Table Of Content

HANDBOOK OF ADHESIVE BONDED STRUCTURAL REPAIR Raymond F. Wegman and Thomas R. Tullos Adhesion Associates Ledgewood, New Jersey NOYES PUBLICATIONS Park Ridge, New Any, USA. Copyright 1992 by Noyes Publications No part of this book may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying, recording or by any informa- tion storage and retrieval system, without permission in writing from the Publisher. Library of Congress Catalog Card Number: 9146660 ISBN 0-8155-1293-7 Printed in the United States Published in the United States of America by Noyes Publications Mill Road, Park Ridge, New Jersey 07656 10 9 8 7 6 5 4 3 2 1 Library of Congress Cataloging-in-Publication Data Wegman, Raymond F. Handbook of adhesive bonded structural repair / by Raymond F. Wegman and Thomas R Tullos. p. cm. Includes bibliographical references and index. ISBN 0-8155-1293-7 1. Sandwich construction. 2. Adhesive joints-Repairing. 3. Composite materials. 4. Laminated materials. I. Tullos, Thomas R 11. Title. TA492.SZW45 1992 624.1’8-dc20 9146660 CIP To the best of our knowledge the information in this publication is accurate; however, the Publisher does not assume any responsibility or liability for the accuracy or completeness of, or consequences arising from, such information. Mention of trade names or commercial prod- ucts does not constitute endorsement or recommendation for use by the Publisher. Final determination of the suitability of any information or product for use contemplated by any user, and the manner of that use, is the sole responsibility of the user. We recommend that anyone intending to rely on any recom- mendation of materials or procedures for adhesive bonded structural repair mentioned in this publication should satisfy himself as to such suitability, and that he can meet all applicable safety and health standards. Methods and materials discussed may be potentially hazardous. "Cautions,"" warnings," and "special notes" printed in the text should be heeded. The book is for information only. It is strongly rec- ommended that users seek and adhere to the manufacturer's or supplier's current instructions for handling each material they use, and obtain expert advice before implementation of any procedures. vi PREFACE The purpose of this book is to provide information and guidance on the repair of adhesive bonded and composite structures. The methods presented have been gen- erally published in the open literature. However, these methods have not been verified by the authors for every appli- cation. It is the user’s responsibility to evaluate any selected method for its adapt- ability to the structure to be repaired. Raymond F. Wegman V CONTENTS . 1 INTRODUCTION .................................... 1 Scope and Limitations ............................... 1 Usage of the Handbook ............................... 2 Personnel Qualification ............................... 3 Workmanship ...................................... 3 Repair Atmospheric Environment ....................... 4 Repair Materials ................................... 4 Quality Assurance ................................... 5 Safety Precautions .................................. 5 Special Note Concerning the Use of Solvents ............. 6 Special Notes Concerning Dust Generated by Machining Composites ............................ 8 ........... Special Note Concerning the Use of Chemicals 10 References ....................................... 10 2. MATERIALS AND PROCESSING ....................... 11 .................................. Material Selection 11 Description of Materials ............................. 12 Adhesive. Repair. Paste ............................ 12 ............................. Adhesive. Laminating 12 Adhesive. Structural Film ........................... 12 Adhesive. Core Splice ............................. 12 Adhesive. Injection ............................... 13 Adhesive. Aerodynamic Smoother .................... 13 Sealant/Aerodynamic Smoother ...................... 14 Prepregs ....................................... 14 Laminates ...................................... 14 vii viii Contents Core Materials .................................. 14 Repair Materials .................................. 15 Storage and Handling of Adhesives and Prepregs .......... 28 Storage of Adhesives .............................. 28 Storage of Prepregs ............................... 28 Handling of Adhesives ............................. 29 Handling of Prepregs .............................. 29 Mixing and Curing Requirements for Adhesives and Sealants ........................................ 29 Adhesive Receiving Acceptance Tests .................... 29 ................................ Material Processing 30 ....................... Application of Paste Adhesives 30 Application of Film Adhesives ....................... 31 Under Repair Application of a Laminating Adhesive ...... 32 Application of Core Splice Adhesive ................... 32 Application of Sealants and Aerodynamic Smoothers ...... 