ABC

Part of GE’s Aviation Business return to TOC

DOWTY PROPELLERS STANDARD PRACTICES MANUAL

MAT 5800
850 G/M² SATIN WEAVE GLASS FIBRE FABRIC

1. Scope

A. This specification covers the material requirements of a nominal 850 g/m² (0.98 oz/ft²) satin weave
glass fibre fabric with a nominal thickness of 0,84 mm (0.033 in).

B. The fabric may be ordered with MAT 5805 polyester based netting bonded to one side of the fabric
to facilitate the manufacture of preforms.

C. When fabric is ordered with MAT 5805 netting bonded to it, it shall be referred to as MAT 5800-C
fabric and will be given the suppliers reference listed in Paragraph 8.B.

D. The material is used to reinforce thermosetting resins in the manufacture of composite propeller
blades.

E. This specification supersedes MAT 800 for all Dowty Propellers contracts.
Any suffix numbers are the same as in the previous MAT 800, i.e. for MAT 800-1 read MAT 5800-1.

2. Health and Safety

A. This specification calls up materials and processes which may cause injury to health, either directly
or indirectly unless precautions are taken. Operators shall wear appropriate clothing and employ
safe working practices.

B. The precautions are listed in the Manufacture Safety Data Sheets (MSDS). At Dowty Propellers,
copies of the MSDS’s are held in the Print Room.

C. Local supervision is responsible for ensuring operators follow health and safety precautions.

3. General Requirement

A. The material must be woven from continuous filament yarns of low alkali glass, E Type.

B. The fabrics must be free from defects of weaving and free from streaks, stains, oil and grease spots.
If a limited number of these defects do occur they must be marked by coloured thread in the
selvedge adjacent to the defect. The defective area of the fabric must not be used in production and
the total area of the cloth made unusable by these defects, rejected. The supplier will not charge for
these defective areas.

C. The fabric must be uniformly woven. The selvedges must be secure, substantially straight and even
and must have approximately the same tension as the remainder of the fabric.

D. The fabric must comply with the requirements of BS 3396 Part 3; Grade "C" chrome finish, except
that the mass per unit area and average breaking strength will be as listed in this specification.

E. The fabric must be constructed nominally of 165 warp threads/100 mm and 138 weft threads/
100 mm. The average number of warp ends and weft picks must not differ by more than 5% from
this construction. The warp and weft counts shall be 136 - 1/2 tex.

MAT 5800
Page 1
60-00-00 May 31/08
GE AVIATION SYSTEMS LTD PROPRIETARY INFORMATION
Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or first page.
 ABC
Part of GE’s Aviation Business

DOWTY PROPELLERS STANDARD PRACTICES MANUAL

F. The mass per unit area must be 850 g/m² ± 6%, for MAT 5800 and 863 g/m² ± 8% for MAT 5800-C.

G. A laminate made from this glass as per Appendix A, must have a ‘dry’ flexural strength of 420 MPa
and a ‘wet’ flexural strength of 360 MPa.

H. The average minimum warp breaking strength must be 650 N/cm when tested in accordance with
Appendix B.

I. The average minimum weft breaking strength must be 600 N/cm when tested in accordance with
Appendix B.

J. The polyester netting on MAT 5800C must be capable of bonding four layers of MAT 5800C glass
cloth to the procedures in Appendix C.

K. The polyester netting on MAT 5800C must be manufactured fully heat set, so that there is < 1%
shrinkage when heated to 90°C (194°F) Refer to Appendix C.

4. Type Approval

A. Before any fabric is supplied for production of parts, samples of the cloth must be forwarded to the
Dowty Propellers for manufacturing trails.

B. The sample must be sufficiently large to allow the examination/tests given in Paragraphs 3.E to 3.I to
be carried out.

C. Fabrics approved by Dowty Propellers must be given a reference number by the manufacturer and
no deviation in construction, treatment or finish of the fabric must be supplied to this specification.

5. Quality Assurance

A. The batch of fabric shall be 100% examined by the manufacturer to ensure it meets Paragraphs 3.B
and 3.C.

B. Each batch of fabric must be tested by the manufacturer for compliance with Paragraphs 3.E, 3.F,
3.H and 3.I of this specification.

C. Each batch of fabric must meet the requirements of Paragraphs 3.G of this specification. Each
batch of MAT 5800C must also be tested to ensure it meets the requirements of paragraphs 3.J. and
3.K.

NOTE: Whilst a manufacturer may decline to carry out this test on every batch of material,
failure to meet these requirements when tested at Dowty Propellers will constitute
grounds for rejection of the batch.

MAT 5800
Page 2
60-00-00 May 31/08
GE AVIATION SYSTEMS LTD PROPRIETARY INFORMATION
Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or first page.
 ABC
Part of GE’s Aviation Business

DOWTY PROPELLERS STANDARD PRACTICES MANUAL

(1) ‘Dry’ Flexural Strength.

Six specimens cut from the laminate must be tested for flexural strength in accordance with
BS 2782 Part 3 Method 340B, (at Dowty Propellers use PMLP 33). The minimum requirement
is 420 MPa.

