About The Authors: Dr. Keith Armstrong Earned His MSC in 1978 and PHD in 1990 in Adhesion Science
About The Authors: Dr. Keith Armstrong Earned His MSC in 1978 and PHD in 1990 in Adhesion Science
Dr. Keith Armstrong earned his MSc in 1978 and PhD in 1990 in Adhesion Science
and Technology from City University in London, England. His career began in 1948
at Vickers-Armstrongs (Aircraft) Ltd. Weybridge as an aviation apprentice and then
as a design draftsperson. He subsequently served as a technical officer in the Royal
Air Force and later as an experimental officer at the National Physical Laboratory in
Teddington, UK.
He spent the next 24 years of his career with British Airways (BA). Along with his
work on carbon fiber/Nomex honeycomb floor panels, he developed many new methods
in the infancy of the industry. He later served as a consultant to DuPont on composite
repairs using honeycomb and Kevlar, and then as a quality audit engineer for Aerobond
in the United Kingdom. After retiring from BA, he worked on a call-out basis advising
on composite repairs for Monarch Airlines.
From 1988 to 1991, Dr. Armstrong chaired the IATA Composite Repair Task Force.
He is also a Fellow of the Institution of Mechanical Engineers, the Royal Aeronautical
Society, and the Institute of Materials, Minerals, and Mining. He retired from BA when
they transferred their composites repair work to Bristol, UK and he was close to BA’s
normal retirement age. Dr. Armstrong has written more than 30 technical papers and
compiled the Composite Metal Bonding Glossary published by SAE. He was a part-time
lecturer at Brunel and Plymouth Universities, the University of Bristol, Brooklands
College, and East Surrey College. He held a private pilot’s license for 28 years, is keen on
family history, and has been a member of the Methodist Church for more than 50 years.
Eric Chesmar graduated from the University of Pennsylvania with a degree in Chemical
Engineering. He started his career working at Hercules Inc. in reliability, quality and
manufacturing of composite structures. He joined United Airlines (United) San
Francisco Maintenance Base in 1991 to support the Composite Shop in Component
Maintenance. He has provided the full range of engineering support for the composite
shop and the airline. This has included repair of structures for all fleet types, failure and
reliability analysis, and support of the PAA tank line, autoclave, and materials testing lab.
He obtained Major Repair Authority in 2010 and is currently a Major Repair Authority
in United’s ODA. He also represented United during 777, 787, and A380 Design-Build
Teams for issues related to composite structures.
From 1999 to 2002, he participated in a Team Certification Program at the University
of Washington. The Team researched moisture ingression in honeycomb structures
through producing multiple design options for wing panels with built-in moisture
monitors that were used in service on a 767 for two years, performed numerous lab
studies on the effects of moisture in honeycomb structures, performed thermographic
inspections of over 30 aircraft, and published many papers on the results.
He has also presented in many government workshops, including the Federal
Aviation Administration (FAA) Bonded Structures Workshop (2004); AMTAS Workshop
on Training (2006); FAA Workshop on Composite Damage Tolerance and Maintenance,
Chicago (2011); and National Academy of Sciences Workshop on the Increased Use of
Advanced Composites (2004), and contributed to GAO Report on FAA Actions to Oversee
the Safety of Composite Airplanes (2011). He authored the section “Product Reliability,
©2020 SAE International 531
532 About the Authors
In-Service Experience, and Lessons Learned” of the ASM International Handbook Volume
21—Composites. He is currently serving on the FAA Aviation Rulemaking Advisory
Committee for Transport Airplane Metallic and Composite Structures Working Group.
Mr. Chesmar joined the CACRC in 1994, serving as Chair on the Design Task
Group which published AE-27 Design of Durable, Repairable, and Maintainable Aircraft
Composites and AIR 5416 Maintenance Life Cycle Cost Model. He served as Chair and
Vice-Chair of the committee and continues to serve on the Executive Committee,
Procedures Task Group, and Design Task Group.