33 Sandwich Construction .............................. 34 Core Materials .................................... 34 Honeycomb Core Materials ......................... 34 Metallic Honeycomb .............................. 36 Glass Reinforced Honeycomb ....................... 37 ................. Aramid-Fiber Reinforced Honeycomb 37 Paper Honeycomb ................................ 38 Solid Core Materials .............................. 41 References ....................................... 47 . 3 DAMAGE ASSESSMENT AND REPAIR METHOD ....................................... SELECTION 48 General ......................................... 48 Damage Assessment ................................ 49 Repair Method Selection ............................. 50 References ....................................... 53 . ................ 4 SURFACE PREPARATION PROCEDURES 56 Preparation of Composite Surfaces ..................... 57 ........... Preparation of Composite Surfaces for Bonding 57 Preparation of Metallic Surfaces for Bonding ............. 58 Preparation of Aluminum-Phosphoric Acid Nontank Anodize Process (Phos-Anodize Containment System. PACS) ................................. 58 Preparation of Aluminum-P2 Etch Tank Process ......... 61 Preparation of Other Metals .......................... 63 .................................... Paint Removal 63 Paint Removal from Metal Parts by Solvents ............ 63 Contents ix Paint Removal by Mechanical Sanding ................. 63 Paint Removal by Plastic Media Blasting (PMB) .......... 63 References ....................................... 67 . 5 TOOLS. EQUIPMENT AND FACILITIES ................. 68 ................................. Composite Repairs 68 Tools for Cutting Composite Fabrics and Laminates ........ 69 Tools for Cutting Prepreg and Fabric Materials .......... 69 Tools for Working on Composite Laminates ............. 69 Equipment ....................................... 80 Hot Bonding Equipment ........................... 80 Processing Facilities ................................ 80 Controlled Atmospheric Lapp Areas .................. 80 Operating Conditions .............................. 84 Area Maintenance ................................ 84 Personnel ...................................... 85 Inspection ...................................... 85 Curing Equipment ................................. 85 Autoclaves ..................................... 85 CuringOvens ................................... 88 Vacuum Bagging of Structures Under Repair ............ 89 Vacuum Bagging Sequence ......................... 91 References ....................................... 93 . ..... 6 FIELD LEVEL REPAIR OF COMPOSITE STRUCTURES 94 Composite Laminate Structures (Non-Structural) .......... 94 . Method No 6.1: Repair of Non-Structural Composite Laminates Containing Minor Damage ................ 94 Method No . 6.2 Repair of Non-Structural Composite Laminates Containing Major Damage ................ % Repair of Structural Laminates ........................ 98 Method No. 6.3: Repair of Structural Laminates Using the Precured Patch Concept ....................... 98 . Method No 6.4 Repair of Structural Laminates Using the Cure-in-Place Concept ........................ 100 . Method No 6.5: Repair of Structural Laminates Using ................... the Flush Patch Repair Concept 101 ... Repair of Advanced Composite Faced Sandwich Structure 104 . Method No 6.6 Repair of Composite Faced Structures Containing Dents (No Voids or Cracks) .............. 104 . Method No 6.7 Repair of Composite Faced Structures .......... Containing Tears, Cracks, or Surface Defects 105 Method No. 6.8 Repair of Composite Faced Structures with Minor Damage ............................ 106 x Contents Method No. 6.9: Repair of Composite Faced Structures Containing Major Core Damage (Hole in One Skin Only) ....................................... 107 Method No. 6.10 Repair of Composite Faced Structures Containing Major Core Damage (Hole in Both Skins) . . . 110 Method No. 6.11: Repair of Composite Faced Structures Having an Inaccessible (Blind-Side) Back Skin . . . . . . . . . 113 Method No. 6.12 Repair of Composite Faced Structures Containing Edge Voids . . . . . . . . . . . . . . . . . . . . . . . . . . 117 References . . . . . . . . . . . . . . . . . . . .*. . . . . . . . . . . . . . . . . . 119 7. LARGE AREA DEPOT REPAIR OF COMPOSITE FACEDSTRUCTURES , . . . . . ... . . . . . . . . . . . ... . . . . . . . 121 Damage Removal Methods . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Removal of Skin Materials . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Removal of Core Material . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 In-Process Quality Assurance . . . . . . . . . . . . . . . . . . . . . . . . 122 Methods of Repair . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Method No. 7.1: Repair of Composite Faced Structures Containing Major Core Damage (Hole in One Skin Only) ....................................... 