manufacture came as a major breakthrough in the search for a more efficient type of structure. Because bonded honeycomb structures are manufactured and perform their jobs in a manner different from the previously used and more familiar conventional structures, new attitudes and methods of repair had to be developed with respect to the advantages, limitations, and physical peculiarities.
CONSTRUCTION FEATURES Sandwich construction design is governed by the intended use of the panel or structure. It can be defined as a laminar construction consisting of a combination of alternating dissimilar materials, assembled and fixed in relation to each other so that the properties of each can be used to attain specific structural advantages for the whole assembly.
Sandwich-constructed assemblies can be found in a, variety of shapes and sizes on modern aircraft.
They may consist of a whole section or a series of panels combined into an assembly. Sandwich-constructed assemblies are used for such areas as bulkheads, control surfaces, fuselage panels, wing panels, empennage skins, radomes, or shear webs.
Figure 5-86 illustrates a section of bonded honeycomb. The honeycomb stands on end and separates facings which are bonded to the core by means of an adhesive or resin. This type of construction has a superior strength/weight ratio over that of conventional structures. Also, it is better able to withstand sonic vibration, has relatively low cost when compared with fastener cost and installation of conventional structures, reduces the number of parts needed, and greatly reduces sealing problems while increasing aerodynamic smoothness.
Facing
- Honeycomb core Bond line • Facing FIGURE 5-86. Bonded honeycomb section.
Special applications of metal-bonded honeycomb may employ stainless steel, titanium, magnesium, plywood, resin-impregnated paper, glass, nylon, or cotton cloth in various combinations.
DAMAGE Causes of Damage The majority of damages to bonded honeycomb assemblies result from flight loads or improper ground handling. Honeycomo structures may also be damaged by sonic vibrations. Such damage is usually a delamination or separation of the core and face along the bond line. (The bond line is the thin line of adhesive between the core and the face that holds the two together.) Occasionally the core may collapse.
Damage Inspection Inspection for damage is more critical for honeycomb assemblies than for conventional structures. A honeycomb structure can suffer extensive damage without any observable indication. Sonic vibration, liquid leakage, internal condensation, or a misstep in manufacture or repair can cause or result in varied amounts of delamination.
The metallic ring test is the simplest way to inspect for delamination damage. When a coin (25- cent piece) is lightly bounced against a solid structure, a clear metallic ring should be heard. If delamination is present, a dull thud will be heard. A 1-oz. aluminum hammer makes an excellent tool for this type of inspection.
Occasionally, the delaminated skin will "oilcan" away from the core, making visual or thumb pressure detection possible. Punctures, dents, scratches, cracks, or other such damage may be inspected by conventional methods. Scratches should be given special attention since, with such thin material as that used in the metal bonded honeycomb, the scratch may actually be a crack.
A caustic soda solution can be used for testing scratches on aluminum surface panels. If the scratch area turns black after the application of a small amount of the solution, the scratch has penetrated through the clad surface. Caustic soda solutions are highly corrosive and must be handled with extreme care. Thoroughly neutralize the area after application of the solution.
Two additional instruments used in damage inspection of bonded panels are the panel inspection analyzer and the borescope.
Damage Evaluation After inspections on metal bonded honeycomb structures are completed, any damage found must be evaluated to determine the type of repair needed to make the structure serviceable.
Damage to aluminum honeycomb structures can vary from minor dents or scratches to total panel destruction. Damage evaluation charts for honeycomb structures can be found in the applicable section of the structural repair manual for the specific aircraft. The charts specify types of damage, allow.
able damage, damage requiring repair, and figure numbers that illustrate similar repairs for each type of damage.
Once the type of repair is determined, procedures outlined in the structural repair manual should be rigidly followed.
REPAIRS Recommendations for the type of repair to make and the methods or procedures to use vary among the different aircraft manufacturers. Tools, materials, equipment, and typical repairs that might be made on metal bonded honeycomb structures will be discussed in the following paragraphs.