(2) ‘Wet’ Flexural Strength

Six further specimens must be immersed in boiling distilled water for 4 hours, then cooled in
distilled water at room temperature, prior to testing for flexural strength. The minimum
requirement is 360 MPa.

D. At Dowty Propellers, the receiving inspector must ensure that the appropriate Certificate of
Conformity accompanies the batch of material.

6. Packing and Identifications

A. The fabric must be sufficiently packaged to protect from deterioration or damage.

B. Each roll of fabric shall be marked with the name of the manufacturer and labelled MAT 5800 or
MAT 5800-C. The following information shall also be visible on the reel:

(1) Manufacturer's reference number

(2) Grade of finish (if not included in the reference number)

(3) Batch number

(4) Roll (cut) number

(5) Release note number and date released.

C. Each box or package shall be marked on the outside MAT 5800 or MAT 5800-C and give the name
of the manufacturer, the batch number and release date.

D. Each roll of MAT 5800-C fabric must be packaged such that the fabric can be unrolled without
debonding the MAT 5805 netting.

E. MAT 5800-C must be supplied with a coloured and / or patterned backing film.

7. Storage

A. The fabric must be stored at a temperature not exceeding 25°C (77°F) and at an ambient humidity
not exceeding 65% relative humidity.

B. The fabric will have a storage life of 1 year under these conditions.

C. Following 1 years storage, or sooner if the storage conditions of Paragraph 7.A are not maintained,
the fabric must be resampled and tested by the Laboratory for compliance with the requirements of
Paragraphs 2.G.

MAT 5800
Page 3
60-00-00 May 31/08
GE AVIATION SYSTEMS LTD PROPRIETARY INFORMATION
Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or first page.
 ABC
Part of GE’s Aviation Business

DOWTY PROPELLERS STANDARD PRACTICES MANUAL

D. At all times the fabric shall be stored in a horizontal position. The boxes or packages shall not be
stacked on end.

E. Hands and faces shall be washed with soap and water at the end of a shift and before meal breaks.

8. Approved Products

Supplier Suppliers Reference Dowty Propellers

Part Number

A. MAT 5800

Fothergill Engineered Fabrics Ltd Y 736/205 finish P999468

P.O. Box 1
Littleborough
Lancs.
OL15 9QP

B. MAT 5800-C

Fothergill Engineered Fabrics Ltd Y 0736/411/0960 P999072

P.O. Box 1 Y 0736/X318/0960 P999477
Littleborough Y 0736/X321/0960 P999480
Lancs.
OL15 9QP

MAT 5800
Page 4
60-00-00 Mar 15/11
GE AVIATION SYSTEMS LTD PROPRIETARY INFORMATION
Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or first page.
 ABC
Part of GE’s Aviation Business

DOWTY PROPELLERS STANDARD PRACTICES MANUAL

APPENDIX A

PREPARATION AND TEST OF LAMINATE TEST BOARD

1. Preform Preparation

A. Prepare 3 layers of glass cloth fabric with the warp fibres laid in the 0° direction, i.e. in the direction
of the test. At Dowty Propellers refer to RPPS 60 and Process Data Sheet 1109 for MAT 5800 and
Process Data Sheet 1108 for MAT 5800-C cloth or alternatively RPPS 100 and Process Data Sheet
1239 for MAT 5800 and Process Data Sheet 1238 for MAT 5800-C cloth. Cut fibre for preform
slightly oversize to allow for trimming later.

B. Stack laminations in correct order with MAT 5805 crenette netting between each layer. This is not
necessary when using MAT 5800-C cloth.

C. Vacuum form laminates together for 10 minutes at 70°C (158°F).

D. Trim fibre preform to the correct size for moulding, at Dowty Propellers use template Drawing No.
RPD 1000480 (RPPS 60) or alternatively RPD 1000995 (RPPS 100).

2. Moulding

A. Ensure mould surfaces and stops are clean and coated with a suitable mould release agent.

B. Set press control conditions as listed below:

Mould temperature 100°C (212°F)

Initial dwell time 20 minutes

Gel time Approximately 40 minutes dependent on gel characteristics of resin

batch.

Gel stop size 2,29 mm (0.090 in)

Finish stop size 2,03 mm (0.080 in)

Press load 6 - 8 ton

Allow 2 hours for press temperature to stabilise before commencing process.

MAT 5800
Page 5
60-00-00 May 31/08
GE AVIATION SYSTEMS LTD PROPRIETARY INFORMATION
Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or first page.
 ABC
Part of GE’s Aviation Business

DOWTY PROPELLERS STANDARD PRACTICES MANUAL

C. Mix resin and hardener as shown below:

LY 556 resin at between 65 and 75°C 150 g (5.29 oz)

(149 and 167°F)

HY 932 hardener at room temperature 48 g (1.69 oz)

or

LY 564 resin at 70°C ± 5°C 150g

Hy 2954 hardened at room temperature 52.5g

D. Pour 2/3 to 3/4 of the resin mix into the mould and allow to flow throughout the mould. Leave to de-
aerate for 5 minutes.

