Diagram for Delamination Not Open to an Edge Repair
Resin Injection For Delaminations Not Open To An Edge Repair Procedure.
Resin Injection For Delaminations Not Open To An Edge Repair Procedure. - Continued
Figure 7-36. Delamination Repair Not Open to an Edge (Blister)
Figure 7-37. Process Flow Diagram for Delamination Open to an Edge Repair
Figure 7-38. Repair to an Open Edge
Skin to Core Disbond
Figure 7-39. Process Flow Diagram for Disbond Repair
Figure 7-40. Veriication of Leak Path: Disbond Repair
Figure 7-41. Disbond Repair
Figure 7-42. Process Flow Diagram for Skin to Closure Member
Skin to Closure Member Disbond and Delamination Procedure.
Figure 7-43. Skin to Closure Member Disbond Repair
EDGE DAMAGE
Figure 7-44. Repair to an Open Edge
Figure 7-45. Process Flow Diagram for Edge Damage Rebuild
Edge Damage Rebuild Procedure.
Figure 7-46. Process Flow Diagram for Flush Corner Repair
Facilities, Equipment and Material
Figure 7-47. Flush Corner Repair Sequence (Only Bonding on Upper Moldline is Shown for Clarity) (Sheet 1 of 2)
Figure 7-48. Repair Rib Layup and Tool
Trailing Edge Repair Procedure
Trailing Edge Repair Procedure - Continued
Trailing Edge Repair Procedure - Continued
Trailing Edge Repair Procedure - Continued
Trailing Edge Repair Procedure - Continued
Figure 7-49. Process Flow Diagram for Fastener Repair
Figure 7-50. Process Flow Diagram for Countersink Repair
Figure 7-51. Process Flow Diagram for Fill and Drill Fastener Hole Repair
Figure 7-52. Template Fabrication
Potting Method
Figure 7-55. Potted Fastener Hole Repair
Potting Fastener Hole Repair Procedure.
Figure 7-56. Process Flow Diagram Fabric Layup Repair
Figure 7-57. Fabric Layup Fastener Hole Repair
Fastener Hole Delamination Repair
Figure 7-59. Vacuum Injection Fastener Hole Repair
Table 7-5. - Clamp-Up Bolts and Torque Values 1
Fastener Hole Delamination Repair Procedure
Figure 7-60. Application of Clamp-Up Pressure
Figure 7-61. Process Flow Diagram for Fastener Hole Repair: Swagged Grommet
Figure 7-62. Swagged Grommet Install
Figure 7-63. Process Flow Diagram Captive Bushing Repair
Figure 7-64. Captive Bushing Repair Components
Figure 7-65. Captive Bushing Repair Flange and Countersink Bushing Installation
Figure 7-66. Installation View of Captive Bushing Repair
Facilities, Equipment and Materials.
DVD Wet Layup Procedure.
Table 7-6. - DVD Parameters
DVD Wet Layup Procedure - Continued
DVD Wet Layup Procedure - Continued
DVD Wet Layup Procedure - Continued
Figure 7-67. DVD Precure Stacking Sequence
Method 2: Cocuring to Part
Figure 7-68. DVD Cocure Stacking Sequence (Typical)
Locally Manufactured DVD Tool
Figure 7-69. Double Vacuum Debulk Locally Manufactured Tool
Figure 7-70. Process Flow Diagram for Lightning Strike
POST CURE PROCEDURES
APPENDIX A - REFERENCES
APPENDIX A - REFERENCES - Continued
APPENDIX B - TOOLS AND CONSUMABLE ITEMS
APPENDIX B - TOOLS AND CONSUMABLE ITEMS - Continued
APPENDIX B - TOOLS AND CONSUMABLE ITEMS - Continued
DRILL MOTOR AND DRILL BITS
CONSUMABLE MATERIALS
Table B-4. - Consumable Materials
Table B-4. - Consumable Materials - Continued
Table B-5. - Vacuum Bagging Materials
Table B-5. - Vacuum Bagging Materials - Continued
Table B-6. - Personal Protective Equipment
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