Tools and Equipment Effective repairs to bonded honeycomb assemblies depend largely on the knowledge and skill of the airframe mechanic in the proper use and maintenance of the tools and equipment used in making bonded honeycomb repairs. The design and high quality of workmanship built into these tools and equipment make them unique in the repair of bonded honeycomb assemblies. Therefore, it is essential that the techniques and procedures established for each tool or piece of equipment be known and practiced. Both personal injury and additional damage to the area being repaired can then be avoided.
Router The primary tool used to prepare a damaged honeycomb area for repair is a pneumatically powered, hand-operated router with speeds ranging from 10,000 to 20,000 r.p.m. The router is used in conjunction with the support assembly, bit, and template as shown in figure 5-87.
The router support assembly threads onto the router body. It has provisions to adjust the desired depth of the cut with a locking (clamping nut) mechanism which secures the depth adjustment in place. One complete turn of the support adjustment changes the depth of cut approximately 0.083 in.
Metal-cutting, ¼-in. mill bits are used with the router for removing the damaged areas. The router bits should be kept sharp, clean, and protected against nicks, breakouts, or other damages.
- Router Router Router support template FIcURE 5-87. Router, support assembly, and template.
Router templates are used as guides when removing damaged honeycomb areas with a router. They can be designed and manufactured to the desired sizes, shapes, or contours of the repair. As an example, the multi-template (figure 5-88) can be used as a guide when cutting holes from ½ in. to 6 in. in diameter. For larger holes, a template can be manufactured locally from aluminum alloy 0.125-in.
thick, whereas smaller holes can be cleaned out without the use of a template. The multi-templates should be kept clean and lightly oiled to prevent rusting and to maintain smooth operation during their use.
A routing template may be applied to a flat surface using the following 'procedures:
1,000 Routing template Bridge Upper facing Damaged area FIGURE 5-88. Multi-template. Lower facing
(1) Apply double-backed tape to the edge or FIGURE 5-89. Wedge blocks and application.
rim of the routing template.
(2) Place the template, centering the desired Routing of Damaged Areas cutout guide hole directly over the dam- aged area. When the extent of damage and type of repair surface by using the follwoing procedures: A routing template may be applied to a tapered (1) Manufacture a bridge consisting of two (3) Press the template firmly down over the and with approximately the same degree of angle as that of the panel. (See figure 5-89. wooden wedge blocks at least 6 in. long secured in place; this will avoid any creeping or misalignment of the template during the routing operation. double-backed tape, making sure that it is it from jumping or creeping. When the router is not should be firmly gripped with both hands to prevent or misalignment of the template. approximate depth required to remove the damaged area. During the routing operations, the router the damage will be removed. The double-backed aged area in such a way that it will ensure that all around the damaged area, thus preventing creeping tape is used to secure the template to the surfaces have been determined, the proper size hole of the router template must be located around the dam- The router bit should be adjusted and set for the
(5) Place another strip of double-backed tape (4) Press the wedge blocks firmly in place. (2) Apply a strip of double-backed tape to one (3) Place a wedge block on each side of the during the routing operation. bridge and support the template properly on the top side of each wooden wedge side of each wedge block. damaged area in a position that will cable aircraft manufacturer. follow the repair techniques specified by the appli- and stored properly until it is to be used again. used by the various airframe manufacturers. Always in use, it should be disconnected from the air hose aged bonded honeycomb areas are typical of those The following procedures for the removal of dam- (1) Determine the extent of the damage. (2) Set up and adjust the router, router supblock. port assembly, and end-cutting mill bit for
(6) Place and align the template over the or misalignment of the template during wedge blocks, thus avoiding any creeping operation. (3) Select a routing template and position the the removal of the damaged area. procedures outlined in the discussion on template over the repair area according to templates.
(4) Attach the router's air intake plug in the socket of the air supply.
(5) Accomplish the routing operation.
(8) Use face shield or goggles for eye protection against flying materials moved.
(b) Place the air hose over the shoulder.
(c) Holding the router firmly and at a 45° angle to the surface, place one edge of the router support assembly against the edge of the routing template.
(d) Start the router by depressing the control lever.
(e) Carefully, but firmly, lower the end-cutting mill bit into the material as close as possible to the center of the damaged area to be removed.
(f) Straighten the router to be perpendicular to the surface.
