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Advanced Composite AircraftAdvanced Composite Aircraft
Structures, StructuralStructures, StructuralRepairs, Adhesive Bonding &Repairs, Adhesive Bonding &
Electrical CharacteristicsElectrical Characteristics
Michael J. HokeMichael J. HokeAbaris Training Resources Inc.Abaris Training Resources Inc.
AEA 2008AEA 2008CopyrightCopyright2008 Abaris Training Resources Inc.2008 Abaris Training Resources Inc. 11
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Who is Abaris Training??Who is Abaris Training?? We have been training in manufacturing,We have been training in manufacturing,
repair, and bonding of advancedrepair, and bonding of advancedcomposite structures since 1983, with overcomposite structures since 1983, with over13,000 graduates to date.13,000 graduates to date.
Three permanent training facilities:Three permanent training facilities: Reno, NVReno, NV
Griffin, GAGriffin, GA Cwmbran, WalesCwmbran, Wales
We also do numerousWe also do numerous onon--sitesite classesclasses
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Who do we train?Who do we train? 40% military40% military
25% manufacturers (Boeing, Airbus,25% manufacturers (Boeing, Airbus,NorthropNorthrop--Grumman, Lockheed, GeneralGrumman, Lockheed, General
Atomics (UAVAtomics (UAVs), Cessna, etc.)s), Cessna, etc.) 20% airlines and large MRO20% airlines and large MROss
10% Gov: FAA, NTSB, NASA, etc.10% Gov: FAA, NTSB, NASA, etc.
5% non5% non--aerospaceaerospace
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Why Reno?Why Reno? -- LearFanLearFan
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WhatWhats up for today?s up for today? Basics of CompositesBasics of Composites Strings and GlueStrings and Glue
Fibers and Fiber FormsFibers and Fiber Forms the Stringsthe Strings
Matrix SystemsMatrix Systems the Gluethe Glue
Adhesive BondingAdhesive Bonding Damage and InspectionDamage and Inspection
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WhatWhats up for today?s up for today? Structural Repair techniquesStructural Repair techniques
Vacuum BaggingVacuum Bagging
Radome RepairRadome Repair
Lightning Strike ProtectionLightning Strike ProtectionAntenna InstallationsAntenna Installations
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What Are Composites?What Are Composites?
Made up of two main types of materials:Made up of two main types of materials: FibersFibers
Carry majority of the loadCarry majority of the load
MatrixMatrix
Gives the part its shape, protects fibersGives the part its shape, protects fibers
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The Basics: Cloth and GlueThe Basics: Cloth and Glue --
Wet LayupWet Layup
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An alternative: PrepregAn alternative: Prepreg
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Typical Sandwich ConstructionTypical Sandwich Construction
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FibersFibers The fibers give the part most of its strength andThe fibers give the part most of its strength and
distinctive characteristics:distinctive characteristics: Glass or fiberglass (white)Glass or fiberglass (white)
Good strength and stiffness, good impactresistance, heavier
Carbon or Graphite fiber (black)Carbon or Graphite fiber (black) Very high bending stiffness, high tensile and
compressive strength, poor impact resistance, light
KevlarKevlar
fiber (yellow)fiber (yellow) Excellent impact resistance, high tensile strength,poor compressive strength, light weight
The fibers carry most of the load!The fibers carry most of the load!
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Matrix systems (resins)Matrix systems (resins) PolyestersPolyesters
Vinyl EstersVinyl Esters
EpoxiesEpoxies BismaleimidesBismaleimides
Cyanate EstersCyanate Esters
PhenolicsPhenolics
OthersOthers
Each type of fiber and resin has different structuralEach type of fiber and resin has different structuralproperties and temperature tolerance.properties and temperature tolerance.
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FabricFabric : material constructed of: material constructed ofinterlaced yarns, fibers, or filamentsinterlaced yarns, fibers, or filaments
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Many Weave Styles; This isMany Weave Styles; This is
Eight Harness Satin weaveEight Harness Satin weave
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Unidirectional TapeUnidirectional Tape: Non: Non--wovenwovenmaterial in which the filaments are laid inmaterial in which the filaments are laid ina single direction within a resin matrix;a single direction within a resin matrix;
multiple plies used.multiple plies used.
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Military AircraftMilitary Aircraft
BB--2:2:Approximately 85% of the structuralApproximately 85% of the structural
weight is compositeweight is composite
FF--2222
FF--3535
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BoeingBoeing
Bird of PreyBird of Prey
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Commercial AircraftCommercial Aircraft
Boeing 777Boeing 777
Boeing 787Boeing 787
Airbus AAirbus A--380380
AA--380 fuselage380 fuselagecrosscross--sectionsection
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HighHigh--Performance SailplanesPerformance Sailplanes
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DiamondDiamond
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Cessna 300/350/400Cessna 300/350/400
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Cirrus SRCirrus SR--20 and 2220 and 22
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Critical Areas of DamageCritical Areas of Damage
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New Honda Jet HF 118New Honda Jet HF 118
Honda Jet employs anHonda Jet employs an
allall--carbon fibercarbon fiberreinforced epoxyreinforced epoxy
fuselagefuselage
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Unmanned Aerial VehiclesUnmanned Aerial Vehicles
(UAV)(UAV)
NorthropNorthrop--
GrummanGrummanGlobalGlobalHawkHawk
BoeingBoeingUCAVUCAV
Tit IVB b fib b t
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Titan IVB carbon fiber boosters:Titan IVB carbon fiber boosters:
114114 long, 10long, 10 diameterdiameter
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Swedish VisbySwedish Visby--class 240 foot (73m)class 240 foot (73m)
all carbonall carbon--fiber lowfiber low--observable shipobservable ship
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Large Sailing VesselsLarge Sailing Vessels
Mirabella VMirabella V-- 246 feet246 feet --Worlds largest composite yachtWorlds largest composite yacht
Cost: $55 MillionCost: $55 Million
246' long with a246' long with abeam of 48.6'.beam of 48.6'.
Her 30,042 sq. ft. ofHer 30,042 sq. ft. ofsail is carried by asail is carried by a290' high carbon290' high carbonfiber mast built in fivefiber mast built in fivesections.sections.
Even a J boat will lookEven a J boat will looksmall next to Mirabella V.small next to Mirabella V.
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Large Windmill BladesLarge Windmill Blades
Blade SectionBlade Section
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Transport of a LM 38.8 m rotor bladeTransport of a LM 38.8 m rotor blade
Onshore Blade TransportationOnshore Blade Transportation
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So composites may be hereSo composites may be hereto stay; not a passing fad.to stay; not a passing fad.
There are many applications in a wideThere are many applications in a wide
variety of industries, and the list isvariety of industries, and the list isgrowing daily.growing daily.
However, this remains a somewhatHowever, this remains a somewhatimmature technology; weimmature technology; were all stillre all still
learning lessons the hard way aboutlearning lessons the hard way aboutthese materials!these materials!
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Advanced CompositeAdvanced CompositeFibers and Fiber FormsFibers and Fiber Forms
The stringy part ofThe stringy part of
the string and glue!the string and glue!