123 Method No. 7.2: Repair of Composite Faced Structures Containing Major Core Damage (Hole in Both Skins) . . . 126 Depot Rebuild of Composite Faced Structures . . . . . . . . . . . . 128 Method No. 7.3: Rebuild of Composite Faced Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Fabrication of New Structures . . . . . . . . . . . . . . . . . . . . . . . . 132 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 8. FIELD LEVEL REPAIR OF METAL FACED HONEYCOMB STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . 133 Method No. 8.1: Repair of Metal Faced Structures Containing Dents (No Cracks or Voids) . . . . . . . . . . . . . . 133 Method No. 8.2 Repair of Metal-Faced Structures Containing a Void Under a Dent (Backside of Structure Accessible) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Method No. 8.3: Repair of Metal Faced Structures Containing a Void Under a Dent (Backside of Structure not Accessible) . . . . . . . . . . . . . . . . . . . . . . . . 135 , Method No. 8.4 Repair of Metal Faced Structures Containing Dents with a Hairline Crack in the Dent . . . . . 138 Method No. 8.5: Repair of Metal Faced Structures Containing Minor Core Damage . . . . . . . . . . . . . . . . . . . 138 Method No. 8.6: Repair of Metal Faced Structures Contents xi Containing Major Core Damage (Hole in One Skin Only) ....................................... 140 Method No. 8.7 Repair of Metal Faced Structures Containing Major Core Damage (Hole in Both Skins) . . . 143 Method No. 8.8: Repair of Metal Faced Structures Containing Edge Voids . . . . . . . . . . . . . . . . . . . . . . . . . . 147 9. LARGE AREA DEPOT REPAIR OF METAL-FACED STRUCTURES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Method No. 9.1: Large Area Major Damage (Hole in One Skin Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Method No. 9.2 Large Area Major Damage in Both Skins ....................................... 152 Rebuild or Fabrication of a Metal Faced Structure . . . . . . . . 155 Method No. 9.3 Rebuild of a Metal-Faced Structure . . . . . 155 Fabrication of New Structures . . . . . . . . . . . . . . . . . . . . . . . . 158 10. REPAIR OF SOLID CORE STRUCTURES . . . . . . . . . . . . . . . 160 Foam Core Sandwich Structures . . . . . . . . . . . . . . . . . . . . . . 161 Method No. 10.1: Repair of a Puncture-Flush Patch Method ...................................... 161 Method No. 10.2 Repair of a Through Hole in a Foam Core Panel-Flush Patch Method . . . . . . . . . . . . . . . . . . . 166 Method No. 10.3: Repair of Minor Damage-External Patch Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Method No. 10.4 Repair of Puncture with Major Core Damage-External Patch Method . . . . . . . . . . . . . . . . . . . 174 Method No. 10.5: Repair of Extensive Panel and Core Damage Using Liquid Foam Core Materials . . . . . . . . . . 178 Method No. 10.6 Repair of Panel Damage Spanning an Internal Structural Member . . . . . . . . . . . . . . . . . . . . . . . 180 Method No. 10.7 Repair of Foam Cored Panel with Damaged Structural Member . . . . . . . . . . . . . . . . . . . . . . 183 Balsa Core Sandwich Panels . . . . . . . . . . . . . . . . . . . . . . . . . 186 Method No. 10.8: Repair of a Puncture-Flush Patch Method-Modification of Method No. 10.1 . . . . . . . . . . . . 186 Method No. 10.9: Repair of a Through Hole-Flush Patch Method-Modifcation of Method No. 10.2 . . . . . . . 191 Method No. 10.10: Repair of Composite Faced Structure Containing Major Balsa Wood Core Damage (Hole in Both Skins)-M&ication of Method No. 6.10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 xii Contents 11. NONDESTRUCTIVE INSPECTION ..................... 199 Introduction ..................................... 199 Terminology and Definitions ......................... 200 Personnel Qualifications ............................ 202 Test Standards ................................... 202 Inspection Without Standards ........................ 203 &-Repair inspection .............................. 203 Post Repair Inspection ............................. 204 General Description of NDI Methods and Equipment ..................................... 205 Visual Nondestructive Inspection .................... 205 Optical Nondestructive Inspection ................... 206 Ultrasonic Nondestructive Inspection ................. 206 Acoustic Emission Nondestructive Inspection ........... 207 Acoustic Transmission Nondestructive Inspection ........ 207 Radiographic Nondestructive Inspection ............... 210 Thermal Nondestructive Inspection .................. 210 Mechanical Nondestructive Inspection ................ 211 Selection of Repair Inspection Methods ............... 213 ...................................... References 215 INDEX .............................................. 216

Description:
Provides repair methods for adhesive bonded and composite structures; identifies suitable materials and equipment for repairs; describes damage evaluation criteria and techniques, and methods of inspection before and after repair.
