General Advanced Composite Repair Process Manual - 1-1-690 Flashcards
Refrigerators are used to store laminating and paste adhesives and should be kept near __.
40°F
Autoclave pressure and temperature capacity should not be less than __ psi at __
100, 450°F
Thermocouples should be between __ and __ feet long
10, 50
Downdraft tables should be sized and maintained to have an average face velocity between __ and __ cubic feet per minute
100, 150
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.
3 standard ft^3/min, 15 torr (0.3 psi absolute)
Shop air should be maintained at or near __ psi
100
An electronic top-loading scale with a minimum __ capacity and __ resolution is needed for repair operations.
500 g, 0.01 g
Belt sanders should be at least __ inches wide
6
Disc sanders should be at least __ inches in diameter.
12
A __-rpm drill motor has been found to perform best when drilling advanced composites.
3500
When drilling through composite structures containing aluminum skins, a __-rpm drill motor works best.
2000
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.
80
For standard 24-gauge wire, the distance shall not exceed __ feet. (thermocouples)
100
Never use less than __ thermocouples to monitor a heating cycle.
three
The thermocouples installed around the perimeter of the repair patch should be placed approximately __ inch away from the edge of the adhesive line.
0.5
Ensure the heat blanket overlaps the repair by a minimum of __ inches on each side to ensure even heating
2
Directional changes in the cutout should be smooth and flowing with a minimum curve radius of __ inch. (Damage removal)
0.5
Use one thermocouple for approximately each __ square inches of patch area.
10
Do not exceed a temperature of __°F on any aluminum part.
350
When a lack of system specific technical data exists, use a minimum of __ inches of mercury (Hg) vacuum.
20
Leak rate of less than __ inHg per minute should be maintained
1
Use one vacuum port for each __ ft^2 of bagging material
10
Paint removal should extend __ inches beyond the repair area and the surfaces surrounding.
2
The proper punch will be __ to __ inch smaller than the hole diameter. (Blind Hole Transfer Punches)
0.001, 0.005
Thus, several sizes of drill bits are required for a drilling operation __.
(e.g., pilot holes, 1/64th undersized, and final hole size)
If the new part is made from advanced composites,
pilot drill __-inch diameter holes at the intersection marks.
0.098
Repair ply overlap formula:
Repair ply thickness X Scarf ratio
Scarf outline dimension forumula:
Skin thickness X scarf outline dimension
If the damage is all the way through the laminate, the inner edge of the cutout can be knife edged __ to __ inch.
0, 0.005
Mechanically fastened or bolted repairs are primarily used for thicknesses over __ inch to keep the repair size manageable.
0.060
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)
1/8, 1/2, 0.005
If honeycomb or foam core is damaged, it may be potted rather than plugged if the damaged area is smaller than __ square inches.
8
Resin mixtures must be accurate to within
__ percent for Parts A and B.
1
A minimum of __ inches of manufacturing excess past engineering or part edge should be included in tool fabrication surface
6
Fabrics shall not be exposed to __ operations.
grinding/machining
Standard __ bits shall not be used for drilling composite structures.
twist drill