Many Types of Fibers but forMany Types of Fibers but for
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Many Types of Fibers, but forMany Types of Fibers, but for
advanced composites:advanced composites: GlassGlass
QuartzQuartz Carbon/GraphiteCarbon/Graphite
Aramid (KevlarAramid (Kevlar
)) BoronBoron
UHMW Polyethylene (SpectraUHMW Polyethylene (Spectra
)) CeramicCeramic
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Fiberglass clothFiberglass cloth
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KevlarKevlarAramid fiber yarnAramid fiber yarn
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Carbon Unidirectional TapeCarbon Unidirectional Tape
Prepreg rollPrepreg roll
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Fiberglass (White)Fiberglass (White)
Good strength in both tension and compressionGood strength in both tension and compression
Good energy absorption propertiesGood energy absorption properties Low costLow cost
Easy to work withEasy to work with
Moisture resistantMoisture resistant Electrical insulatorElectrical insulator
HeavyHeavy
Some types can be affected by an alkalineSome types can be affected by an alkalineenvironmentenvironment
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KevlarKevlar aramid fiber (Yellow)aramid fiber (Yellow)
Much lighter than fiberglassMuch lighter than fiberglass
Very good energy absorptionVery good energy absorption Excellent in tension, poor in compressionExcellent in tension, poor in compression
Electrical insulatorElectrical insulator
Moderately expensiveModerately expensive Absorbs some moistureAbsorbs some moisture
Sensitive to UVSensitive to UV
Bonds poorly to polyester resinsBonds poorly to polyester resins
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Carbon (graphite) fiber (Black)Carbon (graphite) fiber (Black)
Excellent in tension and compressionExcellent in tension and compression
Excellent in bending stiffnessExcellent in bending stiffness Partial absorber of microwaves; donPartial absorber of microwaves; dont use in at use in a
radome!radome!
Poor at impact energy absorptionPoor at impact energy absorption -- brittlebrittle
ExpensiveExpensive
Electrically conductive!Electrically conductive!
Can cause galvanic corrosion problems with carbonCan cause galvanic corrosion problems with carbonsteel, cadsteel, cad--plated fasteners, and especiallyplated fasteners, and especiallyaluminum!aluminum!
MaterialMaterial Galvanic ScaleGalvanic Scale
M i 12 ANODIC
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4040
MagnesiumMagnesium 1212 ANODICANODIC
ZincZinc 1111
Aluminum 7075 CladAluminum 7075 Clad 1010Aluminum 2024 CladAluminum 2024 Clad 99
Aluminum 7075Aluminum 7075--T6T6 99
CadmiumCadmium 88
Aluminum 2024Aluminum 2024--T4T4 77
Wrought SteelWrought Steel 66
Cast SteelCast Steel 66
LeadLead 44
TinTin 44
Manganese BronzeManganese Bronze
33
BrassBrass 22
Aluminum BronzeAluminum Bronze 22
CopperCopper 22
NickelNickel 11
InconelInconel 11
Type 303 StainlessType 303 Stainless 00
TitaniumTitanium 00
MonelMonel 00
SilverSilver 00
Carbon FiberCarbon Fiber 00 CATHODICCATHODICCopyrightCopyright2008 Abaris Training Resources Inc.2008 Abaris Training Resources Inc.
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Boron fiberBoron fiber
Excellent in tensile strengthExcellent in tensile strength
Even better in compressive strengthEven better in compressive strength ananunusual property for a fiberunusual property for a fiber
Very high modulusVery high modulus
Tungsten coreTungsten core
BrittleBrittle ExpensiveExpensive
Difficult to cutDifficult to cut
Now used mostly for bonded repairs to crackedNow used mostly for bonded repairs to crackedmetallic structures.metallic structures.
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Polyethylene (SpectraPolyethylene (Spectra) fiber) fiber
UHMW PolyethyleneUHMW Polyethylene
Excellent in tensionExcellent in tension Very resistant to impactsVery resistant to impacts
BulletproofBulletproof vests, helmets, etc.vests, helmets, etc.
Impervious to waterImpervious to water
Difficult to bond to matrix systemsDifficult to bond to matrix systems
Poor at high temperatures (+212Poor at high temperatures (+212F)F) Occasionally seen in radomes or antennaOccasionally seen in radomes or antenna
covers.covers.
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Quartz fibersQuartz fibers
Another form of glassAnother form of glass
Good at high temperaturesGood at high temperatures Good tensile & compressive strengthGood tensile & compressive strength
Microwave transparentMicrowave transparent
ExpensiveExpensive
Sometimes used in radomes, especiallySometimes used in radomes, especiallyon Airbus aircrafton Airbus aircraft
C f
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Ceramic fibersCeramic fibers
Usually used in short forms, with ceramicUsually used in short forms, with ceramic
or metal matrix systemsor metal matrix systems Excellent at really high temperaturesExcellent at really high temperatures
Often used in ballistic armorOften used in ballistic armor Very expensiveVery expensive
Difficult to processDifficult to process
F f R i f t
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Forms of ReinforcementForms of Reinforcement
Filaments/tows/strands/yarns/rovingsFilaments/tows/strands/yarns/rovings
Mats (chopped strand, continuous)Mats (chopped strand, continuous)
Unidirectional tapeUnidirectional tape
Woven rovingWoven roving
Woven textile fabricsWoven textile fabrics Plain weave, satin weaves, twills, etc.Plain weave, satin weaves, twills, etc.
Stitchbonded fabricsStitchbonded fabrics BraidsBraids
Si i /Fi i hSi i /Fi i h
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Sizing/FinishesSizing/Finishes
Used to coat filaments to improve bondingUsed to coat filaments to improve bonding
Many different types, compatible withMany different types, compatible withdifferent resin systemsdifferent resin systems
Some polyesterSome polyester--compatible sizings are notcompatible sizings are not
compatible with epoxies, and vice versacompatible with epoxies, and vice versa Special surface treatments for some fibersSpecial surface treatments for some fibers
(e.g.: ion bombardment for UHMW(e.g.: ion bombardment for UHMWpolyethylene)polyethylene)
Carbon almost alwaysCarbon almost always sizedsized for epoxiesfor epoxies
Fib /R i R tiFib /R i R ti
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Fiber/Resin RatioFiber/Resin Ratio
Too little resin: resin starvedToo little resin: resin starved
Compressive properties strongly degradedCompressive properties strongly degraded Too much resin: resin richToo much resin: resin rich
Heavy, brittle, weakHeavy, brittle, weak
If the right amount of resin is good, more resin isIf the right amount of resin is good, more resin isNOT better!NOT better!
For most woven cloth, about 60% fiber,For most woven cloth, about 60% fiber,40% resin by weight is OK.40% resin by weight is OK.
C tC t
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CostsCosts
Tremendous variation in cost:Tremendous variation in cost:
Fiberglass: $1Fiberglass: $1 -- $6/lb.$6/lb. Kevlar: $8Kevlar: $8 -- $15/lb.$15/lb.
Carbon fiber: $8Carbon fiber: $8 -- $4,000/lb.$4,000/lb.
Boron: $650/lbBoron: $650/lb
T f Gl FibT f Gl Fib
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Types of Glass FibersTypes of Glass Fibers
AA HighHigh--AlkaliAlkali
EE ElectricalElectrical SS StructuralStructural
SS--22 Commercial grade SCommercial grade S--glassglass
DD Dielectric gradeDielectric grade
MM HighHigh--modulus (Boronmodulus (Boron--rich)rich)
T f Gl Fib (C t )T f Gl Fib (C t )
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Types of Glass Fibers (Cont.)Types of Glass Fibers (Cont.)