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Handbook of Adhesive Bonded Structural Repair PDF

230 Pages·1993·9.6 MB·English
by  Raymond F. Wegman
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HANDBOOK OF ADHESIVE BONDED STRUCTURAL REPAIR Raymond F. Wegman and Thomas R. Tullos Adhesion Associates Ledgewood, New Jersey NOYES PUBLICATIONS Park Ridge, New Any, USA. Copyright 1992 by Noyes Publications No part of this book may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying, recording or by any informa- tion storage and retrieval system, without permission in writing from the Publisher. Library of Congress Catalog Card Number: 9146660 ISBN 0-8155-1293-7 Printed in the United States Published in the United States of America by Noyes Publications Mill Road, Park Ridge, New Jersey 07656 10 9 8 7 6 5 4 3 2 1 Library of Congress Cataloging-in-Publication Data Wegman, Raymond F. Handbook of adhesive bonded structural repair / by Raymond F. Wegman and Thomas R Tullos. p. cm. Includes bibliographical references and index. ISBN 0-8155-1293-7 1. Sandwich construction. 2. Adhesive joints-Repairing. 3. Composite materials. 4. Laminated materials. I. Tullos, Thomas R 11. Title. TA492.SZW45 1992 624.1’8-dc20 9146660 CIP To the best of our knowledge the information in this publication is accurate; however, the Publisher does not assume any responsibility or liability for the accuracy or completeness of, or consequences arising from, such information. Mention of trade names or commercial prod- ucts does not constitute endorsement or recommendation for use by the Publisher. Final determination of the suitability of any information or product for use contemplated by any user, and the manner of that use, is the sole responsibility of the user. We recommend that anyone intending to rely on any recom- mendation of materials or procedures for adhesive bonded structural repair mentioned in this publication should satisfy himself as to such suitability, and that he can meet all applicable safety and health standards. Methods and materials discussed may be potentially hazardous. "Cautions,"" warnings," and "special notes" printed in the text should be heeded. The book is for information only. It is strongly rec- ommended that users seek and adhere to the manufacturer's or supplier's current instructions for handling each material they use, and obtain expert advice before implementation of any procedures. vi PREFACE The purpose of this book is to provide information and guidance on the repair of adhesive bonded and composite structures. The methods presented have been gen- erally published in the open literature. However, these methods have not been verified by the authors for every appli- cation. It is the user’s responsibility to evaluate any selected method for its adapt- ability to the structure to be repaired. Raymond F. Wegman V CONTENTS . 1 INTRODUCTION .................................... 1 Scope and Limitations ............................... 1 Usage of the Handbook ............................... 2 Personnel Qualification ............................... 3 Workmanship ...................................... 3 Repair Atmospheric Environment ....................... 4 Repair Materials ................................... 4 Quality Assurance ................................... 5 Safety Precautions .................................. 5 Special Note Concerning the Use of Solvents ............. 6 Special Notes Concerning Dust Generated by Machining Composites ............................ 8 ........... Special Note Concerning the Use of Chemicals 10 References ....................................... 10 2. MATERIALS AND PROCESSING ....................... 11 .................................. Material Selection 11 Description of Materials ............................. 12 Adhesive. Repair. Paste ............................ 12 ............................. Adhesive. Laminating 12 Adhesive. Structural Film ........................... 12 Adhesive. Core Splice ............................. 12 Adhesive. Injection ............................... 13 Adhesive. Aerodynamic Smoother .................... 13 Sealant/Aerodynamic Smoother ...................... 14 Prepregs ....................................... 14 Laminates ...................................... 14 vii viii Contents Core Materials .................................. 14 Repair Materials .................................. 15 Storage and Handling of Adhesives and Prepregs .......... 28 Storage of Adhesives .............................. 28 Storage of Prepregs ............................... 28 Handling of Adhesives ............................. 29 Handling of Prepregs .............................. 29 Mixing and Curing Requirements for Adhesives and Sealants ........................................ 29 Adhesive Receiving Acceptance Tests .................... 29 ................................ Material Processing 30 ....................... Application of Paste Adhesives 30 Application of Film Adhesives ....................... 31 Under Repair Application of a Laminating Adhesive ...... 