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SWE > General Advanced Composite Repair Process Manual - 1-1-690 > Flashcards

General Advanced Composite Repair Process Manual - 1-1-690 Flashcards

1
Q

Refrigerators are used to store laminating and paste adhesives and should be kept near __.

A

40°F

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2
Q

Autoclave pressure and temperature capacity should not be less than __ psi at __

A

100, 450°F

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3
Q

Thermocouples should be between __ and __ feet long

A

10, 50

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4
Q

Downdraft tables should be sized and maintained to have an average face velocity between __ and __ cubic feet per minute

A

100, 150

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5
Q

A vacuum pump rated at a minimum of __ flow rate and an ultimate vacuum of __ or less is needed to provide adequate vacuum levels for repair operations.

A

3 standard ft^3/min, 15 torr (0.3 psi absolute)

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6
Q

Shop air should be maintained at or near __ psi

A

100

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7
Q

An electronic top-loading scale with a minimum __ capacity and __ resolution is needed for repair operations.

A

500 g, 0.01 g

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8
Q

Belt sanders should be at least __ inches wide

A

6

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9
Q

Disc sanders should be at least __ inches in diameter.

A

12

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10
Q

A __-rpm drill motor has been found to perform best when drilling advanced composites.

A

3500

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11
Q

When drilling through composite structures containing aluminum skins, a __-rpm drill motor works best.

A

2000

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12
Q

Cure temperatures shall not exceed __ percent of the fuel’s auto-ignition temperature unless the fuel tanks have been properly purged, a higher temperature has been approved through appropriate safety organizations or a waiver has been granted by the authority having jurisdiction in accordance with AFI 32-2001, The Fire Protection Operations and Fire Prevention Program.

A

80

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13
Q

For standard 24-gauge wire, the distance shall not exceed __ feet. (thermocouples)

A

100

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14
Q

Never use less than __ thermocouples to monitor a heating cycle.

A

three

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15
Q

The thermocouples installed around the perimeter of the repair patch should be placed approximately __ inch away from the edge of the adhesive line.

A

0.5

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16
Q

Ensure the heat blanket overlaps the repair by a minimum of __ inches on each side to ensure even heating

A

2

17
Q

Directional changes in the cutout should be smooth and flowing with a minimum curve radius of __ inch. (Damage removal)

A

0.5

18
Q

Use one thermocouple for approximately each __ square inches of patch area.

A

10

19
Q

Do not exceed a temperature of __°F on any aluminum part.

A

350

20
Q

When a lack of system specific technical data exists, use a minimum of __ inches of mercury (Hg) vacuum.

A

20

21
Q

Leak rate of less than __ inHg per minute should be maintained

A

1

22
Q

Use one vacuum port for each __ ft^2 of bagging material

A

10

23
Q

Paint removal should extend __ inches beyond the repair area and the surfaces surrounding.

A

2

24
Q

The proper punch will be __ to __ inch smaller than the hole diameter. (Blind Hole Transfer Punches)

A

0.001, 0.005

25
Q

Thus, several sizes of drill bits are required for a drilling operation __.

A

(e.g., pilot holes, 1/64th undersized, and final hole size)

26
Q

If the new part is made from advanced composites,

pilot drill __-inch diameter holes at the intersection marks.

A

0.098

27
Q

Repair ply overlap formula:

A

Repair ply thickness X Scarf ratio

28
Q

Scarf outline dimension forumula:

A

Skin thickness X scarf outline dimension

29
Q

If the damage is all the way through the laminate, the inner edge of the cutout can be knife edged __ to __ inch.

A

0, 0.005

30
Q

Mechanically fastened or bolted repairs are primarily used for thicknesses over __ inch to keep the repair size manageable.

A

0.060

31
Q

Drill one hole at each end of the delamination. Use an approved __-inch carbide drill bit. The holes
must be spaced at least __ inch apart. The holes
should be to the depth of the delamination plus
__ inch. (Resin Injection)

A

1/8, 1/2, 0.005

32
Q

If honeycomb or foam core is damaged, it may be potted rather than plugged if the damaged area is smaller than __ square inches.

A

8

33
Q

Resin mixtures must be accurate to within

__ percent for Parts A and B.

A

1

34
Q

A minimum of __ inches of manufacturing excess past engineering or part edge should be included in tool fabrication surface

A

6

35
Q

Fabrics shall not be exposed to __ operations.

A

grinding/machining

36
Q

Standard __ bits shall not be used for drilling composite structures.

A

twist drill

SWE (9 decks)

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