(g) Holding the router firmly, spiral it clockwise to the outer limits of the template's guide hole, removing all the damaged material.
(h) Release the control lever, allow the router to stop, and remove it from the hole.
Disconnect the router from the air supply.
Check the damaged area removed. If additional removal is required, adjust the router's cutting depth and repeat routing operation.
(6) Upon completion of the routing operation, disconnect and clean the routing equipment.
During the routing operations, the aluminum core cells of a damaged honeycomb area tend to bend or close up. Therefore, they must be opened with tweezers and a pen knife before any further attempts to repair are made. At times, the core cells must be trimmed with a pen knife to the shape of the repair hole.
Pressure Jigs Pressure jigs are used to apply pressure to repairs on the under surfaces of honeycomb panels or assemblies to hold the repair materials and resins in place. The pressure is maintained on the repair area until the repair material is cured.
C-clamps, locally manufactured jigs, or vacuum fixtures may be used to apply the necessary pressure to bonded honeycomb repairs.
The surfaces around the repair area must be absolutely clean and free of any foreign materials to ensure a good vacuum when vacuum fixtures or suction types of equipment are used. An application of water or glycerin to the surface areas will aid in obtaining a good vacuum. Normal cleaning, care, and corrosion prevention will maintain the above equipment in good working condition.
Infrared Heat Lamps Infrared heat lamps are used to shorten the curing time of bonded honeycomb repairs from approximately 12 hrs. to 1 hr. A single-bulb lamp will adequately cure a repair up to 6 in. in diameter, but a large repair may require a battery of lamps to ensure uniform curing of the repair area.
The lamps should be centered directly over the repair at a distance of about 30 in. The setup is ideal to attain the recommended 130° F. curing temperature, provided the surrounding areas are at room temperature (70° F.). Warmer or colder sur rounding areas will require that the heat lamps be adjusted to the prevailing condition. Caution must be used when working under extremely cold conditions, since a temperature differential of 150° or more will cause buckling of the surrounding skin surfaces because of thermal expansion.
As with any ordinary light bulbs, the infrared bulbs require little or no maintenance; however, the support stands, wiring, and switches should be handled carefully and maintained properly.
Fire Precautions The potential of a fire hazard generally exists in the area of bonded honeycomb repairs because of the low flash point of the repair materials, such as cleaning solvents, primers, and resins. Therefore, it is necessary that all fire precautions be observed closely. Certain fire safety prevention equipment, such as utility cans, flammable-waste cans, and vapor- and explosion-proof lights, should be used.
With the potential of fire hazards in a honey.
comb repair area, it is necessary to make sure that a suitable fire extinguisher is on hand or is located nearby and ready for use, if necessary. The extinguishing agents for all the materials used in bonded honeycomb repairs are dry chemicals or carbon dioxide; thus, the standard CO, fire extinguishers should be on hand for use in areas where bonded honeycomb structures will be repaired.
Handtools and Equipment In addition to the tools and equipment described 204
in the preceding paragraphs, standard handtools and shop equipment are utilized in the repair of bonded honeycomb structures. Standard handtools and shop equipment used in the shop include an airframe mechanic's tool kit, face shields, scissors, power shear, drill press, horizontal and vertical belt sanders, contour metal-cutting saw, and pneumatic hand drills. The general uses and maintenance of these standard tools and equipment should be famil iar to any airframe mechanic.
REPAIR MATERIALS Cleaning Solvents Before any repair is made to a bonded honeycomb structure, an area extending several inches away from the damage must be cleaned thoroughly of all paint or surface coating. This is best accomplished by the use of paint remover or MEK (methyl-ethyl-ketone) cleaning solvent, In some cases, Alconox, a powerful wetting and detergent agent, may be used for a final cleanup to remove any residue or oils remaining after application of the paint remover or the MEK cleaning solvent.
Paint removers are applied with a suitable size brush. When the paint or surface coating has loosened, it is either wiped off with a clean rag or removed with a nonabrasive scraper. Paint remover must not be allowed to enter the damaged area or be used along a bonded joint or seam because its chemical action will dissolve the bonding adhesive.