32 Application of Core Splice Adhesive ................... 32 Application of Sealants and Aerodynamic Smoothers ...... 33 Sandwich Construction .............................. 34 Core Materials .................................... 34 Honeycomb Core Materials ......................... 34 Metallic Honeycomb .............................. 36 Glass Reinforced Honeycomb ....................... 37 ................. Aramid-Fiber Reinforced Honeycomb 37 Paper Honeycomb ................................ 38 Solid Core Materials .............................. 41 References ....................................... 47 . 3 DAMAGE ASSESSMENT AND REPAIR METHOD ....................................... SELECTION 48 General ......................................... 48 Damage Assessment ................................ 49 Repair Method Selection ............................. 50 References ....................................... 53 . ................ 4 SURFACE PREPARATION PROCEDURES 56 Preparation of Composite Surfaces ..................... 57 ........... Preparation of Composite Surfaces for Bonding 57 Preparation of Metallic Surfaces for Bonding ............. 58 Preparation of Aluminum-Phosphoric Acid Nontank Anodize Process (Phos-Anodize Containment System. PACS) ................................. 58 Preparation of Aluminum-P2 Etch Tank Process ......... 61 Preparation of Other Metals .......................... 63 .................................... Paint Removal 63 Paint Removal from Metal Parts by Solvents ............ 63 Contents ix Paint Removal by Mechanical Sanding ................. 63 Paint Removal by Plastic Media Blasting (PMB) .......... 63 References ....................................... 67 . 5 TOOLS. EQUIPMENT AND FACILITIES ................. 68 ................................. Composite Repairs 68 Tools for Cutting Composite Fabrics and Laminates ........ 69 Tools for Cutting Prepreg and Fabric Materials .......... 69 Tools for Working on Composite Laminates ............. 69 Equipment ....................................... 80 Hot Bonding Equipment ........................... 80 Processing Facilities ................................ 80 Controlled Atmospheric Lapp Areas .................. 80 Operating Conditions .............................. 84 Area Maintenance ................................ 84 Personnel ...................................... 85 Inspection ...................................... 85 Curing Equipment ................................. 85 Autoclaves ..................................... 85 CuringOvens ................................... 88 Vacuum Bagging of Structures Under Repair ............ 89 Vacuum Bagging Sequence ......................... 91 References ....................................... 93 . ..... 6 FIELD LEVEL REPAIR OF COMPOSITE STRUCTURES 94 Composite Laminate Structures (Non-Structural) .......... 94 . Method No 6.1: Repair of Non-Structural Composite Laminates Containing Minor Damage ................ 94 Method No . 6.2 Repair of Non-Structural Composite Laminates Containing Major Damage ................ % Repair of Structural Laminates ........................ 98 Method No. 6.3: Repair of Structural Laminates Using the Precured Patch Concept ....................... 98 . Method No 6.4 Repair of Structural Laminates Using the Cure-in-Place Concept ........................ 100 . Method No 6.5: Repair of Structural Laminates Using ................... the Flush Patch Repair Concept 101 ... Repair of Advanced Composite Faced Sandwich Structure 104 . Method No 6.6 Repair of Composite Faced Structures Containing Dents (No Voids or Cracks) .............. 104 . Method No 6.7 Repair of Composite Faced Structures .......... Containing Tears, Cracks, or Surface Defects 105 Method No. 6.8 Repair of Composite Faced Structures with Minor Damage ............................ 106 x Contents Method No. 6.9: Repair of Composite Faced Structures Containing Major Core Damage (Hole in One Skin Only) ....................................... 107 Method No. 6.10 Repair of Composite Faced Structures Containing Major Core Damage (Hole in Both Skins) . . . 110 Method No. 6.11: Repair of Composite Faced Structures Having an Inaccessible (Blind-Side) Back Skin . . . . . . . . . 113 Method No. 6.12 Repair of Composite Faced Structures Containing Edge Voids . . . . . . . . . . . . . . . . . . . . . . . . . . 117 References . . . . . . . . . . . . . . . . . . . .*. . . . . . . . . . . . . . . . . . 119 7. LARGE AREA DEPOT REPAIR OF COMPOSITE FACEDSTRUCTURES , . . . . . ... . . . . . . . . . . . ... . . . . . . . 121 Damage Removal Methods . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Removal of Skin Materials . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Removal of Core Material . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 In-Process Quality Assurance . . . . . . . . . . . . . . . . . . . . . . . . 122 Methods of Repair . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Method No. 7.1: Repair of Composite Faced Structures Containing Major Core Damage (Hole in One Skin Only) ....................................... 