Mr. Francois Museux is the chairman of the Repair Task Group of the SAE/IATA/
ATA Commercial Aircraft Composite Repair Committee. He leads the Airbus
Composite Repair Task Group in charge to update the Airbus Structural Repair Manual
Chapter 51. Prior to his current position, Mr. Museux was a Materials and Processes
Engineer with Rohr. He presented several papers on composite repairs in national and
international conferences.
He received his engineering degree in Materials and Physics from the Institut
National des Sciences Appliquees, in Lyon, France. He received his postgraduate degree
in macromolecular and composite materials from the Ecole des Mines in Saint-Etienne,
also in France. His work on the characterization of the mechanical behavior of composite
materials using the local viscoelastic response was presented at the International
Committee on Composite Materials (ICCM IV).
index
Abrading, 252–253 epoxy-based matrix resins and latch positions, damage at, 415
Abrasion, 230 adhesives for aerospace use, lightning damage, 425–428
Acetone, 242 52–53 moisture/fluid ingress
Acrylics, 59 mechanical properties, 51–52 bad edge sealing of honeycomb
Adherend failure, 477 physical and chemical properties, section, 421–422
Adherend interlaminar tension 50–51 composite parts, 420–421
failure, 477 Advisory Circulars (ACs), 224 in radomes, 420
Adhesive behavior, in bonded joints Aerodynamic smoothness, 154, 233 moisture ingress, 432
adhesive shear stress and strain, Aerovac, Airtech International Inc., panel interference, 429
478–479 271–272 panel size, 425
elastic and plastic adhesive behavior, Agitation, 406 pre-preg tape, 428
479–487 Aircraft Maintenance Manual (AMM), resin physical properties, 431–432
adhesive shear stress and strain, 225, 414 sealing honeycomb panel, 422, 424
484, 485 Aircraft structures thermal expansion problem, 429
elastic-elastic condition, 483 early, 5 tooling holes through honeycomb,
elastic-plastic condition, 483 modern, 5 424
plastic-plastic conditions, 483 Airlines for America, 225 toughened resin matrices, 430
typical shear stress-strain, Airvac 22 venturi-type vacuum water wicking problem, 417–420
479–481 pump, 365 Anti-static coatings, 449
joint adherend effects, 488–492 Airworthiness Directives (ADs), Anti-static paint, 86–87
adherend stiffness and thermal 224–225 Aramid fiber, 27–28, 162–163, 252, 317
mismatch, 490–492 Airworthiness Notices, 225 aircraft, aramid fabrics used on, 29
adherend stiffness mismatch, 492 Alodine/Alochrom 1200, 397–399 chemical properties, 29
adherend thermal mismatch, Alumina fiber, 30 considerations, 364
490, 492 Aluminum flame spray, 449 creep properties, 28–29
coefficient of thermal American Military Standards, 301 design considerations, 28
expansion, 488 Amorphous carbon, 24 finishes, 44
shear stress and strain, 489 Analyzed reports in repairs, 28
thermal match, 492 aluminum alloy, 431 water absorption, 29
PABST program, 492–494 aluminum alloy honeycomb, 431 Autoclave bonding, 114–117
temperature and moisture effects, composite parts and test piece, 431 Autoclaves, 366
487–488 composite-skinned honeycomb Automated Dynamics
Adhesive bond, 504 panels, 430 Corporation, 106
Adhesive failure, 477 cowlings being slammed shut, 425
Adhesive fillets, 64 cracking in surface filler, 424 BAE Systems Regional Aircraft Ltd., 7
Adhesives, 152 drilling out blind fasteners, 417 Bagging, 269
film, 60–63 edge of panels, 413–415, 430 Bagging film sealant tape, 269
foaming, 59–60 engine cowlings, 430 Bagging sequence, 274
glue-line thickness control, fastener holes, damage at, 415–417 Bag side, 269
62–65 fatigue strength of scarf joints, 431 Balanced laminate, 130, 132
