TM 1-1500-204-23-11

TECHNICAL MANUAL

AVIATION UNIT MAINTENANCE (AVUM) AND

AVIATION INTERMEDIATE MAINTENANCE (AVIM)
MANUAL
GENERAL AIRCRAFT MAINTENANCE

ADVANCED COMPOSITE MATERIAL GENERAL MAINTENANCE AND PRACTICES

VOLUME 11

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY

$8*867
 TM 1-1500-204-23-11
Personnel performing instructions involving operations, procedures, and practices which are included or implied
in this technical manual shall observe the following instructions. Disregard of these warnings and precautionary
information can cause serious injury, death, or an aborted mission.

WARNINGS, CAUTIONS, and NOTES are means of attracting attention to essential or critical information in
a manual. Definitions are outlined as follows:

An operating or maintenance procedure, practice, condition, statement, etc., which if not strictly
observed, could result in injury to or death of personnel.

An operating or maintenance procedure, practice, condition, statement, etc., which, if not

strictly observed, could result in damage to, or destruction of, equipment or loss of mission
effectiveness or long term health hazards to personnel.

NOTE
An essential operating or maintenance procedure, condition, or statement, which must be
highlighted.

ELECTRICAL EQUIPMENT
All metal apparatus shall be grounded to avoid the danger of igniting test fluid fumes or creating electrical
shock.

USING SOLVENTS/PAINTS
Standard precautions such as fire prevention and adequate ventilation shall be exercised when using solvents
or applying primer and coating.
Wear gloves or gauntlets when handling solvents as solvents may cause skin disorders.
Adhesives and solvents used to repair composite structures are flammable and shall be treated as such.
Never smoke or permit any type of open flame near when using adhesives or solvents.

Dichloromethane (methylene chloride)

Vapor is heavier than air; adequate ventilation shall be provided for working personnel. Dlchloromethane
(methylene chloride) is toxic when vapors are inhaled over an extended period of time. Acrylic monomer and
polymer base adhesive, MIL-A-8576, Type II, contains a volatile liquid which may prove toxic when vapors
are inhaled over extended periods. Use only with adequate ventilation. Observe fire precautions when using
aliphatic naphtha, Federal Specification TT-N-95.

LUBRICATING OIL
Lubricating oil, 1 MIL-L-7808 or MIL-L-23699, contains an additive which is poisonous and absorbed readily
through the skin. Do not allow oil to remain on skin any longer than necessary.

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TM 1-1500-204-23-11

FUEL
When servicing aircraft or support equipment, clean up spilled fuel with cotton mops or cotton rags. Wash
off any fuel on hands, body or clothing.

HANDLING ACID
Wear protective clothing when mixing acid with water. Always pour acid into water, never water into acid.

MAGNESIUM ALLOY FIRE

Do not use water or any standard liquid or foam-type fire extinguishers on a magnesium alloy fire, as they
may cause an explosion. Use dry sand or talcum powder, Federal Specification U-T-30.

FIRE EXTINGUISHERS
Monobromotrifluoromethane (CF3Br) is highly volatile, but not easily detected by odor. Although nontoxic,
CF3Br shall be considered in the same class as other freons and carbon dioxide, i.e., capable of causing
danger to personnel primarily by reduction of oxygen available for proper breathing. The liquid may cause
frostbite or low temperature burns if allowed to come in contact with the skin.
Bromochloromethane (CB) is a narcotic agent of moderate intensity, but of prolonged duration. It is considered
less toxic than carbon tetrachloride, methylbromide, or the usual products of combustion. Normal precautions
should be taken while using bromochloromethane, including the use of oxygen masks.

NOISE HAZARD
Noise levels reached during ground run-up of Army aircraft are of a level that may cause permanent hearing
loss. Maintenance personnel shall wear adequate hearing protection when working on aircraft with engines
in operation.

COMPRESSED AIR
Compressed air shall not be used for cleaning purposes except if reduced to less than 30 psi and then only
with effective chip-guarding and personal protective equipment.

MERCURY
A very small amount of mercury may produce hazardous vapors. Refer to TB 385-4, Safety Precautions for
Maintenance of Electrical/Electronic Equipment, for safety precautions to use when handling mercury and for
methods that are used to clean up mercury spillage.

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 TM 1-1500-204-23-11

SPECIAL INSTRUCTIONS
All equipment must be operated per the manufacturer’s operating instructions if unavailable, instructions for
the use and care of equipment will be developed Standard Operating Procedures (SOPs) will be prepared
and used for all shop operations (refer to AR 385-95). The supporting Safety Office will use their expertise
to provide assistance. Guidance for industrial hazards can be found in Code of Federal Regulations, 29 CFR
1910 and Chemical Hazards in NIOSH/OSHA Guidelines for Chemical Hazards.

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 TM 1-1500-204-23-11

LIST OF EFFECTIVE PAGES

Dates of issue for original and change pages are:

Original . . . . . . . . . . . . . . . . . . . . . . . . . .30 August 2013

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS , CONSISTING OF THE FOLLOWING:

Page No. *Change No. Page No. *Change No.

Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
a ......................................... 0 3-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
b ......................................... 0 3-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
c ......................................... 0 3-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
d Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
A ......................................... 0 3-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
B ......................................... 0 3-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
C......................................... 0 3-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
D......................................... 0 3-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
i.......................................... 0 3-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
iii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
iv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
v ......................................... 0 3-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
vi Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
1-2 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3-36 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-16 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 5-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 5-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
3-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 5-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0

*Zero in this column indicates an original page.

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TM 1-1500-204-23-11

LIST OF EFFECTIVE PAGES (Cont)

Page No. *Change No. Page No. *Change No.

5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-31 ...................................... 0

5-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-32 ...................................... 0
5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-33 ...................................... 0
5-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-34 ...................................... 0
5-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-35 ...................................... 0
5-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-36 ...................................... 0
5-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-37 ...................................... 0
5-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-38 ...................................... 0
5-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-39 ...................................... 0
5-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-40 ...................................... 0
5-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-41 ...................................... 0
5-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-42 ...................................... 0
5-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-43 ...................................... 0
5-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-44 ...................................... 0
5-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-45 ...................................... 0
5-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-46 ...................................... 0
5-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-47 ...................................... 0
5-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-48 ...................................... 0
5-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-49 ...................................... 0
5-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-50 ...................................... 0
5-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-51 ...................................... 0
5-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-52 ...................................... 0
5-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-53 ...................................... 0
6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-54 ...................................... 0
6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-55 ...................................... 0
6-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-56 ...................................... 0
6-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-57 ...................................... 0
6-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-58 ...................................... 0
6-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-59 ...................................... 0
6-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-60 ...................................... 0
6-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-61 ...................................... 0
6-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-62 ...................................... 0
6-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-63 ...................................... 0
6-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-64 ...................................... 0
6-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-65 ...................................... 0
6-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-66 ...................................... 0
6-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-67 ...................................... 0
6-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-68 ...................................... 0
6-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-69 ...................................... 0
6-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-70 ...................................... 0
6-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-71 ...................................... 0
6-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-72 ...................................... 0
6-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-73 ...................................... 0
6-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-74 ...................................... 0
6-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-75 ...................................... 0
6-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-76 ...................................... 0
6-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-77 ...................................... 0
6-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-78 ...................................... 0
6-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-79 ...................................... 0
6-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-80 ...................................... 0
6-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-81 ...................................... 0
6-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-82 ...................................... 0
6-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-83 ...................................... 0
*Zero in this column indicates an original page.
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 TM 1-1500-204-23-11

LIST OF EFFECTIVE PAGES (Cont)

Page No. *Change No. Page No. *Change No.