E. Carefully place the fibre preform in the mould making sure the preform lays flat in the resin. Allow
the resin to seep through the preform displacing the air over a period of at least 5 minutes. When
the entire preform is impregnated with resin, the remainder of the mix is poured over the surface.

F. Ensure the mould stops are in position, then manually close the mould to 2,54 mm (0.100 in) above
finish size. Connect the motor drive to the hydraulic cylinder, to close the mould to the gel stop
0,25 mm (0.010 in) above finished size. Automatic process control will then close the mould to the
required load as set in Paragraph 2.B above.

G. Cure the laminate in the press at 100°C (212°F) for 3 hours after which release press load, opening
the platens. Remove the mould front block and gently lever the test laminate out.

H. Deflash the test board and mark with identification number.

I. Post cure the laminate at 120°C (248°F) for two hours. This may be done after Paragraph 2.K if
more convenient.

J. Cut strips between 9,75 mm (0.383 in) and 10,25 mm (0.403 in) wide from the laminate with the
length of the strip in the direction of the warp fibre.

K. Twelve specimens between 55 mm (2.165 in) and 60 mm (2.362 in) long must be cut from these
strips. The thickness of any one strip shall be uniform, i.e. its thickness must not vary from the mean
by more than 1%. At Dowty Propellers refer to Drawing No. RPD 1000752 laminate Type B (RPPS
60) or alternatively Drawing No. RPD 1000953 laminate Type B (RPPS 100).

MAT 5800
Page 6
60-00-00 May 31/08
GE AVIATION SYSTEMS LTD PROPRIETARY INFORMATION
Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or first page.
 ABC
Part of GE’s Aviation Business

DOWTY PROPELLERS STANDARD PRACTICES MANUAL

APPENDIX B

DETERMINATION OF BREAKING STRENGTH

1. Test Pieces

A. Cut from the test sample six test pieces in the direction of the warp and six in the direction of the
weft, each not less than 63,5 mm (2.50 in) wide. Ensure that no two test pieces cut in the same
direction contain the same longitudinal threads.

B. To prevent the ends of the test pieces from being damaged in the jaws of the testing machine, they
must be resin impregnated before the width in the test area is reduced uniformly to 50 mm (1.98 in).

C. Lay the test piece on stiff paper and attach the end of the test piece to the paper by coating with a
suitable epoxy resin, leaving 200 mm (7.87 in) untreated at the middle of the test piece. After the
resin has cured remove the threads from the sides of the test piece by careful cutting and fraying
and reduce the test width to 50 mm (1.98 in) in the untreated portion. When the test piece has been
fixed in the jaws of the machine, cut across the paper at the middle.

2. Procedure

A. Condition the test pieces for not less than 6 hours in an atmosphere with a relative humidity of 63 to
67% and a temperature of 18 to 22°C (64 to 72°F). Carry out all testing without removing the
material from this atmosphere.

B. Fix each test piece in the jaws of a machine having an accuracy in accordance with Grade A of
BS 1610: Part 1 so that the unsupported length is 200 mm (7.87 in). Steadily apply a load at such a
rate that a load equal to the specified minimum average breaking strength is reached in
approximately 1 minute.

3. Reporting

A. Calculate the average tensile strength in both directions and the standard deviation of the test
results.

B. Calculate the coefficient of variation. If this exceeds 10% repeat the test in six fresh specimens and
average all 12 results. Report the average result and the coefficient of variation.

MAT 5800
Page 7
60-00-00 May 31/08
GE AVIATION SYSTEMS LTD PROPRIETARY INFORMATION
Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or first page.
 ABC
Part of GE’s Aviation Business

DOWTY PROPELLERS STANDARD PRACTICES MANUAL

APPENDIX C

MAT 5800C ONLY

1. Make a four layer preform, 1,0 m (39.37 in) long (parallel with the warp fibres) and 10 cm (0.394 in) wide
from the MAT 5800C fabric under test. All four layers should be laid glass down on top of each other.
The fourth and final layer should then have the polyester netting removed, leaving glass fabric on the top
and bottom of the preform.

2. Place the preform on a layer of silicone paper, and ensure the silicone paper remains in place when
heating or cooling.

3. Bond the four layer preform together on a vacuum table set at 90°C (194°F) for five minutes.

4. Remove the preform from the vacuum table and cool to room temperature, 18 to 20°C (64 to 72°F).

5. Place the preform in an oven at 90°C (194°F) for 45 minutes.

6. Cool at room temperature, 18 to 22°C (64 to 72°F) for 30 minutes.

7. Ensure there are no wrinkles in the preform. If wrinkles are present, the batch of MAT 5800C must be
rejected.

8. Measure the length of the preform to ensure the polyester netting has not caused the preform to shrink
more than 1%.

9. Check the bond between the layers of tape in the preform are firm.

MAT 5800
Page 8
60-00-00 May 31/08
GE AVIATION SYSTEMS LTD PROPRIETARY INFORMATION
Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or first page.