hazards associated with, 160 filament-wound parts, 428–429 Barely visible impact damage (BVID),
in-service effects, on resin systems, fuselage ice protection plates, 425 148, 188, 200, 413
65–66 heat shield inadequate, 424 Barrier creams, 369
liquid and paste, 58–59 honeycomb panels, 412–413 Beetle resin, 384
and matrix resins honeycomb punctures, 413 Blade selection and speed, 363–364
epoxy and phenolic hot exhaust air, 428 Bleeder cloths, 269, 272
pre-pregs and film adhesives, inadequate water drainage, 429 Bleed-out fabric, 269
53–55 laminate thickness, 431 Blind bolt installation, 327
©2020 SAE International 533
534 Index
Blind fastener removal, 329 Casein glues, 384 deterioration in normal service,
Blind repairs, 259, 262–264 Caul plate 9–10
Blind rivet installation, 324–325 honeycomb cores, 282 physical/chemical damage, 8–9
Blind rivets, 303 meatal caul plate, 282 definition, 1–2
Boeing 787, 6, 124 uses of, 281 early aircraft structures, 5
Boeing B.757 SRM 51-40-04, 325 Chart recorders, 367 in high-speed trains, 8
Bolt inserts, 315–316 Cherry MaxiBolt® blind bolts, 312 history of composite materials, 2
Bolt removal, 329 Chlorinated solvents, 164–165 modern aircraft structures and
Bond durability, 405 Chlorofluorocarbons (CFCs), applications, 5
Bonded fasteners, 330 158, 159 monolithic laminated structures,
Bonded joints Chromic acid anodizing, 400 123–125
adhesive behavior in, 478–494 Circumferential winding, 105, 106 projected use of, 5–8
adhesive peel stress and Civil Aviation Authority (CAA), in racing yacht, 7
displacement, 494–502 147, 223 sandwich structures, 125–127, 129
composite material peel Cleaning agents in sports car, 7
failure, 495 alkaline detergent cleaners, 243 tailored design, 130
eccentric joint deflection, 495 AMS 3819 cleaning cloths, 243 thermoplastic resin
loaded lap joint, 496, 499 citrus-based cleaners, 242 advantages, 4
maximum adherend cleaning brushes, 243 disadvantages, 4
displacement, 497 cold-water wash equipment, 244 thermosetting resin
shear stresses, 494 cotton swabs, 243 advantages, 3–4
tapered and untapered, 501–502 emulsion-type cleaners, 243 disadvantages, 3
upper adherend midplane, hot-water wash equipment, 243–244 Composite-skinned Nomex
496, 498 solvents, 242 honeycomb panels, 413
design recommendations, 504–505 steam-cleaning equipment, 243 Composite-skinned sandwich-type
durability, 502–503 vapor-degreasing equipment, 244 tooling, 375–376
failure modes of, 477 wipe cleaning cloths, 243 Computer-aided design (CAD)
repair considerations, 504 Click Bond Inc., 330 methods, 219
types of, 475–476 Coefficient of thermal expansion Conductive coatings, 86–87, 449
Bonding surfaces, 315 (CTE), 116, 117, 331, 372, 420 Contaminants, 135–136
Bond testers, 200 Cohesive failure, 477 Control of Substances Hazardous to
Boron fibers, 30, 167 Color charting, 367 Health (COSHH) Regulations,
Breather, 269 Color samples, 407 157
Breather cloths, 272 Commercial Aircraft Composite Core materials, 66–68
Bridging, 269 Repair Committee (CACRC), fluted core, 76–77
British Airways, 85 222, 241, 317, 411 foam core materials
British Standard BS 7750 Compatibility, 301–302 advantages and disadvantages, 70
Environmental Management Component additional worksheet, foam density, 70
Systems, 158 336, 338 material types, 68–69
Butser Hill farm project, 2 Component documentation, 354 honeycomb core materials
Component Maintenance Manual cell shapes, 75
Calibration records, 351–352 (CMM), 225 honeycomb configurations, 71
Carbide/cobalt-tipped spade Component master worksheet, honeycomb densities and cell
bits, 317 336, 337 sizes, 75–76
Carbon fiber, 27, 449 Component record card, 340, 341 honeycomb manufacturing
carbon fiber manufacture, 22–23 Composite fasteners, 331–332 processes, 70