These areas should be masked and final cleanup accomplished with the MEK cleaning solvent or emery cloth. The MEK cleaning solvent and the Alconox cleaning agent may be applied with a clean sponge.
After a damaged area has been completely removed, the surrounding surface areas must be thoroughly re-cleaned. This is accomplished by the use of the MEK cleaning solvent and gauze sponges.
The MEK cleaning solvent is applied to the area with one sponge and immediately wiped off with another before it has had time to dry. This cleaning process should be continued until the surface area is lusterous in appearance and clean of any foreign matter.
To determine whether an area is completely and thoroughly clean, a water "break" test can be used.
This test is a simple application of a thin film of distilled water to the cleaned area. Any "break" of the applied thin film of distilled water will indicate that the area has not been cleaned thoroughly enough and the cleaning process must be repeated.
Safety precautions must be closely observed when working with the above solvents, especially when the work is overhead or when working in confined areas. For personal protection, rubber gloves, face shields, adequate ventilation, and respirators should be worn. A CO, fire extinguisher should be on hand or nearby and ready for use if necessary.
Primers Primers are applied to the cleaned surface areas primarily to ensure a good bond of the honeycomb repairs. The primer is applied to the cleaned surface areas with a clean gauze sponge or suitable brush.
It is recommended that the primer be applied as rapidly as possible because it will become tacky in 10 to 15 sec., and it will pull and be ruined by any further brushing. The primer will cure in approximately 1 hr. at room temperature; however, this time may be reduced by the application of controlled heat.
Adhesives and Resins Two types of adhesives presently used in the repairs of bonded honeycomb structures of some aircraft are known as the type 38 adhesive and the potting compound. The type 38 adhesive is applied to glass fabric overlay repairs, and the potting compound, as the name implies, to the potted compound (hole filling) repairs. In addition, the type 38 adhesive may be used as an alternate for the potting compound by adding micro-balloons (microscopic phenolic). The adhesives or potting compounds are prepared according to a batch mix (amount required for the repair) formula. The batch mix Accurate mixing of the adhesive ingredients by batches is considered one of the more important steps in the repair of bonded honeycomb structures.
The correct proportions of the epoxies, resins, and micro-balloons to be mixed into batches, both by weight and/or by volume, are given in the applicable section of the structural repair manual for the Core Material Fiberglass honeycomb core materials (16 in, cell size) are usually used to replace the damaged aluminum cores of the bonded honeycomb structures.
Aluminum core materials are not satisfactory for the repairs because of their flimsy and fragile structure. With this condition, it is impractical to cut the aluminum core materials accurately to the desired repair size. Fibergiass core materials are available 205
in various thicknesses and are easily and accurately double-face (two skins) and core damages. (See cut to size by the use of standard shop tools and figure 5-90.)
equipment.
Glass Fabrics Glass fabrics used in the overlay repairs to bonded honeycomb structures are manufactured from glass. The glass is spun into hibers which are in turn woven into a glass cloth with a variety of :
weaves.
Glass fabric cloth must be handled with care, stored properly, and be perfectly clean (free of any dirt, moisture, oil or other contaminants which may cause imperfect adhesion of the adhesives with which it is impregnated). Snags and sharp folds in the cloth will cause its strands to break, resulting in a local strength loss in the finished repair. Exposure to or contact with the glass fabric, dust, or particles may cause bodily itching or irritation.
Erosion and Corrosion Preventives Two coatings of preventives are applied to the bonded honeycomb structure repairs to protect the areas against erosion and corrosion. The first is two layers of zinc chromate, preferably sprayed onto the repair area. The second is two layers of aluminum pigmented Corrogard (EC843), or equal, either mable; therefore, the necessary fire precautions should be observed.
POTTED COMPOUND REPAIR Single face and core Double face and core FIGURE 5-90. Typical potted compound repair areas.
Removal of Damage Normally, no surface preparation is necessary when performing potted compound repairs. Oily or dirty surface areas to which multi-templates or pressure jigs are attached with adhesive tapes should be cleaned with any approved or recommended cleaning solvents, such as MEK.
