1 HEXOEL OOMPOSTES

Sandwich Structures
Th|n, h|gh strength sk|ns are separated by, and bonded to,
||ghtwe|ght honeycomb cores, the th|cker the core the st|er
the pane| w|th m|n|ma| we|ght |ncrease.
Laminate Structures
Lam|nate structures are assemb|ed so that the |bre or|entat|on
prov|des most o the des|red mechan|ca| propert|es and the
matr|x |arge|y determ|nes the env|ronmenta| perormance.
NTRODUOTON
Oompos|tes are used |n a w|de range o app||cat|ons |n
aerospace, mar|ne, automot|ve, surace transport and sports
equ|pment markets. Damage to compos|te components |s not
a|ways v|s|b|e to the naked eye and the extent o damage |s
best determ|ned or structura| components by su|tab|e Non
Destruct|ve Test (NDT) methods.
A|ternat|ve|y the damaged areas can be |ocated by s|mp|y
tapp|ng the compos|te surace and ||sten|ng to the sound. The
damaged areas g|ve a du|| response to the tapp|ng, and the
boundary between the good and damaged compos|te can
eas||y be mapped to |dent|y the area or repa|r.
Awareness o and |nspect|on or compos|te damage shou|d be
|nc|uded |n the regu|ar ma|ntenance schedu|es or compos|te
structures. Part|cu|ar attent|on wou|d be made to areas wh|ch
are more prone to damage.
Pepa|rs to a|rcrat structures are contro||ed and shou|d be
carr|ed out accord|ng to the A|rcrat Btructura| Pepa|r Manua|
(BPM). For other app||cat|ons the repa|red components wou|d
norma||y be expected to meet the or|g|na| spec||cat|on and
mechan|ca| perormance requ|rements.
Th|s gu|de a|ms to g|ve a genera| approach to compos|te
repa|r |n a|| app||cat|ons and w||| exam|ne both sandw|ch and
|am|nate structures.
Apr|| 1999
Pub||cat|on No. TO 102
Hexce| Peg|stered Trademark
Hexce| Oompos|tes, Duxord
OOMPOSTE REPAR
HEXOEL OOMPOSTES 2
OOMPOSTE REPAR
REPAR FLOW OHART
The |ow chart g|ves the key stages or compos|te repa|r.
Excessive
Damage
assessment
Scrap
Easy repair CompIex repair
Repair
type
Submit /
Check
scheme with
manufacturer
/ OEM
Temporary
repair
Improvise
and
return to
repair
workshop
Approved
temporary
repair
Permanent composite repair
according to approved guideIines
QuaIity Check / NDT
Return to service
3 HEXOEL OOMPOSTES
KEY STAGES OF OOMPOSTE REPAR
Bome damage to compos|tes |s obv|ous and eas||y assessed but |n some cases the damage
may |rst appear qu|te sma||, a|though the rea| damage |s very much greater. lmpact damage to
a |bre can appear as a sma|| dent on the re|norced compos|te surace but the under|y|ng
damage can be much more extens|ve.
The dec|s|on to repa|r or scrap |s determ|ned by cons|der|ng the extent o repa|r needed to
rep|ace the or|g|na| structura| perormance o the compos|te. Other cons|derat|ons are the repa|r
costs, the pos|t|on and access|b|||ty o the damage and the ava||ab|||ty o su|tab|e repa|r
mater|a|s.
Easy repairs are usua||y sma|| or do not eect the structura| |ntegr|ty o the component. These
repa|rs are made by o||ow|ng the s|mp|e gu|de||nes |nd|cated or |am|nate or sandw|ch pane|s
(see |eoa|| sec||c|s).
Comp|ex repairs are needed when the damage |s extens|ve and needs to rep|ace the structura|
perormance o the component. The best cho|ce o mater|a|s wou|d be to use the or|g|na| |bres,
abr|cs and matr|x res|n. Any a|ternat|ve wou|d need careu| cons|derat|on o the serv|ce
env|ronment o the repa|red compos|te, |.e. hot, wet and mechan|ca| perormance.
The proposed repa|r scheme shou|d meet a|| the or|g|na| des|gn requ|rements or the structure.
When a compos|te repa|r |s needed or components |n use. Bome repa|rs need the spec|a||st
equ|pment o the workshop and some orm o |mprov|sed repa|r |s needed to return the
component to a su|tab|e repa|r workshop. A temporary repair, usua||y |n the orm o a patch, can
be |xed to the component. sua||y a be|t and braces approach |s taken to ensure saety unt||
the component can be repa|red at a |ater date.
The approved genera| gu|de||nes or |am|nate and sandw|ch repa|rs shou|d be o||owed. These