CC Chemical ResistantChemical Resistant
EE--CRCR Corrosion ResistantCorrosion Resistant RR HighHigh--strength, high modulusstrength, high modulus
LeadLead Radioactivity resistantRadioactivity resistant
LithiumLithium--OxideOxide XX--Ray transparentRay transparent
F b i ll t i lFabric roll terminology
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Fabric roll terminologyFabric roll terminology
Ply OrientationPly Orientation
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Ply OrientationPly Orientation
Warp ClocksWarp Clocks
CCWCCW CWCW
0
90+45
-45
0
90-45
+45
SymmetrySymmetry
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SymmetrySymmetry
BalanceBalance
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BalanceBalance
QuasiQuasi IsotropicIsotropic
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QuasiQuasi--IsotropicIsotropic
Nesting vs StackingNesting vs Stacking
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Stacked Layers
Nested Layers
Nesting vs. StackingNesting vs. Stacking
So to build a part properly:So to build a part properly:
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So to build a part properly:So to build a part properly:
Depending on the weave style, one mightDepending on the weave style, one might
make a quasimake a quasi--isotropic, balanced,isotropic, balanced,symmetrical, nested layup.symmetrical, nested layup.
This is as opposed to the usual repairThis is as opposed to the usual repairtechnique: slap some plies on, and ittechnique: slap some plies on, and itss
Miller time!Miller time!
Practical issues with fibers:Practical issues with fibers:
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Practical issues with fibers:Practical issues with fibers:
DonDont use carbon fiber with polyester ort use carbon fiber with polyester or
vinylester resin systemsvinylester resin systems Make sure fiberglass has the proper sizingMake sure fiberglass has the proper sizing
for the resin system you are usingfor the resin system you are using
Worry about UV attack on KevlarWorry about UV attack on Kevlar it mustit mustbe painted.be painted.
DonDont use Kevlar with polyester resins;t use Kevlar with polyester resins;vinylester is OK; epoxy is best.vinylester is OK; epoxy is best.
Practical issues with fibersPractical issues with fibers
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(continued):(continued):
Be very meticulous about surfaceBe very meticulous about surfacepreparation and cleanliness for adhesivepreparation and cleanliness for adhesivebonding.bonding.
Pay close attention to fiber orientation onPay close attention to fiber orientation onwoven cloth or unidirectional structures.woven cloth or unidirectional structures.
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Matrix SystemsMatrix Systems
The glue that holds the stringsThe glue that holds the stringstogether!together!
Matrix Systems must:Matrix Systems must:
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Matrix Systems must:Matrix Systems must:
Transfer loads from fiber to fiberTransfer loads from fiber to fiber
Keep fibers from bucklingKeep fibers from buckling
Give the component a rigid shapeGive the component a rigid shape
Protect the fibers from the environmentProtect the fibers from the environment Handle temperature extremesHandle temperature extremes
MatrixMatrix requiredrequired to attain theseto attain these
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structural properties:structural properties: CompressionCompression
Fibers can carry compressive loads, but onlyFibers can carry compressive loads, but onlyif they are prevented from buckling!if they are prevented from buckling!
ShearShear
Bending stiffnessBending stiffness
MatrixMatrix dominatesdominates thesethese
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structural properties:structural properties: Interlaminar shear (resistance toInterlaminar shear (resistance to
delamination)delamination) Interlaminar tension (peel)Interlaminar tension (peel)
Service TemperatureService Temperature
Matrix types:Matrix types:
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Matrix types:Matrix types:
Organic (Plastics)Organic (Plastics)
ThermosetsThermosets ThermoplasticsThermoplastics
CarbonCarbon
MetalMetal
CeramicCeramic
Thermoset Matrix SystemsThermoset Matrix Systems
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Thermoset Matrix SystemsThermoset Matrix Systems
CrosslinkingCrosslinking
OneOne--time irreversible chemical reactiontime irreversible chemical reaction
Cannot be reCannot be re--formed or melted after curingformed or melted after curing
Difficult to recycleDifficult to recycle
Thermosets include:Thermosets include:
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Thermosets include:Thermosets include:
PolyestersPolyesters
VinylestersVinylesters EpoxiesEpoxies
PhenolicsPhenolics
Cyanate EstersCyanate Esters
BismaleimidesBismaleimides
Some PolyimidesSome Polyimides PolyurethanesPolyurethanes
Thermoplastic Matrix SystemsThermoplastic Matrix Systems
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Thermoplastic Matrix Systemsp y
LongLong--chain moleculeschain molecules
Undergoes a physical change from a solidUndergoes a physical change from a solidto a liquid when heatedto a liquid when heated
Can be reCan be re--heated and reheated and re--formed, melts atformed, melts athigh temperatures, easier to recycle thanhigh temperatures, easier to recycle thanthermosetsthermosets
Thermoplastics include:Thermoplastics include:
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e op ast cs c udep
PlexiglasPlexiglas
ABS (Acrylonitrile butadiene styrene)ABS (Acrylonitrile butadiene styrene) PolyethylenePolyethylene
PEI (Polyetherimide)PEI (Polyetherimide)
PEEK (Polyetheretherketone)PEEK (Polyetheretherketone)
PPS (Polyphenylene sulfide)PPS (Polyphenylene sulfide)
NylonNylon Many othersMany others
Temperature considerationsTemperature considerations
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in thermosets:in thermosets: Curing temperature and timeCuring temperature and time
Glass Transition TemperatureGlass Transition Temperature (T(Tgg))
Heat deflection or distortion temperature;Heat deflection or distortion temperature;
service temperatureservice temperature
Polyester AdvantagesPolyester Advantages
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y gy g
InexpensiveInexpensive
Good water resistanceGood water resistanceAvailable in wet or a few prepreg systemsAvailable in wet or a few prepreg systems
WellWell--understood, easy to work withunderstood, easy to work with
Commonly availableCommonly available
Polyester DisadvantagesPolyester Disadvantages
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Weaker than the other resin systemsWeaker than the other resin systems
BrittleBrittle -- low elongation to failure (1%low elongation to failure (1% -- 3%)3%) Shrinkage when curingShrinkage when curing -- up to 7% in someup to 7% in some
casescases
Relatively low max. use temperatures (TRelatively low max. use temperatures (Tgg)) Relatively poor adhesionRelatively poor adhesion
Styrene emissionsStyrene emissions
Toxic smokeToxic smoke
Vinylester AdvantagesVinylester Advantages
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y gy g
Stronger, stiffer than polyesterStronger, stiffer than polyester
Better environmental resistance thanBetter environmental resistance thanpolyesterpolyester
Higher elongation to failure (3%Higher elongation to failure (3% -- 6%); this6%); thismeans itmeans its less brittles less brittle
Less shrinkage when curingLess shrinkage when curing
Higher THigher Tgg Better adhesion than polyesterBetter adhesion than polyester
Vinylester DisadvantagesVinylester Disadvantages
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y gy g
Higher cost than polyesterHigher cost than polyester
Not available as prepregNot available as prepreg
Styrene emissionsStyrene emissions Toxic smokeToxic smoke
No long cure times possible, aNo long cure times possible, adisadvantage when building very largedisadvantage when building very largestructures.structures.