categories, 25 Composite parts, 250 honeycomb material types,
finishes, 43–44 Composites 72–75
future development, 23 BAE Systems Regional Aircraft standard honeycomb cell, 72
PAN-based carbon fiber Ltd., 7 syntactic core, 77
production, 26 Boeing 787, 6 wood, 68
preparation, 23 characteristics, 2 Corrosion-inhibiting adhesive primers
properties, 24 composite parts (CIAP), 405
structure, 24 avoidance of damage and Corrosion-resistant bond
types, 25 reduction of deterioration in primers, 505
Carbonization, 24, 25 service, 10–13 Curing/drying, 407
535
Index
Hot air blowers, 366 Poisson’s ratio analysis, 464–466 Lockbolts, 306–309, 326–327
Hot bonders, 290 simplified analysis techniques, Long carbon (LC) fibers, 332
Hot-bonding considerations, 116, 117 457–460 Long glass (LGL) fibers, 332
Huck Ti-Matic® blind bolt, 313 carbon tape lamina, 458 Long quartz (LQ) fibers, 332
Huck UniMatic® blind bolt, 313 classical laminated plate theory LTM 12, 377
Humidity, 135, 350 analysis, 457 LTM 16, 377
Hydrofluoric acid etching, 395–397 glass and aramid fibers, 459 LTM 317-1B, 377
Hygrothermal effects, 137 lamina orientations, 458
original equipment manufacturer, Maintenance Occurrence Reports
Illustrated Parts Catalog (IPC), 218, 457 (MORs), 349
219, 226, 229 thermal stresses and moisture Manufacturing techniques
Impact resistance, 147–148 absorption effects, 458 autoclave bonding, 114–117
Incident reports, 348 variables, 459 filament winding, 105–107
Injected repairs, 265–266 strength (F) analysis, 463–464 injection molding, 111–113
Injection molding, 111–113 Laminate repair design lay-up methods, for fabrics and
Inspection report, 340, 342 aerodynamic smoothness, 455–456 tapes
Intermediate splash, 374 flight control balance moment, 455 automated lay-up, 108–109
Internal documents lightning and electrostatic hand lay-up, 107–108
alternative materials procedures, 221 protection, 448–455 oven curing, 118
alternative parts procedures, 221 aluminum-coated fiber, 451 press molding, 114
design deviation authorizations, aluminum flame spray, 449 pultrusion, 109–110
engineering instructions, aluminum foil, 452–453 RTM, 110–111
220–221 anti-static and conductive tow placement, 113–114
in-house modifications, 221 coatings, 453–455 vacuum bonding, 114
repair schemes, 221 anti-static coatings, 449 Material control records
Internal wrenching, 304 carbon fiber, 449 freezer log, 353
International Air Transport conductive coatings, 449 manufacturer certifications, 353
Association (IATA), 425 diverter strips, 449, 451–452 out-time log, 353–354
ISO Environmental Management expanded foils, 449 receiving inspection, 352–353
Standards, 178–179 flame spray, 449–450 Material safety data sheet (MSDS), 164,
Isopropyl alcohol (IPA), 242 metallic conductive frames, 449 165, 167–169, 171
Isoscope, 407 metallic/expanded foil mesh, Materials record sheet, 336, 339
450–451 Matrix (resin) systems, 44
Joint Airworthiness Requirements/ metallic meshes, 449 and adhesives
Joint Aviation Requirements metallic straps/picture epoxy and phenolic pre-pregs and
(JARs), 217, 224 frames, 452 film adhesives, 53–55
Joint design, 150, 152 radome diverter strips, 449 epoxy-based matrix resins and
Joint durability, 504 viscoelasticity, 448 adhesives for aerospace use,
Joint efficiency, 150 operational and glass transition 52–53
temperature, 448 mechanical properties, 51–52
Ketone solvents, 164 recommendations, 456–457 physical and chemical properties,
Kitting, 102 stability, 447 50–51
Knives, 361 stiffness, 445–447 epoxy wet resins
strength, 447 mixing, 56–57
Laminate analysis techniques Laser-pumped fluorescence (LPF), 212 weighing, 55–56
elastic modulus (E) analysis Lay-up methods, for fabrics and tapes polyester resins, 57–58