repa|r operat|ons shou|d be carr|ed out |n contro||ed workshop areas to ensure h|gh qua||ty
repa|rs. Good housekeep|ng and attent|on to repa|r deta|| w||| ensure success.
For comprehens|ve |nspect|on o repa|red parts a number o Non Destruct|ve Tests (NDT) can
be used. The |nspector shou|d exam|ne the qua||ty o the repa|red area and part|cu|ar attent|on
shou|d be g|ven to the |nterace between the or|g|na| part and the repa|red area.
sua| |nspect|on methods use some orm o u|trason|c test equ|pment where the re|ect|on o the
u|trason|c sound waves detect and |dent|y any damaged areas or au|ts.
Damage
assessment
Repair
type
Temporary
repair
Permanent
repair
QuaIity
Check
HEXOEL OOMPOSTES 4
OOMPOSTE REPAR
De|amination fo||owing impact on a mono|ithic
|aminate
Po|nt o |mpact
nder|y|ng damage can extend to a much greater extent |n
|am|nate structures.
Laminate Sp|itting
The damage does not extend through the u|| |ength o the part.
The eects on the mechan|ca| perormance depend on the
|ength o sp||t re|at|ve to the component th|ckness.
Heat Damage
A |oca| racture w|th separat|on o surace p||es. lts eect on the
mechan|ca| perormance depends on the th|ckness o the part.
Dents in Sandwich Structure
Puncture Damage in a Sandwich Structure
Both sk|ns may be damaged.
Bo|t Ho|e Damage
The damage cou|d be e|ongat|on o the ho|e caus|ng |am|nate
sp||tt|ng, or damage to the upper p||es.
TypicaI Damage
Most damage to |bre re|norced compos|tes |s a resu|t o |ow ve|oc|ty and somet|mes h|gh ve|oc|ty |mpact. ln meta|s the energy |s
d|ss|pated through e|ast|c and p|ast|c deormat|ons and st||| reta|ns a good dea| o structura| |ntegr|ty. Wh||st |n |bre re|norced
mater|a| the damage |s usua||y more extens|ve than that seen on the surace.
5 HEXOEL OOMPOSTES
REPAR OPTONS
When a compos|te structure susta|ns damage |n serv|ce one o
three |eve|s o repa|r must be emp|oyed.
Cosmetic repair
ln th|s case |nspect|on has determ|ned that the damage has
not aected the structura| |ntegr|ty o the component. A
cosmet|c repa|r |s carr|ed out to protect and decorate the
surace. Th|s w||| not |nvo|ve the use o re|norc|ng mater|a|s.
Temporary or interim repairs
lt |s oten the case |n serv|ce, that sma|| areas o damage are
detected wh|ch |n themse|ves do not threaten the |ntegr|ty or
mechan|ca| propert|es o the component as a who|e. However
| |et unrepa|red they may |ead to urther rap|d propagat|on o
the damage through mo|sture |ngress and at|gue.
B|mp|e patch type repa|rs can be carr|ed out, w|th the
m|n|mum o preparat|on, to protect the component unt|| |t can
be taken out o serv|ce or a proper structura| repa|r.
Temporary repa|rs shou|d be sub|ect to regu|ar |nspect|on.
Structura| repair
l the damage has weakened the structure through |bre
racture, de|am|nat|on or d|sbond|ng the repa|r w||| |nvo|ve
rep|acement o the damaged |bre re|norcement, and core |n
sandw|ch structures, to restore the or|g|na| mechan|ca|
propert|es. B|nce a bonded-on repa|r const|tutes a d|scont|nu|ty
o the or|g|na| p||es, and thereore a stress ra|ser, structura|
repa|r schemes norma||y requ|re extra p||es to be prov|ded |n
the repa|r area.
l the damaged area |s very sma|| |t can be quest|onab|e
whether a structura| repa|r, requ|r|ng remova| o a substant|a|
amount o the structure |n damage remova| and preparat|on, |s
preerab|e to a cosmet|c repa|r.
HEXOEL OOMPOSTES 6
OOMPOSTE REPAR
LAMNATES AND SANDWOH PANELS
The ma|n purpose o a structura| repa|r |s to u||y support
app||ed |oads and transm|t app||ed stresses across the
repa|red area. To do th|s the repa|r mater|a|s must over|ap, and
be adequate|y bonded to the p||es o the or|g|na| |am|nate.
There are three bas|c approaches to th|s.
1. Patch repair
ln th|s case the th|ckness o the or|g|na| |am|nate |s made up
w|th |||er p||es and the repa|r mater|a|s are bonded to the
surace o the |am|nate.
Advantages