Epoxy AdvantagesEpoxy Advantages
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p y g
Stronger than polyesters or vinylestersStronger than polyesters or vinylesters
Cure times from minutes to years availableCure times from minutes to years available
No styrene emissionsNo styrene emissions
Less shrinkageLess shrinkage Higher THigher Tggss availableavailable
Excellent adhesive propertiesExcellent adhesive properties
Commonly available wet and in prepregCommonly available wet and in prepreg
Epoxy DisadvantagesEpoxy Disadvantages
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Higher costHigher cost
Precise mix ratios mandatoryPrecise mix ratios mandatory Cannot be mixedCannot be mixed hothot
Hardener Vs.Hardener Vs. CatalystCatalyst discussed belowdiscussed below
Toxic smokeToxic smoke
Phenolic advantagesPhenolic advantages
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Good electrical insulating propertiesGood electrical insulating properties
Good chemical resistanceGood chemical resistance Stable at high loads and temperaturesStable at high loads and temperatures
Good fireGood fire--smokesmoke--toxicity performancetoxicity performance Good ablativeGood ablative
Often used in interiorsOften used in interiors
Phenolic disadvantagesPhenolic disadvantages
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Can be difficult to processCan be difficult to process
Brittle; weaker than epoxiesBrittle; weaker than epoxies Poor adhesive characteristicsPoor adhesive characteristics
Curing Polyesters & VinylestersCuring Polyesters & Vinylesters
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Cure initiated by the addition of aCure initiated by the addition of a catalystcatalyst
Methyl Ethyl Ketone PeroxideMethyl Ethyl Ketone Peroxide -- MEKP (liquid)MEKP (liquid)
Benzoyl PeroxideBenzoyl Peroxide BPO (paste)BPO (paste)
Both have significant health & safety concernsBoth have significant health & safety concerns
These initiators kill off inhibitors, and allow the resinThese initiators kill off inhibitors, and allow the resinmolecules to crossmolecules to cross--linklink
Exact mix ratios not criticalExact mix ratios not critical can mixcan mix hothot or mixor mixcoldcold
Mix timing and sequence is criticalMix timing and sequence is critical
Styrene emission problemsStyrene emission problems
Curing EpoxiesCuring Epoxies
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These resins are cured by crossThese resins are cured by cross--linking with alinking with ahardenerhardener, not by adding a catalyst, not by adding a catalyst
Exact mix ratios are critical, especially as oneExact mix ratios are critical, especially as onemoves away from 50/50 mixes;moves away from 50/50 mixes; 2% by weight2% by weight
needed with the strongest aircraftneeded with the strongest aircraft
--gradegrade
systemssystems
OneOne cannotcannot mixmix hothot ororcoldcold
Different hardenerDifferent hardenerspeedsspeeds are available forare available formany epoxy resin systemsmany epoxy resin systems
Epoxy curing temperatureEpoxy curing temperature
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considerationsconsiderations While many areWhile many are roomroom--temptemp curable, almost allcurable, almost all
develop full strength only after a highdevelop full strength only after a high--temptemp
postpost--curecure: 150: 150FF 200200F for 1F for 1--10 hours.10 hours.
Higher cure temperatures also result in a higherHigher cure temperatures also result in a higher
glass transition temperatureglass transition temperature
Outgassing can be an issue in highOutgassing can be an issue in high--temperaturetemperaturecure cyclescure cycles
Crosslinking rate doubles for every 10Crosslinking rate doubles for every 10C (18C (18F)F)temperature increasetemperature increase
Things to watch out forThings to watch out for
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Improper mix ratiosImproper mix ratios By weight or by volumeBy weight or by volume they are different!they are different!
Incomplete mixingIncomplete mixing
Wrong ingredientsWrong ingredients
Wrong mixing sequenceWrong mixing sequence ExothermsExotherms --A good way to get OSHA onA good way to get OSHA on
your case!your case! Excessive moistureExcessive moisture
Old materialsOld materials
The Least You Need to KnowThe Least You Need to Know
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When you laminate, unlike with aluminum,When you laminate, unlike with aluminum, YouYouare the Creator of the material propertiesare the Creator of the material properties dodo
it right!it right! Repairs and assembly cures areRepairs and assembly cures are secondarysecondary
bondsbonds excellent surface preparation is critical!excellent surface preparation is critical!
Errors here are NOT detectable with ANY NDIErrors here are NOT detectable with ANY NDIprocess!process!
Use resins with adequate propertiesUse resins with adequate properties thosethose
approved by the airframe manufacturer ONLY!approved by the airframe manufacturer ONLY!
Structural Properties ResultStructural Properties Result
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From Many Design Choices andFrom Many Design Choices andFabrication ProcessesFabrication Processes
Material ChoicesMaterial Choices FibersFibers
Fiber FormsFiber Forms
ResinsResins
CoresCores Fiber AlignmentFiber Alignment
ProcessProcess
Contact LayupsContact Layups
Vacuum Bagged LayupsVacuum Bagged Layups
Elevated Temperature CureElevated Temperature Cure
Peel Ply UsePeel Ply Use
Practice Safe CompositesPractice Safe Composites
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Epoxy SensitizationEpoxy Sensitization
Through the SkinThrough the Skin
InhalationInhalation Fillers and FibersFillers and Fibers
VaporsVapors
BlindnessBlindness Polyester Activator (MEKP)Polyester Activator (MEKP)
Resin Uncontrolled ExothermsResin Uncontrolled Exotherms
Electrical Motor ShortsElectrical Motor Shorts Carbon DustCarbon Dust
Top 10 ListTop 10 List
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1.1. Protect Your HealthProtect Your Health2.2. Peel Ply Is Your Friend, EXCEPT forPeel Ply Is Your Friend, EXCEPT for
secondary bondline surface preparation!secondary bondline surface preparation!3.3. Mix Epoxy Resins AccuratelyMix Epoxy Resins Accurately4.4. Use The Right Materials When MakingUse The Right Materials When Making
StructureStructure Fiber FinishFiber Finish
Structural ResinStructural Resin
Wet Layup/Honeycomb usually turns out ugly.Wet Layup/Honeycomb usually turns out ugly.
Top 10 List (cont.)Top 10 List (cont.)
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5.5. Secondary Bonds Require Careful PreparationSecondary Bonds Require Careful PreparationCleaning Solvents usually contaminate, not clean!Cleaning Solvents usually contaminate, not clean!
6.6. Epoxies Do Not Reach Their Full PropertiesEpoxies Do Not Reach Their Full PropertiesUnless PostUnless Post--CuredCured
7.7. Only Low Viscosity Resins Will EncapsulateOnly Low Viscosity Resins Will Encapsulate
The Individual Tiny Reinforcement FibersThe Individual Tiny Reinforcement Fibers
8.8. Laminate Only When The Temperature AndLaminate Only When The Temperature AndHumidity Are Correct For The Resin In UseHumidity Are Correct For The Resin In Use
9.9. Vacuum Bagging Improves Material PropertiesVacuum Bagging Improves Material Properties
10.10. Face Sheet To Core Bonds Are Critical!Face Sheet To Core Bonds Are Critical!
More on surface prep for bonding:More on surface prep for bonding:
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NylonNylon peel plies ALL contain releasepeel plies ALL contain releaseagents, usually siliconeagents, usually silicone--based, even thosebased, even thoseadvertised as being heatadvertised as being heat--cleaned!cleaned!
If there was no release agent in them atIf there was no release agent in them at
all, they would never release, and wouldall, they would never release, and wouldhave to be ground off.have to be ground off.
PolyesterPolyesterpeel plies may or may not havepeel plies may or may not haverelease agents in them.release agents in them.