Damages ¼ in. or less in diameter can be satisfactorily removed with a twist drill. The multi-template and a high-speed router (10,000 to 20,000
r.p.m.) should be employed in the removal of damaged areas for potted compound repairs up to 1 in.
in diameter. The amount of material removed by either method must be kept to a minimum to maintain as much of the original strength of the panel or structure as possible. Always use a face mask or protective glasses when using the router to remove damaged materials.
The following techniques, methods, and procedures are related to potted compound repairs and are typical of those used on most bonded honey.
comb structures. For all repairs, consult the applicable section of the structural repair manual. The manufacturer's procedures should always be followed.
Bonded honeycomb structure damages up to 1 in.
in diameter may be repaired by a hole-filling technique, using approved materials. The repair method is commonly known as the ipotted compound repair." It is the easiest and fastest method of repairing a damaged area of a bonded honeycomb structure. However, be sure to follow the techniques, methods, or procedures established for potted compound repairs to avoid any further damage which might result in a more complicated repair.
Potted compound repairs may be applied both to single-face (one skin) and core damages, or to After a damaged area has been completely removed and cleaned, the necessary materials for the potted compound repair (s) are prepared.
Pieces of sheet plastic materials are prepared to provide a smooth surface effect of the potted compound repair, to provide part of the reservoir for the hole (cavity) filling operation of the repair, and to hold the potting compound in place until it is completely cured. The pieces of sheet plastic to be used for any or all of the above purposes should be at least ½ in. larger in diameter than the repair hole diameter.
A thinner piece of sheet plastic material (approximately 16 in. thick) is applied to the lower (bottom) surface of the double-face repair (figure 5-91). This is done not only to give the repaired surface a smooth effect, but mainly to hold the repair surface (potting compound) in place until it is cured. The same may be applied to a single-face 206
Dixieal, sealing compound Masking tape Plexigias or acetate Drill 0.25 dia. hole Lower skin
DAMAGE TO UPPER SKIN AND CORE Duxssel, sealing compound Masking tape Plexiglas or acetate Drill 0.25 dia. hole Plexigias or acetate
DAMAGE TO BOTH SKINS AND CORE FICURE 5-91. Potted compound repairs.
repair where the work must be accomplished in an overhead position.
Sheet plastic materials ranging from ¼ in. to 16 in. in thickneas are used on the upper (top side) surface of the repair during the hole (cavity) filling procedures. A ¼-in, hole is drilled directly in the center to permit easy application of the potting compounds to the repair cavity. The hole is also countersunk, allowing a buildup of the potting compound and thus assuring that the repair cavity has been completely filled.
This piece of plastic material is also a part of the "Duxseal" dam. After the prepared pieces of sheet plastic materials are properly located and taped in place over the repair area, the Duxseal (or equal) dam is built up around the hole. (See figure 5-91.)
This dam is partially filled with the potting compound during the hole-filling operation to ensure an adequately filled repair cavity. The dam also acts as the reservoir.
Next, & sufficient batch mix of the potting compound is prepared for the repair. The cavity is filled with the potting compound, and the air bubbles are removed with a toothpick or similar tool. The air bubbles are removed to ensure that the repair cavity is solidly filled.
When the potting compound within the repair cavity is completely cured, the pieces of plastic may then be removed. Generally, these pieces of plastic can be lifted off by hand; but, if necessary, they can be pried off easily with any dull straight handtool. When the drilled top piece of plastic is removed, it will leave a broken stem protruding above the repair surface, This stem may be filed, micro- 207
shaved, or routed down to make the repair surface area smooth.
The soundness of the repair can be tested by the metallic ring test. Pressure jigs may be used on the undersurface potted repairs as necessary. The repair is surface finished by the application of the recommended coatings of erosion or corrosion preventives, and a final coating of a finish of the same specifications as that of the original finish.
GLASS FABRIC CLOTH OVERLAY REPAIRS Presently, two acceptable methods of repair are being applied to the damaged skin and core materials of some aircraft bonded honeycomb structures.
One is the potted compound repair method previously discussed, and the other is the laminated glass fabric cloth overlay method applied to the various damages of honeycomb skin and core materials which exceed the repair limitations of the potted compound repair.