Qu|ck and s|mp|e to do

Pequ|res m|n|mum preparat|on
Disadvantages
A repa|red |am|nate |s th|cker and heav|er than the or|g|na|
very careu| surace preparat|on |s needed or good
adhes|on
2. Taper sanded or scarf repair
ln th|s case an area around the ho|e |s sanded to expose a
sect|on o each p|y |n the |am|nate. Bomet|mes one |||er p|y |s
added to produce a |atter surace. Taper |s usua||y |n the
reg|on o 30-60:1
Advantages
Pepa|r |s on|y marg|na||y th|cker than the or|g|na|

Each repa|r p|y over|aps the p|y that |t |s repa|r|ng g|v|ng a

stra|ghter, stronger |oad path
Good bonds can be ach|eved on the resh|y exposed
suraces
Disadvantages
T|me consum|ng
H|gh sk||| needed and d||cu|t to ach|eve
3. Step sanded repair
The |am|nate |s sanded down so that a |at band o each |ayer
|s exposed, produc|ng a stepped |n|sh. Typ|ca| steps are 25-
50mm per |ayer.
Advantages

Bame as taper sanded repa|r

Disadvantages

Extreme|y d||cu|t to do
7 HEXOEL OOMPOSTES
TYPOAL LAMNATE REPARS
1. Patch repair
2. Taper sanded repair
(Scarf repair)
3. Step sanded repair
Note: l the component has been |n serv|ce |t must be dr|ed to
remove any mo|sture to obta|n the best repa|r.
Extra ply
Pepair plies
Film adhesive
Filler ply
Backup ply
Extra ply
Pepair plies
Film adhesive
Filler ply
Backup ply
Extra ply
Pepair plies
Film adhesive
Filler plies
Backup ply
HEXOEL OOMPOSTES 8
OOMPOSTE REPAR
TYPOAL SANDWOH PANEL REPARS
Note: l the component has been |n serv|ce |t must be dr|ed to
remove any mo|sture to obta|n the best repa|r.
1(a) Patch repair
1(b) A|ternative
patch repair
2 Taper sanded repair
(scarf repair)
3. Step sanded repair
Extra ply
Pepair plies
Film adhesive
Filler plies
Peplacement core Core splice adhesive
Extra ply
Pepair plies
Film adhesive
Peplacement core Core splice adhesive
Extra ply
Pepair plies
Film adhesive
Filler ply
(optional)
Peplacement core Core splice adhesive
Extra ply
Pepair plies
Film adhesive
Filler ply
(optional)
Peplacement core Core splice adhesive
9 HEXOEL OOMPOSTES
REPAR SEQUENOE FOR DOUBLE SDED REPAR
1. Puncture damage
2. Remove damage
3. Taper sand
4. Bond new honeycomb
5. Repair first side
6. Repair second side
typically 12.5mm
Pelease film
(peel ply)
Temporary
mould
Packing piece
Core splice adhesive
Extra ply
Pepair plies
Filler ply
(opt)
Temporary
mould
Packing piece
HEXOEL OOMPOSTES 10
OOMPOSTE REPAR
Typica| Layup and Equipment for one side access repair
When access |s poss|b|e rom both s|des then a comp|ete enve|ope bag |s recommended.
Oompressed a|r
vacuum ||ne to repa|r patch
Power supp|y
Pepa|r patch
Thermocoup|es
vacuum bag
Heater mat
Output to
heater mat
Hot bond un|t
REPAR USNG PRE-OURED DOUBLER
Bome compos|te repa|rs can be ach|eved by the use o pre-
cured doub|ers.
A pre-cured doub|er |s a sheet o compos|te mater|a| made
rom |ayers o |bre re|norced epoxy wh|ch has been cured |n
us|ng heat and pressure.
A patch |s cut rom the pre-cured mater|a| and bonded on to
the surace o the component.
The edges o the doub|er are chamered to |ncrease the pee|
o strength.
Pre-cured doub|ers can be bonded on to the component us|ng
wet |ay-up res|ns or adhes|ve ||ms. However one ma|or
drawback o th|s method has been entrapment o a|r under the
doub|er wh|ch |eads to a weak repa|r.
The repa|r can be |mproved by us|ng a |ayer o scr|m c|oth
under the adhes|ve ||m to a||ow the a|r to escape.
EQUPMENT AND ANOLLARES FOR REPARS
11 HEXOEL OOMPOSTES
Hot Bonders
Heater B|ankets
Bagg|ng Mater|a|s
- vacuum bags
- sea|ant tape
- re|ease ||m
- breather
- vacuum take o connector
EQUPMENT AND ANOLLARES FOR REPARS
A|| the components o a vacuum bag |ay-up are shown |n the
d|agram above. Th|s |ay-up |s |dea| or h|gh qua||ty
components, however a|ternat|ve |ay-ups are poss|b|e to su|t
the mater|a|s and app||cat|on.
Consumab|es for Vacuum Bag Processing