More on surface prep for bonding:More on surface prep for bonding:
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CoronaCorona--treatedtreated polyester peel plies dopolyester peel plies donot have release agents, but do have anot have release agents, but do have a
limited shelf life, about one year.limited shelf life, about one year. Even these peel plies cause a problem;Even these peel plies cause a problem;
the weave texture of the peel ply leavesthe weave texture of the peel ply leavesthousands of small sharpthousands of small sharp--edged groovesedged groovesin the resin.in the resin.
These grooves are not filled later by theThese grooves are not filled later by theadhesive; the viscosity is too high.adhesive; the viscosity is too high.
More on surface prep for bonding:More on surface prep for bonding:
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The best solution is GENTLE grit blastingThe best solution is GENTLE grit blastingto remove the peel ply impressions in theto remove the peel ply impressions in thesurface, without damaging the fibers of thesurface, without damaging the fibers of thesurface ply.surface ply.
However, grit blasting with compressed airHowever, grit blasting with compressed airwill contaminate the surface with oil, water,will contaminate the surface with oil, water,
etc. Dry nitrogen works, but is expensive.etc. Dry nitrogen works, but is expensive. SoSo what to do?what to do?
More on surface prep for bonding:More on surface prep for bonding:
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First of all, NEVER use nylon peel plies onFirst of all, NEVER use nylon peel plies ona surface which will be accepting ana surface which will be accepting anadhesive bond later. Itadhesive bond later. Its fine on nons fine on non--bonding surfaces.bonding surfaces.
Probably the best workable solution is toProbably the best workable solution is touse coronause corona--treated polyester peel plies,treated polyester peel plies,
followed by GENTLE hand sanding tofollowed by GENTLE hand sanding toremove the peel ply weave texture.remove the peel ply weave texture.
More on surface prep for bonding:More on surface prep for bonding:
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Use cheap sandpaper, which does not haveUse cheap sandpaper, which does not haveantianti--cloggingclogging properties. The expensiveproperties. The expensive
papers are coated with release waxes to helppapers are coated with release waxes to helpthe sanding residue fall off the paper.the sanding residue fall off the paper.
Use a fine grit paper, 320 or higher. You areUse a fine grit paper, 320 or higher. You areNOT trying to getNOT trying to get toothtooth in the bondline. Thisin the bondline. Thiswill break fibers. Bond strengths improve all thewill break fibers. Bond strengths improve all the
way up to 600 grit.way up to 600 grit.
Still more on surface prep for bonding:Still more on surface prep for bonding:
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Do NOT solvent wipe after sanding, dry wipe!Do NOT solvent wipe after sanding, dry wipe!
The final sanding step should be done as closeThe final sanding step should be done as closeas possible to the application of adhesive;as possible to the application of adhesive;preferably within 4 hours. Do not wait overnight.preferably within 4 hours. Do not wait overnight.
The sanding produces aThe sanding produces a high surface energyhigh surface energyon the part. This effect goes away after a fewon the part. This effect goes away after a fewhours, as the broken crosshours, as the broken cross--links on the surfacelinks on the surface
link back together.link back together. Cleanliness in all steps is mandatory!Cleanliness in all steps is mandatory!
How can you tell if your surfaceHow can you tell if your surface
ti i OK?ti i OK?
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preparation is OK?preparation is OK? Try the water break test. However, youTry the water break test. However, you
must dry the parts thoroughly, usingmust dry the parts thoroughly, usingCLEAN white (no printing) paper towelsCLEAN white (no printing) paper towelsand a hair dryer.and a hair dryer.
If the waterIf the wateravoidsavoids an area on youran area on yoursurface, so will the adhesive. Thesurface, so will the adhesive. The
adhesive must uniformly wet out the entireadhesive must uniformly wet out the entirebonding surface.bonding surface.
Water Break TestingWater Break Testing -- beforebefore
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Water break testWater break test after:after:right side clean, left sideright side clean, left side
contaminatedcontaminated
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contaminatedcontaminated
SoSo the details matter!the details matter!
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Creating longCreating long--lasting, durable compositelasting, durable compositeSTRUCTURAL bonds is not easy.STRUCTURAL bonds is not easy.
Even more difficult in aluminum bonding.Even more difficult in aluminum bonding.
The difference between good surfaceThe difference between good surface
preparation and slipshod surfacepreparation and slipshod surfacepreparation means obtaining a joint whichpreparation means obtaining a joint whichwill last many years under load, aswill last many years under load, as
opposed to perhaps only a few months,opposed to perhaps only a few months,especially in a hotespecially in a hot--wet environment.wet environment.
C it D dC it D d
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Composite Damage andComposite Damage andInspection IssuesInspection Issues
Visual inspection is notVisual inspection is notenough!enough!
IntroductionIntroduction
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A vast majority of damage occurs on the
ground. Brittle nature of matrix/fiber combination
contributes to ease of damage. Composites are not as tough as metals,
(dont yield and bend like metals);damage is often hidden to the eye.
Unusual Damage MechanismsUnusual Damage Mechanisms
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To those untrained in these materials,there are unexpected ways to causedamage:
Water ingress into honeycomb cores Paint stripper!
Minor impacts such as tool drops, etc.
Heat, Hydraulic fluid, UV, etc.
Lightning StrikesLightning Strikes
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Bird StrikesBird Strikes
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Impact DamageImpact Damage
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Water DamageWater Damage
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Battle DamageBattle Damage
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JackstandsJackstands
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MidMid--Air CollisionsAir Collisions
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Your flight has arrivedYour flight has arrived
in the gate area!in the gate area!
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in the gate area!in the gate area!
Sheet metal damage assessmentSheet metal damage assessmentis not covered in this presentationis not covered in this presentation
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Damage AssessmentDamage Assessment
I t ff t i ibilit llI t ff t i ibilit ll
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Impact energy affects visibility, as well asImpact energy affects visibility, as well asseverity, of damage:severity, of damage:
High and medium energy impacts, whileHigh and medium energy impacts, whilesevere, are easy to detect.severe, are easy to detect.
Low energy impacts can easily causeLow energy impacts can easily causehiddenhidden damage.damage.
Impact Energy LevelsImpact Energy Levels
Medium Energy ImpactLow Energy Impact0
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0
0
0
00
+ 45
+ 45
-45
-45
0
9090
High Energy Impact
Through penetrationsmall damage zone
Delamination
Pyramid Pattern Matrix Crack from impact.Delaminations
Back side fiber fracture
0
0
0
00
-45
-45
0
9090
+ 45
+ 45
Why NDI?Why NDI?Delta II launchDelta II launch
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111111
CopyrightCopyright
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Primary NDI Technologies usedPrimary NDI Technologies used
in Composite Structuresin Composite Structures
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in Composite Structuresin Composite Structures VisualVisual
Tap TestingTap Testing
UltrasoundUltrasound
XX--RayRay ThermographyThermography
Laser Shearography / InterferometryLaser Shearography / InterferometryAcoustic EmissionsAcoustic Emissions
Visual InspectionVisual Inspection
One can visually detect (to some extent):One can visually detect (to some extent):
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One can visually detect (to some extent):One can visually detect (to some extent):
BurnsBurns
DisbondsDisbonds
DelaminationsDelaminations
ContaminationContamination OverOver--stressed or fractured areasstressed or fractured areas
Paint RemovalPaint Removal
Paint must be removed before a visualPaint must be removed before a visual
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Paint must be removed before a visualPaint must be removed before a visualinspection can be performed.inspection can be performed.