6-84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-45 ...................................... 0

6-85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-46 ...................................... 0
6-86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-47 ...................................... 0
6-87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-48 ...................................... 0
6-88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-49 ...................................... 0
6-89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-50 ...................................... 0
6-90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-51 ...................................... 0
6-91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-52 ...................................... 0
6-92 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-53 ...................................... 0
7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-54 ...................................... 0
7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-55 ...................................... 0
7-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-56 ...................................... 0
7-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-57 ...................................... 0
7-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-58 ...................................... 0
7-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-59 ...................................... 0
7-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-60 ...................................... 0
7-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-61 ...................................... 0
7-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-62 ...................................... 0
7-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-63 ...................................... 0
7-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-64 ...................................... 0
7-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-65 ...................................... 0
7-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-66 ...................................... 0
7-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-67 ...................................... 0
7-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-68 ...................................... 0
7-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-69 ...................................... 0
7-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-70 ...................................... 0
7-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-71 ...................................... 0
7-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-72 ...................................... 0
7-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-73 ...................................... 0
7-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-74 ...................................... 0
7-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-75 ...................................... 0
7-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-76 ...................................... 0
7-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-77 ...................................... 0
7-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-78 ...................................... 0
7-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-79 ...................................... 0
7-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-80 ...................................... 0
7-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-81 ...................................... 0
7-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-82 ...................................... 0
7-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-83 ...................................... 0
7-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-84 ...................................... 0
7-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-85 ...................................... 0
7-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-86 ...................................... 0
7-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-87 ...................................... 0
7-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-88 ...................................... 0
7-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-89 ...................................... 0
7-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-90 ...................................... 0
7-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-91 ...................................... 0
7-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-92 ...................................... 0
7-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-93 ...................................... 0
7-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-94 ...................................... 0
7-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-95 ...................................... 0
7-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-96 ...................................... 0
7-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 7-97 ...................................... 0
*Zero in this column indicates an original page.
C
TM 1-1500-204-23-11

LIST OF EFFECTIVE PAGES (Cont)

Page No. *Change No. Page No. *Change No.

7-98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 B-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 B-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 B-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 B-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 B-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 B-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Glossary-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Glossary-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Glossary-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Glossary-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Glossary-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Glossary-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Glossary-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Glossary-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Glossary-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Glossary-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Glossary-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Glossary-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Glossary-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Glossary-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
7-118 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Glossary-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Glossary-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
A-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Glossary-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
B-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Glossary-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
B-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Glossary-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
B-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Glossary-20 Blank . . . . . . . . . . . . . . . . . . . . . . . . . 0
B-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0

*Zero in this column indicates an original page.

D
 TM 1-1500-204-23-11

TECHNICAL MANUAL U.S. ARMY AVIATION

AND MISSILE COMMAND
No. 1-1500-204-23-11 30 August 2013

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can improve this manual. If you find any mistakes or if you know of a way to improve these
procedures, please let us know. Mail your letter or DA Form 2028 (Recommended Changes to
Publications and Blank Forms) located in the back of this manual, directly to: Commander, U.S.
Army Aviation and Missile Command, ATTN: AMSAM-MSS-LP, Redstone Arsenal, AL 35898-5000.
A reply will be furnished to you. You may also provide DA Form 2028 information to AMCOM via
e-mail, fax, or the World Wide Web. Our fax number is: DSN 788-6546 or Commercial 256-842-
6546. Our e-mail address is: 2028@redstone.army.mil. Instructions for sending an electronic 2028
may be found at the back of this manual immediately preceding the hard copy 2028. For the World
Wide Web use: https://amcom2028.redstone.army.mil.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TABLE OF CONTENTS
Page
CHAPTER 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
CHAPTER 2 Composite Material Facility Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
CHAPTER 3 Repair Equipment, Tools and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
CHAPTER 4 Composite Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
CHAPTER 5 Typical Damage and Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CHAPTER 6 Repair Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
CHAPTER 7 Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
APPENDIX A References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
APPENDIX B Tools and Consumable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary-1

LIST OF ILLUSTRATIONS

Figure Title Page

2-1 Carbon Fiber and Human Hair Diameters Compared to Filtration Level of HEPA Filter . . . . . 2-4
2-2 Removing Disposable Gloves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-3 Temperature and Humidity Allowables for Bonding and Layup . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
3-1 Alternating Tooth Bandsaw Blade for Cutting Aramid Laminates . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2 Heat Blanket Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-3 Welded Thermocouple Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-4 Twisted Thermocouple Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-5 Heat Lamp Temperature Affects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-6 Double Vacuum Debulk (DVD Tool Schematic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-7 Rigid Box Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3-8 Blind Fastener Differences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3-9 Hi-Lok® Installation: Hand Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3-10 Pistol Extension Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3-11 Blind Fastener Grip Length Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3-11 Blind Fastener Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-12 Typical Drill Reamer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3-13 Typical Drill Reamer Diagram (ST1257B Shown for Reference) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-14 Dagger Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-15 Spade Drill for Aramid Laminates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-16 Brad Point Bit for Aramid or Fiberglass Laminates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3-17 Eight–faceted Bit for Hybrid Metal/Composite Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

i
TM 1-1500-204-23-11

LIST OF ILLUSTRATIONS (Cont)

Figure Title Page

3-18 Split Helix Router Bit for Trimming Aramid Composites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3-19 Countersink for Aramid Laminates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3-20 Coated Abrasive Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3-21 Hole Saw and Guide Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3-22 Honeycomb Core Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3-23 Industrial Hypodermic Syringe and Needles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3-24 SEMCO Model 250 Sealant Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3-25 Vacuum Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3-26 Moisture Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3-27 Adhesive Comb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
4-1 Laminate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-2 Sandwich Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-3 Structural Property Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-4 Fiber Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-5 Warp vs. Fill Fibers in a Roll of Fabric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-6 Plain Weave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-7 Twill Weave (2X2 Twill Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-8 Satin Weave (4 & 8 Harness Satin Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-9 Example Satin Weave Showing Alternating Warp and Fill Faces Used for Lamination . . . . . . 4-8
4-10 Braid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-11 Weave and Stitch Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4-12 Simultaneous Stitch Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4-13 Honeycomb Core Orientation and Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-14 Sample Vendor Callouts for Honeycomb Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-15 Overexpanded Honeycomb Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-16 Flexible Honeycomb Cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-17 X-Cor® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
5-1 Inspection Tap Hammer Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-2 Pulse-Echo Ultrasonic Inspection with A-Scan Presentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-3 Through-Transmission Ultrasonic Inspection, A-Scan Presentation . . . . . . . . . . . . . . . . . . . . . . 5-9
5-4 Types of Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5-5 Defect Mapping of Damage Extent from NDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-6 Damage Work Lines Drawn on Part Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5-7 Typical Orientation Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-8 Ply and Ply Fiber Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5-9 Fiber Orientations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5-10 Typical Laminate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5-11 Stacking Sequence Effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5-12 Patch Drawing Example and Typical Scarf Repair Stackup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5-13 Scab Patch Ply Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5-14 Repair Ply Cutting Template (Example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5-15 ASTM Standard for Measuring Ply Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5-16 Example Standard Code Element and Laminate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5-17 Example for Positive and Negative Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5-18 Example for Accommodating Larger Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5-19 Example Even Symmetric Laminate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5-20 Example Odd Symmetric Laminate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5-21 Example Odd Symmetric Laminate with Multiple Same Angled Plies . . . . . . . . . . . . . . . . . . . . . 5-26
5-22 Example Sets for Symmetric Laminates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5-23 Example Sets for Non-Symmetric Laminates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5-24 Excerpt from CMH-17F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
6-1 Paint Removal Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2 Damage Outlining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