carbon fabric, 462 automated lay-up, 108–109 thermoplastic composites, 45–46
carbon tapes, 461 hand lay-up thermosetting resins, 46–50
glass and aramid woven pre-preg lay-ups, 108 Measuring devices, 367–368
fabrics, 462 wet lay-up, 107–108 Mechanical anchoring theory, 388
laminate orientations, 461 Leading and lagging Mechanical damage, 208–209
woven fabrics, 461 thermocouples, 289 Mechanical fastening systems
in-plane shear modulus, 466–467 Length determination, 322 blind fastener removal, 329
in-plane shear strength, 467, Lightning strike energy dispersion, 143 blind rivets, 303
469–470 Liquid and paste adhesives, 58–59 bolt removal, 329
538 Index
pleating, 274 Safety and environment, 157 Seemann Composites Resin Infusion
ply compaction and debulking, chemical spillage, 175 Molding Process
284–285 electrical appliances (SCRIMP), 111
post-repair inspection, 294–295 hangar areas, 178 Selectively strippable paint system
potted repairs, 266, 267 high risk, 177 (SSS), 244
repair sanding and ply labeling portable equipment, 178 Self-locking nuts, 325
determination remotely high risk, 177–178 Semco Pasa-Jell, 395
abrading, 252–253 exothermic reactions, 169–170 Separator, 270
step sanding and cutting, explosion risk, 175–176 Service Bulletins, 223–224
253–255 fire prevention, 176–177 Service Newsletters, 224
taper sanding/scarfing, 253 fumes and vapors Shearography, 203–205
selection criteria, 271–272 acid fumes and splash, 165–166 Shelf life/out-time, 101–102
solid laminate repairs, 265, 266 coatings, 165 Shop equipment
squeeze-out, 283–284 exposure limits, 166 air compressors, 364–365
surface bagging, 272–273 fuel, 165 bandsaws, 363–364
surface restoration, 295–297 resin fumes, 163–164 Short carbon (C) fibers, 332
vacuum requirements and sealant vapors, 165 Short glass (G) fibers, 332
principles solvent vapors, 164–165 Shur-Lok inserts, 316
practical techniques, 277–281 ISO Environmental Management Silica, 79
vacuum bonding, 274–275 Standards, 178–179 Silicon carbide fibers, 32
vacuum pressure and MSDS, 169 Silicone sealants, 83
nonperforated honeycomb, respirable fibers and dust Skin contact
275–277 aramid fibers, 162–163 fibers, 166–167
vertical bleed method, 282–283 carbon and graphite fibers, 162 personal protection, skin creams
water break test, 255 fiberglass, 162 for, 169
work area, 241 sanding dust, 163 resins, 167–168
zero-bleed method, 284 safety procedures selection of suitable gloves, 168
Resin fumes, 163–164 dermatitis, 173–175 solvents, 168
Resin infusion under flexible tooling emergency action first-aid Skin peelers, 361
(RIFT), 111 procedures, 171 Society for the Advancement of
Resin transfer molding (RTM), 4, 50, general safety procedures, Material and Process
51, 57, 58, 110–111 171–172 Engineering (SAMPE), 159
Robotic installation, 327 personal safety precautions, Sol-gel process, 399
Rolls-Royce Trent engine, 415 172–173 Solid laminate composites, 299
Router bits, 362 skin contact Solid laminate repairs, 265, 266
Routine work documents fibers, 166–167 Solid laminate tools, 375
component additional worksheet, personal protection, skin creams Solid rivets, 302–303
336, 338 for, 169 installation, 322–324
component master worksheet, resins, 167–168 removal of, 329
336, 337 selection of suitable gloves, 168 Solvay Composite Materials, 380
component record card, 340, 341 solvents, 168 Solvent-repellent creams, 169
FAA/JAA form 1, 340, 344 static discharge prevention, 176 Solvent vapors, 164–165
inspection report, 340, 342 waste disposal, 170–171 Source documents
materials record sheet, 336, 339 workshop conditions, for good Aircraft Maintenance
quality control form 1, 340, bonding, 160–161 Manual, 225