DO NOT USE PAINT STRIPPER!! It willDO NOT USE PAINT STRIPPER!! It willattack andattack and eateat the resin.the resin.
Use gentle hand sanding to remove paint;Use gentle hand sanding to remove paint;DO NOT SAND INTO THE FIBERS!DO NOT SAND INTO THE FIBERS!
Wing impact loading on aft attachWing impact loading on aft attachpoints causes floor to break herepoints causes floor to break here
(Picture courtesy of Cirrus Design)(Picture courtesy of Cirrus Design)
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115115
Composite turns white at the point of
fracture
CopyrightCopyright2008 Abaris Training Resources Inc.2008 Abaris Training Resources Inc.
Look at flat angle toLook at flat angle todetect small defectsdetect small defects
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Tap TestingTap Testing
EffectiveEffective Less Effective OnLess Effective On
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EffectiveEffective
Cheap, .25Cheap, .25 & Up& Up
Less Effective OnLess Effective OnThick LaminatesThick Laminates
WonWont Go Throught Go ThroughCoreCore
Possible FalsePossible FalseReadingsReadings
Must Be Able To HearMust Be Able To Hear
Quiet Area NeededQuiet Area Needed
Tap TestingTap Testing
Wichitech Electronic Tap HammerWichitech Electronic Tap Hammer
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Wichitech Electronic Tap HammerWichitech Electronic Tap Hammer
Ultrasonic InspectionUltrasonic Inspection
AA--ScanScan
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AA ScanScan
PulsePulse--Echo DisplayEcho Display
CC--ScanScan
Through TransmissionThrough Transmission
UltrasonicUltrasonic AA--ScanScan InspectionInspection
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Ultrasonic InspectionUltrasonic Inspection
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Noise From ImperfectionsNoise From Imperfections
Material AttenuationMaterial Attenuation Kevlar Reads Poorly, Carbon Reads BetterKevlar Reads Poorly, Carbon Reads Better Autoclave cured reads better than vacuumAutoclave cured reads better than vacuum
bag curedbag cured
Hidden DelaminationsHidden Delaminations
A-Scan DisplayAA--ScanScan DisplayDisplay
ThroughThrough--transmission ultrasonicstransmission ultrasonics
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ThroughThrough--transmission ultrasonics:transmission ultrasonics:CC--scanscan display of Fdisplay of F--18 carbon18 carbon
fiber upper inner wing skinfiber upper inner wing skin
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XX--Ray InspectionRay Inspection
Sees Changes In DensitySees Changes In Density
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g yg y
May see Delaminations When ViewedMay see Delaminations When ViewedFrom An AngleFrom An Angle
Shows Some InclusionsShows Some Inclusions
Can Show WaterCan Show Water
XX--Ray Inspection of FRay Inspection of F--1818horizontal stabilizerhorizontal stabilizer
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ThermographyThermography
Uses Infrared Video CameraUses Infrared Video Camera
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Sees small changes in temperatureSees small changes in temperature
Can see many kinds of defectsCan see many kinds of defects
Cutting Edge: Pulsed ThermographyCutting Edge: Pulsed Thermography
Computer enhancedComputer enhanced
MOSAIQ SoftwareMOSAIQ Software
Pulsed ThermographyPulsed Thermography
Disbonded Honeycomb Panel
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127127CopyrightCopyright2008 Abaris Training Resources Inc.2008 Abaris Training Resources Inc.
Methods of limitedMethods of limitedvalue in composites:value in composites:
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Eddy CurrentEddy Current Dye PenetrantDye Penetrant
ThoroughlyThoroughly
contaminatescontaminates
laminatelaminate nono
repair possible.repair possible.
AA--300 Vertical Fin Spar Failure300 Vertical Fin Spar Failure
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129129CopyrightCopyright2008 Abaris Training Resources Inc.2008 Abaris Training Resources Inc.
Not The First TimeNot The First Time
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130130CopyrightCopyright2008 Abaris Training Resources Inc.2008 Abaris Training Resources Inc.
Problems in Composite NDIProblems in Composite NDI
Hidden DamageHidden Damage more prevalent inmore prevalent in
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composites than in metals.composites than in metals.
Therefore there is more of a requirementTherefore there is more of a requirementfor NDI, but if no one is even aware thefor NDI, but if no one is even aware the
component may be damaged, NDI willcomponent may be damaged, NDI willlikely not be utilized.likely not be utilized.
More ProblemsMore Problems
Water in honeycomb coreWater in honeycomb core
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Can easily be detected if there is a lot ofCan easily be detected if there is a lot of
water.water.
MoistureMoisture not so easy to detect, and oftennot so easy to detect, and oftencauses skins to blow off sandwich corescauses skins to blow off sandwich coresduring highduring high--temperature cured repairs.temperature cured repairs.
Difficult to detect moisture, therefore difficultDifficult to detect moisture, therefore difficult
to know if the component is dry enough toto know if the component is dry enough toproceed with repair.proceed with repair.
Yet More ProblemsYet More Problems
Heat damageHeat damagefE t d t t if i ll i
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Easy to detect if severe, especially inEasy to detect if severe, especially in
fiberglass, but essentially impossible to detectfiberglass, but essentially impossible to detectin carbon fiber if it is less severe but stillin carbon fiber if it is less severe but stillsignificant damage.significant damage.
Resin matrix becomes more brittle, crackResin matrix becomes more brittle, crack--proneprone Caused permanent grounding of a Navy ACaused permanent grounding of a Navy A--66
Intruder after engine fire; no one could determineIntruder after engine fire; no one could determinethe extent of the heat damage to the new allthe extent of the heat damage to the new all--
carbon fiber wing. Led to the writecarbon fiber wing. Led to the write--off of a ~$40off of a ~$40million aircraft.million aircraft.
More Problems StillMore Problems Still
Cannot detect a weak but stillCannot detect a weak but still--stuckstuckdh i b ddh i b d
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adhesive bond.adhesive bond.
Easy to detect destructivelyEasy to detect destructively
Unknown how to detect nonUnknown how to detect non--destructively.destructively.
Big problem, relatively common occurrenceBig problem, relatively common occurrenceAging epoxy degrades, especially hotAging epoxy degrades, especially hot--wetwet
Improper surface preparations commonImproper surface preparations common
Many process control issuesMany process control issues
So this is an Opportunity!So this is an Opportunity!
The industry badly needs the ability toThe industry badly needs the ability toth t th f dh i b dth t th f dh i b d
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measure the strength of an adhesive bondmeasure the strength of an adhesive bond
nonnon--destructively.destructively.
Many organizationsMany organizations manufacturers,manufacturers,
military, airlines, etc.military, airlines, etc. would pay dearly towould pay dearly tohave this capability.have this capability.
Probably the biggest missing link in theProbably the biggest missing link in theadvanced composites field at this time.advanced composites field at this time.
Composite DamageComposite Damage
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Repair TechniquesRepair Techniques
FieldField--level repairs conductedlevel repairs conductedwithout an autoclave.without an autoclave.
IntroductionIntroduction
Damaged composite structures areDamaged composite structures ared fi it l i bldefinitel repairable
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definitely repairable.definitely repairable.
However, there are problems:However, there are problems:
Hidden damage issues, includingHidden damage issues, including
manufacturing defects.manufacturing defects. Unexpected damage sources.Unexpected damage sources.