ii
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LIST OF ILLUSTRATIONS (Cont)

Figure Title Page

6-3 Router Template Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-4 Partial Thickness Damage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-5 Core Cell Axis Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-6 Removal of Core With Core Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-7 Template Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6-8 Typical Router Setup With Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6-9 Average Drying Time for Advanced Composite Laminates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6-10 Patch Edge Taper Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6-11 In-Plane Versus Out-Of-Plane Cutting Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6-12 Spoiling and Potting Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6-13 Basic Repair Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
6-14 Basic Repair Joints (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
6-15 Basic Repair Joints (Bonded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
6-16 Basic Repair Joints (Bolted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6-17 Ply Overlap Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
6-18 Dimensions of a Scarf Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
6-19 Cross Section of Typical Scarf Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
6-20 Scarf Joint Outline Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
6-21 Scarf Joint Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
6-22 Laminate Fiber Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
6-23 Scarf Joint Inspection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
6-24 Step Joint Outline Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
6-25 Step Joint Inspection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
6-26 Ply Layup Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
6-27 Vacuum Assist Impregnation Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
6-28 Two Part Adhesives and Filler Compounds Formula . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
6-29 Examples for Preparing Two Part Adhesives and Filler Compounds . . . . . . . . . . . . . . . . . . . . . . 6-49
6-30 Vacuum Bagging Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
6-31 Envelope Bagging a Part on a Worktable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
6-32 Vacuum Bag the Part Contour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
6-33 Component Sizes and Slotted Disc Geometry for Single-Side Access Seal . . . . . . . . . . . . . . . 6-61
6-34 Single-Sided Access Backside Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
6-35 Heat Blanket Placement and Temperature Variations in Repair Area . . . . . . . . . . . . . . . . . . . . . 6-68
6-36 Typical Thermal Survey Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69
6-37 Typical Cure Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71
6-38 Typical Vacuum-Bagged Cure Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72
6-39 Typical Thermocouple Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76
6-40 Thermocouple Placement in Repair Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79
6-41 Pressure Levels Produced Using Various Pressure Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82
6-42 Methods for Applying Positive Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86
6-43 C-Clamp Sequence and Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87
6-44 Typical Two Part Adhesive Heat Cure Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-88
6-45 Inspection of Adhesive Squeeze Out Following Cure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
7-1 Process Flow Diagram for Surface Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-2 Process Flow Diagram For Partial Thickness Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-3 Partial Thickness Bonded Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-4 Patch Edge Taper Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-5 Layup of Stacked Patches and Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-6 Process Flow Diagram for Partial Thickness Scarf Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7-7 Process Flow Diagram for Penetration Damage Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7-8 Cross Section of Typical Stepped Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7-9 Core Replacement Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7-10 Replacement Core Fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

iii
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Figure Title Page

7-11 Weight Versus Hole Diameter for Two Core Replacement Methods . . . . . . . . . . . . . . . . . . . . . . 7-22
7-12 Process Flow Diagram for Honeycomb Core Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7-13 Procedure for Core Replacement Using the Core Potting Method . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7-14 Process Flow Diagram for Core Repair, Paste Adhesive Method . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
7-15 Procedure for Core Replacement Using the Paste Adhesive Method . . . . . . . . . . . . . . . . . . . . . 7-28
7-16 Process Flow Diagram for Rapid Densification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
7-17 Layup of Stacked Patches and Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
7-18 Basic Repair Joints (Bolted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
7-19 Hi-Lok® Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
7-20 Removal of Tightly Clamped Blind Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
7-21 Removal of Loose Blind Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
7-22 Hole Finder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
7-23 Blind Hole Transfer Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
7-24 Measuring and Scaling Method of Transferring Blind Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44
7-25 Mold Method of Transferring Blind Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
7-26 Arc Method of Locating Blind Fastener Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47
7-27 Process Flow Diagram for Penetration Damage Bolted Repair, External Patch . . . . . . . . . . . . 7-51
7-28 Sump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
7-29 Sealing Bolted Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
7-30 Process Flow Diagram for Partial Thickness Bolted Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
7-31 Types of Delaminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
7-32 Impact Damage Injection Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
7-33 Injection Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
7-34 Process Flow Diagram for Delamination Not Open to an Edge Repair . . . . . . . . . . . . . . . . . . . . 7-59
7-35 Verification of Leak Path: Delamination Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
7-36 Delamination Repair Not Open to an Edge (Blister) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62
7-37 Process Flow Diagram for Delamination Open to an Edge Repair . . . . . . . . . . . . . . . . . . . . . . . . 7-63
7-38 Repair to an Open Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64
7-39 Process Flow Diagram for Disbond Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66
7-40 Verification of Leak Path: Disbond Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
7-41 Disbond Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
7-42 Process Flow Diagram for Skin to Closure Member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69
7-43 Skin to Closure Member Disbond Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71
7-44 Repair to an Open Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
7-45 Process Flow Diagram for Edge Damage Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
7-46 Process Flow Diagram for Flush Corner Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76
7-47 Flush Corner Repair Sequence (Only Bonding on Upper Moldline is Shown for Clarity) . . . . 7-78
7-48 Repair Rib Layup and Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
7-49 Process Flow Diagram for Fastener Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85
7-50 Process Flow Diagram for Countersink Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
7-51 Process Flow Diagram for Fill and Drill Fastener Hole Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
7-52 Template Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
7-53 Fastener Hole Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
7-54 Process Flow Diagram for Potting Fastener Hole Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-90
7-55 Potted Fastener Hole Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-90
7-56 Process Flow Diagram Fabric Layup Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-92
7-57 Fabric Layup Fastener Hole Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-93
7-58 Process Flow Diagram for Fastener Hole Delamination Repair (Vacuum Injection) . . . . . . . . . 7-95
7-59 Vacuum Injection Fastener Hole Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-95
7-60 Application of Clamp-Up Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-98
7-61 Process Flow Diagram for Fastener Hole Repair: Swagged Grommet . . . . . . . . . . . . . . . . . . . . 7-99
7-62 Swagged Grommet Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100
7-63 Process Flow Diagram Captive Bushing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-101

iv
 TM 1-1500-204-23-11

LIST OF ILLUSTRATIONS (Cont)