345–346 Sanding discs, 359–360 Airlines for America, 225
reject note, 340, 349 Sanding dust, 163 Component Maintenance
stock record card, 340, 349 Scarf joints, 238–239 Manual, 225
technical instruction form, Scissors, 361 drawing numbering systems
340, 347 Sealants, 80–81 ply charts, 220
three-part serviceable label, 340, 348 new-generation polythioether production drawings, 219
unserviceable label, 340, 350 sealants, 82 repair drawings/repair
warranty investigation report, old-generation Thiokol sealants, 82 schemes, 220
340, 343 silicone sealants, 83 effectivity, 218
Royal Aircraft Establishment Viton rubber sealants, 83 Engine Manual, 227
process, 23 Sealant vapors, 165 Illustrated Parts Catalog, 226
542 Index
Templates, 362 Thickness, of primer coating, 406 line tool/ramp checker, 193–194
Temporary clamping, 321 Three-part serviceable label, 340, 348 pulse-echo mode, single transducer,
Temporary hole clamps, 321 Threshold limit value-ceiling 189, 190
Temporary revisions (TRs), 218 (TLV-C), 166 through-transmission mode, two
Textile glass, 42 Threshold limit values (TLVs), 166 transducers, 189, 190
Thermal stresses, 137 Threshold limit value-short-term ultrasonic phased array, 195
Thermocouples exposure limit Ultraviolet (UV) radiation, 158
defined, 292 (TLV-STEL), 166 Unprotected carbon fiber composite
extension cables, 293 Threshold limit value-time-weighted (CFC) structures, 426
types of, 292–293 average (TLV-TWA), 162, Unserviceable label, 340, 350
Thermography 163, 166 U.S. military specifications, 222
advantages, 199 Titanium, 330
disadvantages, 199–200 Tooling and mold making Vacuum-assisted resin transfer
Thermoplastic composite braided autoclave cure, 379 molding (VARTM), 111
tubing (TCBT), 107 caul plate, 372–373 Vacuum bags, 270, 271
Thermoplastic composites (TPCs) composite tools, 381–382 Vacuum bonding, 114
amorphous type, 45 dam fabrication, 373–374 Vacuum de-bulks, 378
semicrystalline type, 45–46 de-bulk procedure, 378 Van der Waals forces, 388, 389
Thermoplastic polyimide (TPI), 45 factors, 372 Venturi-type vacuum pumps, 364
Thermoplastic resin composites final bagging procedure, 379 Vertical bleed method, 282–283
advantages, 4 lay-up tooling, 377–378 Visual inspection, 182–186
disadvantages, 4 in low-temperature curing Viton rubber sealants, 83
Thermosetting resins, 46 materials, 382 Volatile organic compounds (VOCs),
acrylics, 48 release agents/films, 374–375 158, 159, 164
bismaleimides, 49 requirements, 372
composites simple room-temperature tooling, Warranty investigation report,
advantages, 3–4 375–376 340, 343
disadvantages, 3 splash mold making, 374 Water break test, 255
cyanate ester, 49 step post-curing procedure, 380 Water/oil contamination and filtration,
epoxy resins, 48, 49 support structures, 380–381 364–365
melamine formaldehyde, 47 thermal properties, 372 Water-repellent creams, 169
modified phenolic resin time limits, 380 Wedge tests, 256
pre-pregs, 47 Tow placement, 113–114 Weighing scale, 368
phenol formaldehyde, 47 Training records, 354–356 Wetting, 405
phenolic resins, 47, 50 Transmissivity tester, 367–368 Wood, 68
polyester, 48 1,1,1-Trichloroethane, 242 Woven fabric weave styles, 34–36
polyimides, 48
polyurethane, 48 Ultrasonic inspection X-ray methods, 197
polyvinyl formal phenolics, 47 advantages, 192 advantages, 198
resorcinol phenol formaldehyde, 47 calibration standards, 191 disadvantages, 198
silicone, 48 disadvantages, 192
urea-formaldehyde, 47 echo amplitude measurements, Young’s modulus, 445
vinyl ester, 48 normal incidence, 190–191
“The Wooden Wonder,” 384 Fokker bond tester, 192–193 Zero-bleed method, 284
Care and Repair of
Advanced Composites
Third edition
An SAE Deep Dive
ISBN: 978-0-7680-9317-9