BestBest repair techniques heavily dependent onrepair techniques heavily dependent on
details of the structuredetails of the structure..
Impact spreads in a coneImpact spreads in a cone--shapedshapedarea from the point of impactarea from the point of impact
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Damage RemovalDamage Removal
Additional damage assessment must beAdditional damage assessment must beperformed after paint removal or Tedlarperformed after paint removal or Tedlar
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performed after paint removal or Tedlarperformed after paint removal or Tedlar
film removal, as hidden damage oftenfilm removal, as hidden damage oftenbecomes more apparent.becomes more apparent.
Damaged composite skin may be removedDamaged composite skin may be removedby careful routing or grinding through theby careful routing or grinding through thedamaged surface.damaged surface.
Diamond Router BitDiamond Router Bit Good forGood forCarbon Fiber and Fiberglass, notCarbon Fiber and Fiberglass, not
for Kevlarfor Kevlar
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Single Helix RouterSingle Helix Router Good forGood forCarbon Fiber and Fiberglass, notCarbon Fiber and Fiberglass, not
for Kevlarfor Kevlar
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Split Helix Router for KevlarSplit Helix Router for Kevlar
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Sanding DrumSanding Drum Good for CarbonGood for CarbonFiber and Fiberglass, not for KevlarFiber and Fiberglass, not for Kevlar
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Diamond Hole SawDiamond Hole Saw Good forGood forCarbon Fiber and Fiberglass, notCarbon Fiber and Fiberglass, not
for Kevlarfor Kevlar
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Kevlar Hole Saw with pilot bitKevlar Hole Saw with pilot bit
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Die Grinder with 180 grit diskDie Grinder with 180 grit disk
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Die Grinder with ScotchBriteDie Grinder with ScotchBritepadpad
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Damage RemovalDamage Removal
For a solid laminate with through damage,For a solid laminate with through damage,routing is recommended.routing is recommended.
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gg
For a sandwich skin, with damage into theFor a sandwich skin, with damage into thecore, routing also works well.core, routing also works well.
For a thick solid laminate with damageFor a thick solid laminate with damageonly on surface plies, use careful sandingonly on surface plies, use careful sandinguntil undamaged plies are reached.until undamaged plies are reached.
Damage RemovalDamage Removal
Damaged core should also be removedDamaged core should also be removed
Remove damage in circular or ovalRemove damage in circular or oval
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Remove damage in circular or ovalRemove damage in circular or oval
shapes, and do not use sharp corners.shapes, and do not use sharp corners.
If an irregular shape must be used, thenIf an irregular shape must be used, then
round off each corner to as large a radiusround off each corner to as large a radiusas practical.as practical.
Drying laminates, especially coredDrying laminates, especially coredstructures, is crucial for highstructures, is crucial for high--
temperature cured repairs.temperature cured repairs.
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Composite Repair PrinciplesComposite Repair Principles
Taper edges of repair plies in doublers.Taper edges of repair plies in doublers. This is true whether the doubler is to beThis is true whether the doubler is to be
bonded or mechanically fastened and isbonded or mechanically fastened and is
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bonded or mechanically fastened, and isbonded or mechanically fastened, and ismounted inside or outside the skin.mounted inside or outside the skin.
Cross-sections
Avoid stress concentrations
Composite Fastener StylesComposite Fastener Styles
BlindBlind
Access to one side onlyAccess to one side only
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Access to one side onlyAccess to one side only
Cherry / TextronCherry / Textron
HuckHuck
MonogramMonogram
TwoTwo--PartPart
Require access to both sidesRequire access to both sides
HuckHuck
HiHi--LokLok
Blind FastenersBlind Fasteners
Access to one sideAccess to one sideonlyonly
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Pulls stem throughPulls stem throughrivet bodyrivet body
Expands back sideExpands back side
Stem breaks flushStem breaks flush
Sets locking ringSets locking ring
Blind FastenersBlind Fasteners
Access to one sideAccess to one sideonlyonly
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Pulls stem throughPulls stem throughrivet bodyrivet body
Expands back sideExpands back side
Stem breaks flushStem breaks flush
Sets locking ringSets locking ring
Two Part FastenersTwo Part Fasteners
Access From BothAccess From BothSides RequiredSides Required
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HiHi--Shear,HiShear,Hi--Lok,HiLok,Hi--TigueTigue
Lock BoltsLock Bolts
Mechanism FastensMechanism FastensBy Threading OrBy Threading Or
SwagingSwaging
Metallic vs. Composite FastenersMetallic vs. Composite Fasteners
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Bearing Area DramaticallyBearing Area Dramatically
Increased To ReduceIncreased To ReduceTipping and fiber crushingTipping and fiber crushing
Bearing AreaBearing Area
Metallic vs. CompositeMetallic vs. CompositeCountersinksCountersinks
100
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and 130and 130 for composites.for composites.
130
Countersinks Come In TwoTypes; 100 for metals;
MaterialsMaterials
Fasteners For CompositesFasteners For Composites
A282 StainlessA282 Stainless
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TitaniumTitanium
MonelMonel
Corrosion ConsiderationsCorrosion Considerations
Fastener InstallationFastener Installation
Variety Of Installation ToolsVariety Of Installation Tools
Frequently Heavy / CumbersomeFrequently Heavy / Cumbersome
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q y yq y y
Each Manufacturer Has Their Own Go /Each Manufacturer Has Their Own Go /NoNo--Go CriteriaGo Criteria
Fastener RemovalFastener Removal
OEM Removal SystemsOEM Removal SystemsOEM Removal Systems
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Monogram (ComposiMonogram (Composi--lok II)lok II)
Huck InternationalHuck InternationalHuck International
Cherry TextronCherry TextronCherry Textron
YES
YES *
NO
Fastener RemovalFastener Removal
BasicsBasics
Disengage Locking Ring (if blind)Disengage Locking Ring (if blind)
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Drive Out PinDrive Out Pin
Drill Through Head Only Using SlightlyDrill Through Head Only Using SlightlyUndersized BitUndersized Bit
Remove HeadRemove Head
Drive Out ShankDrive Out Shank
Fastener RemovalFastener Removal
BasicsBasics
Disengage Locking Ring (if blind)Disengage Locking Ring (if blind)
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Drive Out PinDrive Out Pin
Drill Through Head Only Using SlightlyDrill Through Head Only Using SlightlyUndersized BitUndersized Bit
Remove HeadRemove Head
Drive Out ShankDrive Out Shank
Fastener RemovalFastener Removal
BasicsBasics
Disengage Locking Ring (if blind)Disengage Locking Ring (if blind)
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Drive Out PinDrive Out Pin Drill Through Head Only Using SlightlyDrill Through Head Only Using Slightly
Undersized BitUndersized Bit
Remove HeadRemove Head
Drive Out ShankDrive Out Shank
Fastener RemovalFastener Removal
BasicsBasics
Disengage Locking Ring (if blind)Disengage Locking Ring (if blind)
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Drive Out PinDrive Out Pin Drill Through Head Only Using SlightlyDrill Through Head Only Using Slightly
Undersized BitUndersized Bit
Remove HeadRemove Head
Drive Out ShankDrive Out Shank
Fastener RemovalFastener Removal