Figure Title Page

7-64 Captive Bushing Repair Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-102

7-65 Captive Bushing Repair Flange and Countersink Bushing Installation . . . . . . . . . . . . . . . . . . . . 7-103
7-66 Installation View of Captive Bushing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-104
7-67 DVD Precure Stacking Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-111
7-68 DVD Cocure Stacking Sequence (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-113
7-69 Double Vacuum Debulk Locally Manufactured Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-115
7-70 Process Flow Diagram for Lightning Strike. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-116

LIST OF TABLES

Number Title Page

2-1 Personal Protective Equipment, Equipment/Facilities and Personal Hygiene for Working
with Advanced Composite Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
3-1 Thermocouple Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-2 Material Temperature Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-3 Mechanical Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3-4 Composi-Lok® Installation Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-5 Composi-Lok® II and IIa Installation Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3-6 Visu-Lok® Installation Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3-7 Visu-Lok® II Installation Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
4-1 Qualitative Comparison of Fabrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-2 Shelf Life Data for Common Two-Part Epoxy Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4-3 Pot Life Data for Common Two-Part Epoxy Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
6-1 Ranking of Damaged Material Removal Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-2 Filler Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
6-3 Vacuum Pressure Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
6-4 Maximum Cure Temperatures on Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
6-5 Typical Heat Lamp Performance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
6-6 Common Bonded Repair Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
7-1 General Description of Different Repair Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-2 Blind Fastener Inspection Requirements (VISU—LOK®) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
7-3 Blind Fastener Inspection Requirements (COMPOSI-LOK®) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
7-4 Pilot and Shank Drill Sizes for Blind Fastener Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
7-5 Clamp-Up Bolts and Torque Values 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-96
7-6 DVD Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-107
B-1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
B-2 Drill Motor and Drill Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
B-3 Hot Bonder Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
B-4 Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
B-5 Vacuum Bagging Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
B-6 Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10

v/(vi blank)

CHAPTER 1
INTRODUCTION
1-1. PURPOSE. This volume provides general infor-
mation pertaining to the repair of aircraft composite
structures. The application of techniques and materi-
als on specific aircraft is not covered in this volume.
Specific aircraft application and usage are found in
the individual system specific technical manuals. The
purpose of this technical manual is to provide repair
methods for structures manufactured from advanced
composite materials (ACM). In addition, the repair
process rationale is described (where applicable) to
provide the repair technician with an understanding
of the process sensitive nature of advanced compos-
ite repair. This manual also lists the equipment and
materials required for performing the repairs. These
repair methods are for use at organizational and inter-
mediate levels of maintenance. The repairs described
in this manual are permanent and will restore the part
being repaired to its required strength, stiffness and
service life. This volume is of maximum benefit to
the mechanic who desires information about compos-
ites and adhesives, composite and adhesive tools and
procedures, and structural repair techniques. This vol-
ume furnishes the mechanic a source of information
TM 1-1500-204-23-11
about how to perform various mechanical functions
which are used on all aircraft. This volume is not
a requisitioning authority, and applicable repair parts
and special tools lists should be consulted to obtain
the unit of issue and National Stock Number of the
items required for maintenance.
1-2. SCOPE. General information to guide aircraft
maintenance personnel is covered in this volume;
however, no attempt has been made to include special
parts or equipment which are applicable only to
individual or special aircraft. Repair facility operations
are covered in Chapter 2. Repair equipment, tools
and supplies are discussed in Chapter 3. Composite
Materials are presented in Chapter 4. Chapter 5
covers typical damage and assessment of composite
materials. Finally, repair processes and procedures
are discussed in Chapter 6 and Chapter 7.
1-3. CONSUMABLE MATERIALS. Refer to Appen-
dix B in this volume for tools and consumable mate-
rials.
1-1/(1-2 blank)