The differences between the two repair methods are in the techniques of removing the damaged area, preparing the damaged area for the repair, preparing and applying the repair materials, finishing and final inspection of the completed repair, and use and maintenance of the handtools and shop equipment.
Cleaning Before repairing a damaged bonded honeycomb panel or section, thoroughly clean all paint or surface coatings from a surface area extending several inches away from the damage. Basically, this is necessary to attach and secure the templates or wedge blocks to the repair area with double-backed tape. Second, thoroughly clean the area of all foreign matter to ensure a perfect adhesion of the overlay repair materials.
Effective surface cleaning is of primary importance to the success of any repair. An area that is contaminated with paint, grease, oil, wax, oxides, or such, will not take a good bond. This cannot be emphasized too strongly since the quality of the repair will be no higher than the quality of the cleaning that precedes it. Even a fingerprint will prevent a good bond, because of natural oils in the skin.
Materials such as solvents, abrasives, alkaline detergents, and chemical etches can be used for effective cleaning. One of the easiest and most effective cleaning methods known is to apply MEK to the area with a sponge and immediately wipe it away with another sponge. This procedure should be continued until a lusterous surface is obtained.
In removing paint, use caution, since paint remover will dissolve adhesives if allowed to enter the damaged area of a joint.
Removal of Damage A high-speed router in conjunction with a router support assembly, metal-cutting mill bit, and template should be used in the removal of the damaged area. (Information about the uses and maintenance of the router was discussed earlier in this chapter.)
The techniques of removing damaged honeycomb skin and core material may differ from one repair to another. Their selection depends largely on the construction features of the bonded honeycomb panels, which are primarily of either flat, tapered, or combined (flat and tapered) surface design.
Also, the location of the damaged area must be considered; that is, whether the damage occurred on the upper or lower side of the panel. Another factor that must be considered is that the honeycomb core is always installed within the panel with the cells perpendicular to the lower surface.
The techniques of preparing for and removing a damaged area on a tapered or upper surface of a panel are somewhat different from those for a flat or lower surface. Prior to the routing of a damaged area of an upper or a tapered surface, the routing template must be bridged over the repair area. This is done in such a manner that the routing template will be perpendicular to the core cells and parallel to the opposite (lower) facing. The bridge consists of two wedge blocks made of wood, at least 6 in.
long, approximately 2 in. wide, and tapered to the same degree of angle as that of the panel. The method by which the bridge is attached to the damaged area is shown in figure 5-89.
Adhesives Overlay repair adhesives consist of a type 38 batch mix. Micro-balloons are added to the resins and curing agent for "buttering" the fiber glass honeycomb core plug and cavity of the glass cloth overlay repair. The micro-balloons can also be used to control the consistency of the potted compound adhesive.
The type and location of the repair will determine the method of adhesive application. For example, a repair on an upper surface would use a low micro-balloon content and would be poured into the cavity, whereas the same repair on an under surface would use a high micro-balloon content and would 208
have to be spooned into the cavity with a spatula or putty knife. Whichever method is used, the adhesive for all repairs should be applied evenly, without trapping any air bubbles.
The type 38 adhesive will set up and bond at room temperature. If a faster bond is required, the repair area should be preheated to 130° F., the repair parts and adhesives applied, and the whole repaired area heated at the same temperature for 1 hr. to effect a complete bond.
Upon completion of the repair, test it for any separation or other flaws, using the metallic ring test.
Coro Plug Core plugs are cut slightly larger than the desired thickness and shape from a glass fabric honeycomb core material (16-in, cell size). They are sanded to the correct shape and thickness with a belt or disk sander to a tolerance of +0.010 in. of the required size.
Before a core plug is inserted or assembled into the repair area, all contacting (faying) side surfaces of the core plug and the repair area must be "buttered" with an application of adhesive.
After the core plug has been properly installed into the repair area, the excessive potting compound is removed with a plastic scraper and the surface area thoroughly cleaned with a cleaning solvent.
The core plug repair area should be cured for at least 30 min. to 1 hr. This is done to assure that the core plug is firmly in place before any further repair steps are accomplished.