BasicsBasics
Disengage Locking Ring (if blind)Disengage Locking Ring (if blind)
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Drive Out PinDrive Out Pin Drill Through Head Only Using SlightlyDrill Through Head Only Using Slightly
Undersized BitUndersized Bit
Remove HeadRemove Head
Drive Out ShankDrive Out Shank
Fastener RemovalFastener Removal
BasicsBasics
Disengage Locking Ring (if blind)Disengage Locking Ring (if blind)
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Drive Out PinDrive Out Pin Drill Through Head Only Using SlightlyDrill Through Head Only Using Slightly
Undersized BitUndersized Bit
Remove HeadRemove Head
Drive Out ShankDrive Out Shank
Fastener RemovalFastener Removal
Old Methods Cannot Be Used:Old Methods Cannot Be Used:
Grinding HeadGrinding Head
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Heats Rivet ExcessivelyHeats Rivet Excessively
Cold Chisel To Cut Locking RingCold Chisel To Cut Locking Ring
Will Not Cut TitaniumWill Not Cut Titanium
Drilling To Cut Locking RingDrilling To Cut Locking Ring
Risk Slipping / Wandering Off Head On ToRisk Slipping / Wandering Off Head On ToLaminateLaminate
Fastener RemovalFastener Removal
Drill FixtureDrill Fixture
Necessary To Stay Centered & PreventNecessary To Stay Centered & Prevent
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WanderingWandering Several ApproachesSeveral Approaches
Carbide ToolsCarbide Tools RequiredRequired For Cutting TitaniumFor Cutting Titanium
Cobalt May Work For Stainless SteelCobalt May Work For Stainless Steel
Fastener RemovalFastener Removal
Monogram FastenersMonogram FastenersMonogram Fasteners
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Fastener RemovalFastener Removal
Monogram FastenersMonogram FastenersMonogram Fasteners
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Fastener RemovalFastener Removal
Not Well Addressed By MostNot Well Addressed By MostManufacturers
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Manufacturers Exception: MonogramException: Monogram Removal Tools Are CumbersomeRemoval Tools Are Cumbersome
Stick To The BasicsStick To The Basics Disengage Locking RingDisengage Locking Ring
Use Only Carbide ToolsUse Only Carbide Tools
Only Drill Deep Enough To RemoveOnly Drill Deep Enough To RemoveFastener HeadFastener Head
Scarfed (taper sanded) repairsScarfed (taper sanded) repairs
After initial damage removal, we usuallyAfter initial damage removal, we usuallyscarf (taper sand) gently around the repairscarf (taper sand) gently around the repair
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area.area. Rule of thumbRule of thumb -- crude approximationcrude approximation -- is 1/2is 1/2
per ply.per ply.
Lightly loaded structures may be able toLightly loaded structures may be able totolerate a smaller scarf; heavily loadedtolerate a smaller scarf; heavily loaded
structures may require more.structures may require more.
ScarfingScarfing
Scarf distance is often referred to by angles,Scarf distance is often referred to by angles,rather than distance per ply.rather than distance per ply.
20:1 up to as much as 100:120:1 up to as much as 100:1
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The flatter the scarf, the larger the adhesiveThe flatter the scarf, the larger the adhesivebond, and the lower the load per square inchbond, and the lower the load per square inchon the bond.on the bond.
The steeper the scarf, the less undamagedThe steeper the scarf, the less undamagedmaterial is removed.material is removed.
0:10:1 -- Butt joint;Butt joint; :1:1 New PartNew Part
Scarfed RepairsScarfed Repairs
Scarf distance
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Double-sided
Single-sided
Scarf distance
Repair Sequence forRepair Sequence forScarfed Repair:Scarfed Repair:
Inspect for extent of damage:Inspect for extent of damage: VisualVisual
Tap, Ultrasonic, and/or XTap, Ultrasonic, and/or X--raysrays
G b ibl b h id if f iblG t b t ibl b th id if f ibl
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Get best access possible, both sides if feasible.Get best access possible, both sides if feasible.
Remove all damaged and delaminated material.Remove all damaged and delaminated material.
Circular or rounded cornersCircular or rounded corners Grind away scarf angle taper:Grind away scarf angle taper:
Smooth, flat ground surfaceSmooth, flat ground surface
Repair Sequence forRepair Sequence forScarfed RepairScarfed Repair
Determine ply orientations and materials ofDetermine ply orientations and materials oforiginal structure.original structure.
Replace plies:Replace plies:
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Adhesive layer firstAdhesive layer first
One or more filler plies, orientation not important.One or more filler plies, orientation not important.
Repair pliesRepair plies -- match orientations with originalmatch orientations with originalstructure.structure.
Extra pliesExtra plies -- usually orientation matches originalusually orientation matches originalouter ply.outer ply.
Often an outer adhesive layer.Often an outer adhesive layer.
Scarfed Repair sequenceScarfed Repair sequence
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Basics of Vacuum BaggingBasics of Vacuum Bagging
Purpose of Vacuum Bag:Purpose of Vacuum Bag: To provide compaction pressure to laminate or bondTo provide compaction pressure to laminate or bond
Maximum 29.92Maximum 29.92 Hg @ sea levelHg @ sea level O t h f 14 7 PSI @One atmosphere of press re 14 7 PSI @ sea
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One atmosphere of pressure = 14.7 PSI @ seaOne atmosphere of pressure = 14.7 PSI @ sealevellevel
Loss of approx. 1Loss of approx. 1 Hg (.5 psi) per 1000 ft. ofHg (.5 psi) per 1000 ft. of
elevationelevation To extract resin, air, & volatilesTo extract resin, air, & volatiles
BleedBleed excess resin to reduce contentexcess resin to reduce content Distribute resin equally throughout theDistribute resin equally throughout the
laminate/bond jointlaminate/bond joint Remove trapped air, steam, & volatilesRemove trapped air, steam, & volatiles
Basics of Vacuum BaggingBasics of Vacuum Bagging
MaterialsMaterials
Release LayerRelease Layer
Peel PlyPeel Ply
Nylon/release treatedNylon/release treated porousporous
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Nylon/release treatedNylon/release treated--porousporous
Can transfer release agent residue to partCan transfer release agent residue to part--laminatelaminate
Polyester/Corona discharge treatedPolyester/Corona discharge treated
leaves no release agent residue but harder toleaves no release agent residue but harder toremoveremove
Teflon coated fabrics (TFP or TFNP)Teflon coated fabrics (TFP or TFNP)
More expensiveMore expensive--easy to removeeasy to remove--does not transferdoes not transfer
Basics of Vacuum BaggingBasics of Vacuum Bagging
Materials (continued)Materials (continued)
Release filmsRelease films
Solid filmsSolid films
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Solid filmsSolid films Completely restricts resin bleed and limits volatileCompletely restricts resin bleed and limits volatile
extractionextraction
Perforated filmsPerforated films Allows resin/volatile movement through holes in filmAllows resin/volatile movement through holes in film
Hole diameters range from .015Hole diameters range from .015 (pin(pin--prick) to .045prick) to .045 (full(fullhole)hole)
Hole spacing ranges from 1/4Hole spacing ranges from 1/4 to 12to 12 centers incenters incommercial filmscommercial films
Basics of Vacuum BaggingBasics of Vacuum Bagging
Materials (continued)Materials (continued)
FlashFlash--breaker tapebreaker tape
Used to hold ancillary materials in place forUsed to hold ancillary materials in place for
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Used to hold ancillary materials in place forUsed to hold ancillary materials in place forprocessingprocessing--removable after heat and pressureremovable after heat and pressure
Polyester or Kapton film in various widths availablePolyester or Kapton film in various widths available