CHAPTER 2
COMPOSITE MATERIAL FACILITY OPERATIONS
2-1. GENERAL. This chapter outlines the compos-
ite repair facility requirements for composite repairs
at organizational and intermediate level maintenance
activities. The facilities required for performing repairs
to composite structures depend upon the type of repair
being performed. Uncured resins and adhesives used
for bonded composite repairs are sensitive to environ-
mental exposure. Additionally, exposing the surfaces
to be bonded to contaminates (such as hydrocar-
bons from diesel powered equipment or mold release
agents) will adversely affect the strength of the bond.
Bolted repairs to composite materials are not nearly as
sensitive to environmental exposure; however precau-
tions must be taken to prevent surface contamination
and ensure adhesion of sealant material. While both
bolted and bonded repairs can be made in an uncon-
trolled area, patch and adhesive material preparation
for bonded repairs must be performed in a controlled
environment. Both bolted and bonded repairs require
facilities and equipment to control composite dust
generated during the repair process. Facility require-
ments are established by system specific technical
manual or by the unit.
2-2. GENERAL SHOP RULES. The practices and
procedures described in this paragraph pertain to
the manufacturing and repair functions of aviation
activities and are applicable to all levels of mainte-
nance. Because of the many types of Army aircraft,
each repair section must, of necessity have personnel
trained in general practices and procedures to the
extent that different type and model of aircraft so not
upset a smooth running shop.
a. Responsibility. All supervisory personnel in
the repair facility are responsible for a continuing
and effective shop safety program. To implement
and maintain this program, shop supervisors will
utilize bulletin boards, signs, and any other effective
method. Shop personnel will cooperate in the shop
safety program by making helpful recommendations,
and continually exercising care and caution in the
operation of all shop equipment. All shop personnel
will strive to improve the safety program and be
especially alert to observe and correct hazardous
conditions and unsafe shop practices. All accidents,
no matter how minor, shall be reported to the shop
supervisor, and all published instructions regarding
safety shall be strictly adhered to. Also, safety
engineers and safety officers will ensure that proper
safety procedures are adhered to in accordance with
AR 385-10, Army Safety Program; AR 385-30, Safety
Color Code Markings and Signs; AR 385-32, Protective
Clothing and Equipment; The Occupational Safety and
TM 1-1500-204-23-11
Health Act of 1971, OSHA 1910.251; all applicable
fire codes, NFPA 410; and other accepted civilian
and military safety practices.
b. Shop Housekeeping. Housekeeping is the
yardstick by which the shops in the manufacturing
section are judged. A clean, well arranged shop
is a safe shop and reflects credit on all personnel
concerned with its operation. The following shop
practices shall be observed.
(1) Foot Traffic. Traffic should be restricted to
necessary personnel only.
(2) Eating, Drinking and Smoking. Eating,
drinking and smoking are prohibited in the controlled
area.
(3) Hand Cream. The use of hand creams or
other contamination sources, such as weapon cleaning
fluids, is prohibited.
(4) Trash Receptacles. Trash receptacles
should be emptied once per shift. To prevent con-
tamination of the bonding/layup area, ensure that
dedicated refuse containers are used. These contain-
ers shall not be cycled in and out of the bonding/layup
area; instead remove refuse bags from the trash
receptacles within the controlled area and dispose of
the bags in a normal fashion.
(5) Doors and Windows. Doors and windows
should be kept closed unless utilized for entry of per-
sonnel or components. Windows should be included
in the design to allow personnel outside the room to
look into the room without actually going in; this will
aid in keeping contamination to a minimum.
(6) Floors. Floors should be vacuumed and/or
damp-mopped as needed to eliminate dust and
dirt. The floor should be stripped, wet-mopped, and
resealed as necessary. The use of dust mops and
brooms is discouraged as it stirs up the dust. The
use of sweeping compounds shall be prohibited. Dis-
posable tacky-mats should be located at the entrance
to the layup area and replaced when soiled.
(7) Non-Work Surfaces. Vacuum dust collect-
ing surfaces when dust is visible from 5 feet away.
Storage cabinet tops, shelves, workbenches, and
other surfaces should be wiped with water damp-
ened lint-free cloths as needed. A mild detergent
may be added to the water.
2-1
TM 1-1500-204-23-11
(8) Work Surfaces. Work tables and benches
should be wiped with water and a dampened lint-free
cloth at the beginning of each shift. A mild detergent
may be added to the water.
(9) Release Agents. The use of release
agents of any kind, especially silicones, in the bond-
ing/layup area is prohibited. Release agents should
be applied in an area away from the bonding/layup
area. Do not store or use aerosols or release agents
of any kind in the controlled area.
(10) Parts Cleaning. Only those parts that
have had aircraft grease, dirt and fluids removed
should be allowed in the layup area.
(11) Ventilation. The operation of fume pro-
ducing or fuel powered equipment shall not be per-
mitted within the bonding/layup area during layup
and bonding operations. Only air powered equipment
necessary for curing a repair should be used in the
bonding/layup area. Incoming air shall be locally fil-
tered to remove oil and moisture. Care should be
taken to direct the exhaust away from other surface
cleaning, layup, and bonding operations.
(12) Dust Collection. A ventilated and iso-
lated machining area is preferred for operations that
generate dust, such as trimming, sanding, grinding,
or drilling. A dust collection system with a HEPA
filter must be employed to collect generated dust.
Dust producing processes should not be conducted
in the bonding/layup area. If isolation from the layup
area is not feasible, do not perform repair material
preparation or repair layup during dust generating
operations and ensure the layup area is vacuumed
cleaned prior to performing material preparation or
layup operations. Damage removal/preparation and
other dust producing activities shall be stopped 30
minutes prior to bonding/layup. For the intermediate
level, this area should have a sanding booth or down
draft table with a vacuum and dust collection system
with HEPA filters. A portable vacuum cleaner with
a HEPA filter should be used by the organizational
level to collect the dust at the source of generation.
c. Shop Safety. Unsafe equipment and fire haz-
ards are the main factors to be observed while plan-
ning safety procedures. Unsafe equipment shall be
reported immediately. The following equipment safety
practices shall be observed:
(1) Machines shall be located to provide opera-
tors with sufficient space to handle materials
and perform job operations without interfer-
ence.
2-2
(2) Bolt down all machinery that can move or
walk due to vibration (drill press, bench
grinder, etc.)
(3) Substantial low resistance conductors shall
be used to ground all stationary and portable
machines, equipment, or other devices in
which static charges may be generated, or
which require electrical circuits of a haz-
ardous nature.
(4) Shop machinery shall be operated only by
qualified personnel observing safe practices.
2-3. HAZARDOUS MATERIALS. The use of new
materials brings with it a concern for health and safety.
Often, new materials have not been adequately tested
to determine all possible health hazards associated
with their use. Therefore, it is prudent to exercise
caution in their use, handling and disposal. The
information provided in this section is based upon
guidelines provided by the Occupational Safety and
Health Administration (OSHA), the American Confer-
ence of Governmental Industrial Hygienists (ACGIH),
and the National Institute of Occupational Safety and
Health (NIOSH). The local safety office determines
the exposure limits applicable to the processes and
equipment being maintained.
a. Toxicity versus Hazard. Toxicity is the inherent
harmful effect of a material. Most materials, no matter
how "safe" one thinks they may be, are toxic. On
the other hand, if materials are handled correctly and
carefully, even the most toxic materials may pose
little hazard to the worker. No substance is a hazard
by itself. It is the dosage that makes a substance a
hazard. The term hazard takes into account not only
the material’s inherent toxicity, but also the exposure
to the material. For example, if one is exposed to a
large amount of a chemical with relatively low toxicity,
the resultant hazard may be great. However, without
exposure even the most toxic chemical presents no
hazard.
(1) Acute Toxicity. The acute toxicity of a
material is the harmful effect after a single or short
term exposure. Materials exhibiting acute toxicity are
normally classified as irritants, corrosives or sensitiz-
ers.
(a) Irritants. An irritant causes a localized
reaction resulting from either a single or multiple
exposures. It is characterized by the presence of
redness and swelling. It may or may not cause cell
death. Irritants are classified as mild, moderate or
severe depending on the degree of damage they
inflict.