Laminated Glass Cloth Overlay A laminated glass cloth overlay consists of two layers of glass fabric cloth number 181 (three lay.
ers if number 128 is used) impregnated with type 38 adhesive and sandwiched between two sheets of polyethylene film. The glass cloth layers and sheets of polyethylene film are cut larger (spproximately 4 in.) than the damage cutout. This is done to accom.
modate the cutting of the laminated overlay to correct size, allowing for the required minimum overlap of at least 1-½ in. beyond the edge of the damage cutout.
Before a laminated glass cloth overlay is applied to a repair area, the faying surface must be cleaned until no trace of foreign matter appears. After the area has been thoroughly cleaned and dried, a thin and continuous film of adhesive primer EC-776R (or equal) is applied to the faying surfaces of the area. The adhesive primer may be allowed to dry at room temperature or may be accelerated by heat at a recommended temperature.
Protective coatings to prevent erosion and corrosion should be applied in accordance with the procedures outlined in the manufacturer's structural repair manual for the specific aircraft. A control surface repair should be checked to determine whether it is within balance limits or will require the surface to be re-balanced.
ONE SKIN AND CORE REPAIR PROCEDURES Two typical methods of repairing damages to the honeycomb skin and core materials of aircraft are:
(1) Single-face repair with damage extending through the core material and to the bond line of the opposite facing; and (2) transition area repair.
When the damage to the honeycomb structure is inspected and evaluated as damage to only one skin and the core (figure 5-92), the procedures Glass cloth laminates Fiber glass Butter edges of honeycomb core honeycomb •with potting.
core compound before installing core in repair area.
14" overlap Glass cloth Butter edges of prepared laminates hole with potting compound, CORE REPLACEMENT 2071220
SECTIONAL VIEW OF REPAIR AREA FICURE 5-92. Skin and core repair.
discussed in the following paragraphs can be used.
These procedures are typical but may not apply to all types of aircraft. Consult the manufacturer's repair manual for the specific aircraft, and follow the instructions for the particular type of repair.
Removing Damaged Area A router and the applicable template should be used to remove the damaged material from the area.
The depth of the router bit is determined by gradually increasing the depth of cut until it removes all of the damaged area. If the core is only partially damaged, remove only that portion. If the entire core is damaged, remove the core down to the opposite adhesive layer.
nated sections of fiber glass cloth needed to complete the repair should be accomplished as follows:
(1) Remove surface coating from repair area.
(2) Wipe surface with clean cheesecloth moistened with MEK unil no trace of foreign material appears. Do not allow MEK to dry, but wipe it off with a clean cloth.
(3) Apply adhesive primer EC-776R (or equal) with a clean 1-in. varnish brush to faying surface area and allow to dry.
hr. at may eat not Preparing the Core Replacement be ap- The core replacement must be fabricated from m. Do fiber glass core material. If the correct thickness is ıry for not available, the replacement section may be cut to cloth size by hand sawing and/or sanding. The core plug laminates.
should be flush or within +0.010 in. of all ccom- Potting Compound paper Prepare the potting compound as follows:
(1) Select the desired mix for the repair. A hylene stiff mix is desired when making overhead an the repairs or for core plug bonding. The average mix or thin mix is desirable when sh leet making upper surface repairs. inated
(2) Add micro-balloons to the resin and mix age for 3 to 5 min.
(3) Add the curing agent to the resin and sive micro-balloon mixture. Mix for 3 to 5 usly min.
(4) Apply the potting compound to the edges of the core replacement and around the cOredges of the damaged area in the struc- flm Insertion of Core Plug Place the core plug in the repair area as follows:
(1) Insert the core plug into the repair area.
(2) Remove any excessive potting compound with a plastic scraper and clean the repair area thoroughly.
(3) Allow the core plug repair to cure for at least ½ to 1 hr. at room temperature (72° F) to assure that the core plug is firmly in place.
Application of Glass Cloth Laminates The preparation for and application of the lami- 210 sive sive ene film.
(10) Place and center one layer of the glass fabric cloth over the adhesive-covered area of the sheet of polyethylene film.