Pee| p|y (opt|ona|)
A||ows ree passage o vo|at||es and excess matr|x dur|ng the
cure. Oan be removed eas||y ater cure to prov|de a bondab|e
or pa|ntab|e surace.
Re|ease fi|m
Th|s prevents urther |ow o matr|x and can be s||ght|y porous
(w|th p|n pr|cks) to a||ow the passage o on|y a|r and vo|at||es
|nto the breather |ayer above.
Fig. 1 Detai| of vacuum bag |ay-up
Breather fabric
Prov|des the means to app|y the vacuum and ass|sts remova|
o a|r and vo|at||es rom the who|e assemb|y. Th|cker breathers
are needed when h|gh autoc|ave pressures are used.
Vacuum bag/sea|ant tape
Prov|des a sea|ed bag to a||ow remova| o a|r to orm the
vacuum bag.
|c|e. || |s |eccmme|oeo ||a| |e. cc|s0mao|es a|e 0seo eac|
||me |c e|s0|e ||e ma|0/ac|0|e c/ cco q0a|||, ccmocs||es.
vacuum bag
Breather abr|c
Heater b|anket
Pe|ease ||m
Pee| p|y
Prepreg
Pepa|r patch
Damaged compos|te
To vacuum pump
Bea|
F||m adhes|ve
HEXOEL OOMPOSTES 12
OOMPOSTE REPAR
REPAR PROOESS
Vacuum bag or autoc|ave - which process?
vacuum bag and autoc|ave process|ng are the two ma|n methods or the repa|r o components rom prepreg. The process|ng
method |s determ|ned by the qua||ty, cost and type o component be|ng manuactured.
Component Processing costs
Processing method Qua|ity Section thickness Equipment cost Cure cyc|e time
vacuum bag Good Th|n Moderate Bhort
Autoc|ave Exce||ent Th|ck H|gh Long
Vacuum bag processing |s su|ted to components w|th th|n sect|ons and |arge sandw|ch structures. The vacuum bag techn|que
|nvo|ves the p|ac|ng and sea||ng o a |ex|b|e bag over a compos|te |ay-up (|g. 1) and evacuat|ng a|| the a|r rom under the bag
(|g. 2).
The remova| o a|r orces the bag down onto the |ay-up w|th conso||dat|on pressure o 1 atmosphere (1 bar). The comp|eted
assemb|y, w|th vacuum st||| app||ed, |s p|aced |ns|de an oven w|th good a|r c|rcu|at|on, and the compos|te |s produced ater a
re|at|ve|y short cyc|e cure.
Autoc|ave processing |s used or the repa|r o h|gh qua||ty structura| components. The autoc|ave techn|que requ|res a s|m||ar
vacuum bag (|g.1) but the oven |s rep|aced by an autoc|ave. The autoc|ave |s a pressure vesse| wh|ch prov|des the cur|ng
cond|t|ons or the compos|te where the app||cat|on o vacuum, pressure, heat up rate and cure temperature are contro||ed. H|gh
process|ng pressures a||ow the mou|d|ng o th|cker sect|ons o comp|ex shapes. Honeycomb sandw|ch structures can a|so be made
to a h|gh standard. Long cure cyc|es are requ|red because the |arge autoc|ave mass takes a |ong t|me to heat up and coo| down.
Bomet|mes s|ow heat up rates are requ|red to guarantee even temperature d|str|but|on on the too||ng and compos|te components.
vacuum bag
Prepreg
Connector to
vacuum pump
Seal
Atmospheric pressure
Fig. 2 Sea|ing f|exib|e bag over |ay-up Fig. 3 App|ying vacuum to the system
13 HEXOEL OOMPOSTES
HEXOEL'S PRODUOTS FOR OOMPOSTE REPAR
Hexce| |s the |ead|ng wor|dw|de supp||er o compos|te mater|a|s or aerospace, sports goods, mar|ne, ra|| and automot|ve app||cat|ons.
Hexce| manuactures a range o compos|te mater|a|s, wh|ch are |dea||y su|ted or the repa|r o compos|tes. These |nc|ude:
A w|de se|ect|on o prepregs, |nc|ud|ng the new M20, 130O cur|ng system or vacuum bag or autoc|ave process|ng (qua|||ed to PMB
167).
Pedux

structura| ||m adhes|ves

A|um|n|um, Nomex

and spec|a||st honeycombs

Mod|pur

po|yurethane oams
(Nomex |s a reg|stered trademark o Du Pont).
mportant
A|| |normat|on |s be||eved to be accurate but |s g|ven w|thout acceptance o ||ab|||ty. sers shou|d make the|r own assessment o the
su|tab|||ty o any product or the purposes requ|red. A|| sa|es are made sub|ect to our standard terms o sa|e wh|ch |nc|ude ||m|tat|ons on
||ab|||ty and other |mportant terms.
W|th thanks to Aerosk|||s or ass|stance w|th se|ected draw|ngs |n th|s manua|.
13