(b) Corrosives. Corrosive materials cause
tissue destruction without normal healing.
(c) Sensitizers. Repeated exposure to a
material that is a sensitizer may result in sensitization.
Sensitization results in an allergic reaction either to the
skin or in the respiratory system upon re-exposure to
the material. Persons sensitized to a certain material
can react strongly to trace amounts of that material
upon re-exposure. Sensitized persons require zero
exposure to that material to prevent a repeat of the
allergic reaction.
(2) Chronic Toxicity. Chronic toxicity refers to
the adverse health effects caused by exposure to a
toxic material over a long period of time. Chronic
toxicity testing is performed to determine a specific
dose or exposure level that will produce a long-term
toxic effect. Some of these effects include blood
disease, liver damage, kidney damage and may have
carcinogenic (cancer producing) potential.
(a) Exposure Routes. During handling and
processing, toxic materials can enter the body through
three main methods: direct contact, inhalation and
ingestion.
1 Direct Contact. Direct contact with a
toxic material can result in surface damage to the
skin or eyes and internal damage to body organs
if the material is absorbed. The areas of the body
most susceptible to exposure are the unprotected
parts of the skin, such as the hands, lower arms and
face. Skin or eye contact with liquids, gases, vapors
and particulate materials (dusts) should be minimized.
Special precautions should be taken to prevent contact
with chemicals absorbed through the skin. Direct
contact can also take the form of secondary exposure
TM 1-1500-204-23-11
caused by handling gloves, pencils, mixing cups,
etc., that are contaminated with a toxic material after
removal of protective equipment.
2 Inhalation. Inhalation is the process
by which material is drawn into the body by breath-
ing. During mixing and layup of adhesives and patch
materials, the release of solvents and other vapors
may occur. Inhalation of these materials cured lam-
inates can generate composite dust. Inhalation of
dust can be harmful to respiratory organs.
a Total Dust. This refers to all the
dust generated by an operation. Figure 2-1 shows a
comparison between the diameters of a typical human
hair (about 60 microns), the diameter of a carbon
fiber (about 7-9 microns) and the filtration size of
particulate trapped by a high efficiency particulate air
(HEPA) filter (0.3 micron).
b Respirable Dust. Articles smaller
than about 10 microns in diameter are able to bypass
normal respiratory defenses and reach the deep lung
where they can cause respiratory damage. There
are respirable exposure limits for some dusts, based
only on the fraction that is able to penetrate into the
deep lung.
3 Ingestion. To ingest means literally
"to take into the body as food or liquid". While
it is doubtful that anyone would purposefully ingest
these materials, it is definitely possible to ingest them
accidentally. This commonly occurs via secondary
contamination. Simple measures such as thorough
washing of hands prior to eating or drinking and
keeping food and drinks out of the work area provide
significant protection from accidental ingestion.
2-3
TM 1-1500-204-23-11
Figure 2-1. Carbon Fiber and Human Hair Diameters Compared to Filtration Level of HEPA Filter
2-4. OCCUPATIONAL EXPOSURE LIMITS. Occu-
pational Exposure Limits (OELs) have been estab-
lished that represent values under which it is believed
that nearly all workers may be exposed without
adverse effects. OELs are based on the best available
information from industrial experience and from exper-
imental studies on animals and/or humans. These
limits are expressed as allowable airborne concen-
trations of the material in question. Army industrial
hygiene guidance promotes the use of the lower of
either the Permissible Exposure Limit set by OSHA or
the Threshold Limit Value set by the American Confer-
ence of Governmental Industrial Hygienists (ACGIH).
a. Permissible Exposure Limits (PELs). Permis-
sible exposure limits are issued by OSHA and are
the legally binding exposure limits. There are several
categories of PELs:
(1) Time Weighted Average (TWA). This is the
employee’s average airborne exposure in any 8 hour
work shift of a 40 hour work week which shall not
be exceeded.
(2) Short Term Exposure Limit (STEL). This is
the short period TWA exposure assessment (usually
15 minutes) which shall not be exceeded during the
work day.
(3) Ceiling (C). This is the employee’s expo-
sure which shall not be exceeded during any part of
the work day.
2-4
(4) Skin Designation. Substances that may
cause adverse effects by being absorbed through the
skin, mucous membranes or eyes are marked with
a skin designation. This serves as an alert that skin
exposure should be prevented or reduced as much
as possible by using appropriate personal protective
equipment (e.g., gloves, coveralls, and goggles).
b. Threshold Limit Values (TLVs). Threshold limit
values are consensus recommendations published
by ACGIH. They are not legally binding but are
reviewed on a regular basis and are generally more
up-to-date than PELs. TLVs have the same categories
(TWA, STEL, C, and Skin) of exposure limits as the
PELs. Most PELs were established when the OSHA
regulations were originally put in place in 1970.
c. Use of Defined Exposure Limits. PEL and TLV
information, when established for the substance in
question, will be provided on the Material Safety Data
Sheets (MSDS). If a skin or S notation is used with
the PEL or TLV, it indicates that the material may be
absorbed through the skin, mucous membranes and
eyes. Use of the above units of measure to deter-
mine concentrations of suspect materials to ensure
PEL or TLV limits have not been exceeded requires
sophisticated measurement equipment and sampling
techniques. These techniques should be performed
by an industrial hygienist on a regular basis. For many
activities regular monitoring of the work place is not
feasible, especially when deployed. Some advanced
composite materials and some of the materials used

in repair do not yet have PELs or TLVs established.
However, the materials used to perform repair can be
used safely and successfully if the composite worker
takes the proper safety precautions such as appro-
priate engineering controls and personal protective
equipment (PPE) as outlined in this section. Periodic
monitoring by an industrial hygienist of dust collection
and exhaust/ventilation equipment can ensure proper
operation.
(1) Units of Measure. PEL and TLV concen-
trations are expressed on MSDSs using the following
units of measure:
(a) mg/m3. Milligrams of the contaminant
per cubic meter of air. A unit usually used for
expressing concentrations of dusts, or mists but may
also be used for gases and vapors in air.
(b) ppm. Parts per million. A unit for
measuring the concentration of a gas or vapor in
air. It is the number of parts of a gas or vapor in a
million parts of air.
(c) f/cc. Fibers per cubic centimeter of air.
A unit for measuring airborne fiber levels.
2-5. PERSONAL PROTECTIVE EQUIPMENT (PPE)
. Personal protective equipment (eye protection,
gloves, aprons, respirators, etc.) should be worn
during handling and repair of advanced composite
materials. The PPE required to safely handle a spe-
cific material is provided in the supplier’s MSDS and
should be consulted to determine the PPE to use.
If the PPE recommended by the MSDS differs from
the PPE recommended in table 2-1, the MSDS takes
precedence.
a. Chemical Resistant Gloves. Chemical resis-
tant gloves of different materials vary in their ability
to prevent certain chemicals from soaking through to
your skin. The gloves must provide a positive liquid
proof barrier to the chemicals used. The gloves must
neither degrade upon exposure to these chemicals
nor permit permeation of them. Gloves used for repair
operations should allow enough dexterity to facilitate
hand layup operations as well as being free of pow-
der, silicone or other loose surface particles.
(1) Latex, Nitrile or Vinyl-barrier Gloves.
Nitrile, latex or vinyl-barrier gloves are normally used
when handling adhesives, pre-pregs, and dry fibers.
Thick butyl rubber chemical-resistant gloves interfere
with proper handling and placement of repair plies
and should not be used for ply layup. Nitrile gloves
TM 1-1500-204-23-11
have a moderate resistance to some solvents and
can usually be used for all advanced composite repair
processes. Vinyl gloves lack solvent resistance and
should not be used for solvent wiping. If routinely
using MEK or acetone, latex gloves will stand up
better to the solvent. Powder-free gloves should be
used when available. Powdered gloves may be used
on advanced composites; however, excess powder
should be removed.
(2) Plastic Gloves. Plastic gloves are accept-
able for working with epoxy resin systems used to
repair composite parts. They provide the operator
with more than adequate dexterity for repair opera-
tions. They also can be used to prevent dust buildup
in skin pores during machining operations but provide
little protection against fiber penetration or abrasion.
Plastic gloves should not be used when working with
solvents.
(3) Latex, Surgeon Gloves Surgeon Latex
gloves are acceptable for working with Methyl Ethyl
Ketone (MEK) and Methyl Isobutyl Ketone (MIBK).
They have the disadvantage of being somewhat stiff
and do not conform well enough to the hand to allow
good dexterity.
(4) Cotton Gloves. Cotton gloves may be used
as a liner in latex, nitrile or vinyl gloves. They can
also be used to prevent contamination of dry fabrics
and honeycomb from the oils and dirt found on the
skin; only clean, low-lint gloves should be used.
Clean-barrier gloves can be used in place of cotton
gloves. White cotton gloves should be used for
handling film adhesives and prepared repair details
during layup. These gloves do not provide worker
protection from resins. It is recommended that plastic
gloves be worn under the cotton gloves to provide
the required protection.
(5) Leather and Leather Palmed Gloves.
Leather provides protection against fiber penetration
and abrasion when handling cured composites which
have not been trimmed or which have been damaged.
They also provide some thermal insulation when
handling parts subjected to elevated temperatures
(less than 300 °F). They are not impermeable to
chemicals and will allow them to soak through to
the skin.
(6) Glove Removal. The proper method to
remove protective gloves contaminated with a toxic
material without experiencing secondary exposure is
shown in figure 2-2.
2-5
TM 1-1500-204-23-11

worn. Refer to your local safety office for additional

requirements on respirator masks.