(11) Pour an adequate amount of type 38 adhesive over the first layer of glass fabric cloth to cover and penetrate its entire area. Spread the adhesive evenly over the area with a plastic scraper.
(12) Apply a second layer of glass fabric cloth in the same manner as the first layer.
(13) Apply a sufficient amount of type 38 adhesive over the second layer of glass fabric cloth in the same manner as over the first layer.
(14) Place and center the second sheet of polyethylene film over the layers of adhesive-impregnated glass fabric cloth.
(15) With a plastic scraper, work out all the air bubbles towards the edges of the laminated overlays. Turn the laminated overlay as necessary in working out the air bubbles.
(16) With a pair of scissors, cut the sandwiched polyethlyene-laminated overlay with MEK cleaning solvent. Take care to prevent any of the cleaning solvent from entering the bond of the repair area.
(27) Allow the laminated overlay repair to cure for at least 12 hrs. at room temperature (72° F.) before the final sheet of polyethylene film is removed.
Transition Area Repair Some bonded honeycomb panels are constructed of a doubler separating an upper and lower skin and sectioned into bays of honeycomb core material. (See figure 5-93.) The edge section of a bay _Flange - Transition By area ½ in. to ¾ in. larger than the actual size of the laminated overlay.
(17) Place and center the sandwiched polyethylene-laminated overlay between the two Doubler disk templates that were previously prepared for the repair.
(18) With a pair of scissors, carefully cut the Transition laminated overlay around the edge of the area disk templates.
(19) Remove the disk templates from the sandwiched polyethylene-laminated overlay. Bav area
(20) Peel off one sheet of polyethylene film from the sandwiched laminated overlay.
Discard the polyethylene film.
(21) Place the laminated overlay with the exposed adhesive side down and in position over the repair surface area.
(22) Remove the remaining sheet of polyethylene film from the top side of the lami- CRUSHED EDGE DESIGN nated overlay. Discard the polyethylene film. Flange area
(23) Cut another sheet of polyethylene film ¾ in. to 1 in. larger than the laminated Transition overlay. area
(24) Place and center this sheet of polyethyl: Bay area ene film over the laminated overlay positioned over the repair surface area.
(25) With a smooth plastic scraper, sweep out any excess resin or air bubbles that may be present within the laminated overlay.
This step is of utmost importance to the overall quality of the repair. Therefore, this step should be accomplished with the greatest of care and patience.
(26) Clean the surrounding area of the repair
FORMED RING EDGE DESIGN FicURE 5-93. Typical bonded honeycomb panel bay construction.
area in which the honeycomb structure joins the laminated area of the panel or section is known as the transition area. Effective repairs to the transltion areas are particularly essential because of the local transferring of the streases.
The preparation of the repair materials and the assembly and curing of the core plug are basically the same as for the bonded honeycomb skin and core repairs. However, because of the, shape and contour of a transition area, especially at the corners of a bay, give special attention to the cutting and shaping of the glass fabric honeycomb core material.
In this repair, four layers of impregnated glass cloth, number 181, are preferred for the overlays.
The preference for glass cloth number 181 is because of its flexibility and ease of application, particularly when making repairs to a corner of a bay where a compound (double) contour is encountered.
Glass cloth laminates Fiber glass honeycomb core Repair Procedures The steps to be followed in the repair of a transition area are as follows:
(1) Outline the repair to a circular shape (not to exceed 2 in. in diameter) that will encircle the damaged area.
(2) Using a router, remove the damaged area down to the opposite adhesive layer.
Depth of the router cut is determined by gradually increasing the depth of the cut until the adhesive layer is reached.
(3) Fabricate a fiber glass honeycomb core to replace the damaged core section. The correct thickness and contour of the transition area may be obtained by hand sawing and/or sanding. The core plug must be shaped to fit flush or within +0.010 in.
(4) Prepare the potting compound.
(5) Butter the edges of the fiber glass honey-
• 2.0" Max. →
2.0" Max. (typ.)
Butter edges and bottom of prepared hole with potting compound before Butter edges of honeycomb installing honeycomb core. core with potting compound before installing core in repair area.
FIGURE 5-94. Transition area repair.