123 Method No. 7.2: Repair of Composite Faced Structures Containing Major Core Damage (Hole in Both Skins) . . . 126 Depot Rebuild of Composite Faced Structures . . . . . . . . . . . . 128 Method No. 7.3: Rebuild of Composite Faced Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Fabrication of New Structures . . . . . . . . . . . . . . . . . . . . . . . . 132 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 8. FIELD LEVEL REPAIR OF METAL FACED HONEYCOMB STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . 133 Method No. 8.1: Repair of Metal Faced Structures Containing Dents (No Cracks or Voids) . . . . . . . . . . . . . . 133 Method No. 8.2 Repair of Metal-Faced Structures Containing a Void Under a Dent (Backside of Structure Accessible) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Method No. 8.3: Repair of Metal Faced Structures Containing a Void Under a Dent (Backside of Structure not Accessible) . . . . . . . . . . . . . . . . . . . . . . . . 135 , Method No. 8.4 Repair of Metal Faced Structures Containing Dents with a Hairline Crack in the Dent . . . . . 138 Method No. 8.5: Repair of Metal Faced Structures Containing Minor Core Damage . . . . . . . . . . . . . . . . . . . 138 Method No. 8.6: Repair of Metal Faced Structures Contents xi Containing Major Core Damage (Hole in One Skin Only) ....................................... 140 Method No. 8.7 Repair of Metal Faced Structures Containing Major Core Damage (Hole in Both Skins) . . . 143 Method No. 8.8: Repair of Metal Faced Structures Containing Edge Voids . . . . . . . . . . . . . . . . . . . . . . . . . . 147 9. LARGE AREA DEPOT REPAIR OF METAL-FACED STRUCTURES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Method No. 9.1: Large Area Major Damage (Hole in One Skin Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Method No. 9.2 Large Area Major Damage in Both Skins ....................................... 152 Rebuild or Fabrication of a Metal Faced Structure . . . . . . . . 155 Method No. 9.3 Rebuild of a Metal-Faced Structure . . . . . 155 Fabrication of New Structures . . . . . . . . . . . . . . . . . . . . . . . . 158 10. REPAIR OF SOLID CORE STRUCTURES . . . . . . . . . . . . . . . 160 Foam Core Sandwich Structures . . . . . . . . . . . . . . . . . . . . . . 161 Method No. 10.1: Repair of a Puncture-Flush Patch Method ...................................... 161 Method No. 10.2 Repair of a Through Hole in a Foam Core Panel-Flush Patch Method . . . . . . . . . . . . . . . . . . . 166 Method No. 10.3: Repair of Minor Damage-External Patch Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Method No. 10.4 Repair of Puncture with Major Core Damage-External Patch Method . . . . . . . . . . . . . . . . . . . 174 Method No. 10.5: Repair of Extensive Panel and Core Damage Using Liquid Foam Core Materials . . . . . . . . . . 178 Method No. 10.6 Repair of Panel Damage Spanning an Internal Structural Member . . . . . . . . . . . . . . . . . . . . . . . 180 Method No. 10.7 Repair of Foam Cored Panel with Damaged Structural Member . . . . . . . . . . . . . . . . . . . . . . 183 Balsa Core Sandwich Panels . . . . . . . . . . . . . . . . . . . . . . . . . 186 Method No. 10.8: Repair of a Puncture-Flush Patch Method-Modification of Method No. 10.1 . . . . . . . . . . . . 186 Method No. 10.9: Repair of a Through Hole-Flush Patch Method-Modifcation of Method No. 10.2 . . . . . . . 191 Method No. 10.10: Repair of Composite Faced Structure Containing Major Balsa Wood Core Damage (Hole in Both Skins)-M&ication of Method No. 6.10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 xii Contents 11. NONDESTRUCTIVE INSPECTION ..................... 199 Introduction ..................................... 199 Terminology and Definitions ......................... 200 Personnel Qualifications ............................ 202 Test Standards ................................... 202 Inspection Without Standards ........................ 203 &-Repair inspection .............................. 203 Post Repair Inspection ............................. 204 General Description of NDI Methods and Equipment ..................................... 205 Visual Nondestructive Inspection .................... 205 Optical Nondestructive Inspection ................... 206 Ultrasonic Nondestructive Inspection ................. 206 Acoustic Emission Nondestructive Inspection ........... 207 Acoustic Transmission Nondestructive Inspection ........ 207 Radiographic Nondestructive Inspection ............... 210 Thermal Nondestructive Inspection .................. 210 Mechanical Nondestructive Inspection ................ 211 Selection of Repair Inspection Methods ............... 213 ...................................... References 215 INDEX .............................................. 216

Description:
Provides repair methods for adhesive bonded and composite structures; identifies suitable materials and equipment for repairs; describes damage evaluation criteria and techniques, and methods of inspection before and after repair.
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