c. Clothing. Protective clothing may be cover-

alls or lab coats; they may be either disposable or
launderable. Long-sleeved and long-legged clothing
should be worn to minimize skin contact. Openings
should be taped closed with masking tape. When
dealing with liquid chemicals, a rubber coated apron,
A-A-55063, should be worn. Only clean garments
should be used during layup and bonding operations.

d. Eye Protection. Goggles shall be worn when

performing damage removal, machining and drilling
of advanced composite materials unless a full face
respirator is used. Chemical splash goggles and/or
face shields shall be worn when working with liquid
adhesives, paste adhesives and solvents. Safety
glasses shall be worn with face shields.

2-6. MATERIAL HANDLING. This paragraph

describes physical and chemical processes which
may cause injury or death to personnel or damage
to equipment if not properly followed. This safety
summary includes general safety precautions and
instructions that must be understood and applied
during operation and maintenance to ensure per-
sonnel safety and protection of equipment. Prior to
performing any task, the WARNINGs, CAUTIONs,
and NOTEs included in that task shall be reviewed
and understood. Always ensure all safety precautions
are followed as per the applicable system specific
technical manual.

a. Safety. The following safety precautions must

be strictly observed while repairing advanced com-
posite structures.

(1) Damaged composite components should be

Figure 2-2. Removing Disposable Gloves
b. Respirator Masks. Respiratory protection is
provided against dusts and fibers by wearing a res-
pirator equipped with a HEPA filter. The respirator
will also require chemical cartridges (suitable organic
vapor type) if protection is needed against chemi-
cal vapors or gases. A half mask is the minimum
recommended. Only NIOSH/MSHA (National Institute
of Occupational Safety and Health/Mine Safety and
Health Administration) approved respirators shall be
handled with care. Single fibers can easily
penetrate the skin, break off, and become
splinters lodged in the skin. Sharp tweez-
ers and a magnification lens are generally
required to remove the splinter. If the splin-
ter is hard to remove, seek medical attention
immediately.
(2) Respiratory protection is usually required
for all operations where dust is present or
generated. All dust generating tools should
utilize vacuum attachments to capture dust
where practical. Refer to your local safety
office for specific respiratory protection
requirements. Additional guidance can be
found in AR 385-10, Army Safety Program,
and AR 11-34, Army Respiratory Protection
Program.

2-6

(3) Residual composite dust and scraps should
be removed through a vacuum system or
collected in a plastic bag. Do not use com-
pressed air for cleaning as this will scatter
the dust.
(4) Advanced composite materials can be han-
dled and repaired safely and successfully
only if the composite worker takes the proper
safety precautions and wears the prescribed
PPE as determined by the local safety office
for their specific operations. The use of
gloves not only protects the workers but also
protects the composite parts from contam-
ination, thus ensuring structural integrity of
the finished product.
(5) If the repair is to be made on the equipment,
consult the system specific technical manual
for safety procedures. If certified Class I Div
II hot bonders or other heat curing equipment
per 29 CFR 1926.449 is used, consult the
local fire department prior to using. Never
leave these heating devices unattended.
(6) Fuel tanks should be purged, inert, and
checked continuously for explosive mixtures
when repairs are being performed in the fuel
tank or on an aircraft with open fuel tanks.
The repair area should be kept well-ven-
tilated. Fire-fighting equipment should be
available and special precautions should be
taken while working with flammable materi-
als.
(7) Adequate ventilation should be provided dur-
ing mixing and while using adhesives and
solvents. Breathing vapors from these mate-
rials should be avoided. The local safety
office should be contacted for appropriate
ventilation and/or PPE requirements.
(8) Acids should be added to water, never water
to acid. The acid should not come in contact
with skin or clothing. In case of contact, the
acid should be washed off immediately with
generous amounts of cold water. Eye pro-
tection and rubber gloves should always be
worn when using these solutions.
(9) Heat insulating gloves should be worn when
handling hot equipment.
(10) All applicable safety standards and proce-
dures should be closely observed.
(11) Heating equipment should be monitored
throughout the entire thermal process.
TM 1-1500-204-23-11
(12) Graphite fibers are electrically conductive;
for this reason it is best to use pneumatic
tools and equipment. All graphite dust and
fibers must be controlled or contained to
prevent damage to electrical and electronic
equipment.
(13) Bag all waste graphite fibers, dust, and lam-
inates containing graphite fibers. Normally,
the waste can be disposed of in the landfill;
however, primers and top coats may contain
locally restricted substances. Consult your
local safety office for disposition. Consult
the system specific technical manual for any
exceptions.
(14) The grounding or bonding of all conductive
parts of the system is an effective means of
controlling hazards created by electrostatic
energy. Grounding is the process of con-
necting one or more metallic objects and
ground conductors to ground electrodes.
Bonding is the process of connecting two
or more metallic objects together by means
of a conductor. Bonding is done to equal-
ize electrostatic potential between two or
more conductive objects. When work-
ing on aircraft or other equipment, ensure
grounding/bonding has been accomplished
in accordance with the applicable system
specific technical manual.
2-7. MATERIALS STORAGE. Care must be taken
to ensure materials are maintained at temperatures in
accordance with manufacturer’s specifications during
transit and local storage. Repair materials must remain
free of contaminants (e.g., dust, moisture, oil) during
handling. Contaminants may degrade the bonding
properties of the repair. Protective hand creams must
not come in contact with the adhesives or bonding
surfaces. Adhesive materials exceeding the shelf life
must not be used. Reducing storage temperature
will increase the useful life of the material. Adhesive
materials that are to be scrapped should be cured
prior to disposal to react the chemicals in the resin.
The cured material can usually be disposed of as a
nonhazardous material with other composite waste;
check with your local safety office for disposition.
a. Material Storage Area. Proper material stor-
age is essential for successful composite repairs.
Material storage areas include cold/frozen storage
for pre-pregs, room temperature storage for multipart
adhesives and resins, and basic particulate controls
to protect rolls of dry fabric and other layup supplies.
Failure to meet particulate, humidity, and temperature
requirements can limit the useful life of many mate-
rials used in composite repairs. See Chapter 3 for
cold storage equipment.
2-7
TM 1-1500-204-23-11
b. Fibers. Aramid fibers must be stored out of
direct sunlight to prevent ultraviolet radiation damage
to the fiber. Wear latex, nitrile or lint free cotton
gloves when handling dry fabrics. If powdered gloves
are all that are available, ensure exterior of gloves are
cleaned before handling repair materials and hands are
washed thoroughly immediately after removal of gloves
to prevent contaminating the area and materials.
c. Dry Fabrics. To prevent particulate contami-
nation, dry fabrics shall be stored in original shipping
containers or sealed plastic bags before use. After
a roll of dry fabric has been opened, appropriate
measures should be taken to prevent the accumu-
lation of particulate contamination on the material.
Fabrics shall not be exposed to grinding/machining
operations. If this occurs, the outer layers of the
material roll should be disposed of to ensure clean,
uncontaminated material is used for repairs.
d. Vacuum Bag Materials. Store the required
types of bagging and separator films, bleeders,
breathers, insulation, and other type bagging materials
in a location that will minimize airborne contaminates,
such as a storage cabinet. Plastic covers are an
inexpensive method of protecting roll materials and
can be used independently or in combination with
other protective measures. Separate the bagging
films from the bleeder, breather, and insulation cloth
to minimize contamination of the films from the cloths.
Store nylon bagging films in a clean area. Nylon has
a tendency to dry out in low humidity environments;
this will degrade the bagging film and shorten its shelf
life. See the glossary for a description of bagging
materials. Since moisture is the plasticizer in nylon
bagging material, the nylon can become brittle when
stored in areas of low humidity; strive to store it at
55 percent or higher relative humidity. One way to
accomplish this is to store the nylon material in a
closed container with a wet cloth inside. If immediate
flexibility is required, the roll can be restored by
placing the nylon bagging material in a small tent
with a steam vaporizer for 4 hours.
e. Laminating Resins and Paste Adhesives Stor-
age. Laminating resins and paste adhesives must
be stored in clean containers and in accordance with
manufacturer’s instructions. The containers must be
kept closed to prevent moisture absorption which will
degrade the resin properties. Most two-part systems
should be stored around 75 º F; higher tempera-
tures often shorten the shelf life. Shelf life limitations
imposed by the manufacturer must be observed; con-
sult the manufacturer’s technical data sheet for storage
options and their effect on the shelf life. Check the
shelf life of each component; they may be different.
Before opening refrigerated materials, the containers
must be allowed to warm up, typically a few hours or
2-8
until moisture is no longer condensing on the pack-
age.
(1) Receiving Inspection. Upon receipt at the
operating activity, inspect containers for damage and
ensure material is within shelf life. Identify and imple-
ment proper storage conditions in accordance with
the appropriate technical manual or manufacturer’s
instructions.
(2) Epoxies. Epoxies are prone to storage,
handling, and processing issues. Some of the more
common issues are carbamation, “amine blush”, and
oxidization.
(a) Carbamation, Carbamation sometimes
called carbonation, is the formation of ammonium
salts at the surface of a mixed epoxy adhesive. The
hardener, typically an aromatic or aliphatic amine
compound, reacts with carbon dioxide and water
present in the air to form a barrier at the surface of
the adhesive. Undisturbed, this barrier can prevent
wet-out and reduce the strength of the cured adhe-
sive. Immediate assembly of bonded parts under the
least humid conditions available reduces the likelihood
of this happening. Additionally, elevated temperature
cures, above 160 °F, tend to break down the car-
bonate barrier, sometimes producing bubbles in the
adhesive, which can also decrease strengths.
(b) Amine "blush". Sometimes called
"sweating", or "bloom", Amine “blush” is the result
of the same type of chemical reaction that causes
carbamation. In this case, the result is an oily,
waxy or chalky deposit on the surface of the cured
adhesive. Possibly affecting the repair strength, blush
needs to be removed before conducting any painting
or secondary bonding operations. Rinsing with clean
water, followed by sanding with fine-grit sandpaper is
the preferred removal method. Solvents will typically
not remove the deposits adequately and may cause
undesirable swelling of the cured epoxy.
(c) Oxidization. Do not leave resin com-
ponents exposed to the environment for an extended
period of time. However, during normal use the open-
ing and closing of the Part B container causes it to be
exposed to a certain amount of fresh air. Over time,
especially at warmer temperatures, this can cause the
hardener to react with oxygen in the air (in addition
to the carbon dioxide and water absorption previously
mentioned). This is called oxidation. The result may
be a slow darkening, or discoloration of the hardener
and/or an increase in viscosity (that is, a decrease
in fluidity). Such oxidation of hardeners is a fairly
common condition and does not appreciably affect
the strength of the cured epoxy. Note that hardener
color may vary one batch to the next. Therefore,

color variations in the hardener component should not
be considered, by itself, cause to reject the batch.
f. Core. Core materials shall be stored in an
original shipping container, clean bag or box to protect
them from damage, moisture, oils, shop contamination,
and weathering. Cleaned and primed detail parts that
are to be stored rather than used immediately in
a bonded assembly, should be wrapped in wax-free
paper, black polyethylene film or a similar material as a
protection from deterioration caused by contamination
or ultraviolet exposure.
g. Pre-cured/Pre-primed Patches. Both pre-cur-
ed composite patches and pre-primed metallic patches
should be shipped and stored in MIL-PRF-131 heat-
sealed, water-vapor proof bags. No other special
shipping, receiving or storage requirements exist for
these materials.
2-8. MATERIAL DISPOSAL. Fully cured waste
material, composite dust, contaminated coveralls, vac-
uum filters, mixing cups and spatulas containing cured
resin can normally be disposed of as non-hazardous
waste. Place in drums or double bag and seal.
Dispose of in accordance with all Army, local, state
and Federal guidelines, laws and regulations. For
chemical waste (uncured adhesives, solvents, etc.),
dispose of as hazardous waste in accordance with
local, state, Federal and Army guidelines, laws and
regulations.
2-9. COMPOSITES IN FIRES. Composite materials
involved in a crash or fire, pose a potential health
hazard to firefighters, crash investigators, site clean-up
personnel, repair personnel, and the environment. The
matrix material can burn, producing toxic gases as
well as releasing fibers. The fibers can be broken
down in size by the fire into the respirable range.
The released fibers are very light and can be blown
to areas beyond the crash site by prevailing winds.
a. PPE. Personnel performing operations for
crash/fire damaged composite parts which generate
loose fibers should be protected by wearing the PPE
recommended in table 2-1.
b. Fibers. Composite materials that have burned
or been damaged by an aircraft crash can liberate
fibers small enough and in sufficient quantity to be
hazardous if inhaled. If the resin is still intact, the
fibers are less likely to become airborne. They may
still pose a handling hazard, as they are very stiff
and can easily penetrate protective clothing.
c. Matrix Materials. Smoke emissions from burn-
ing carbon/epoxy and carbon/ bismaleimide compos-
ites consist primarily of carbon monoxide. Burning
TM 1-1500-204-23-11
carbon/epoxy materials also emit small amounts of
carbon dioxide, hydrogen cyanide, and hydrogen chlo-
ride. The toxic gases emitted from burning epoxy
matrix materials may be more toxic than the gases
emitted from any burning aircraft. Breathing these
emitted gases should be avoided.
d. Procedures to Minimize Exposure. To mini-
mize exposure to fire-damaged composites, only fire-
fighters equipped with fullface, self contained breathing
units should be allowed in the accident area while the
wreckage is still burning or smoldering. In addition,
the following precautions should be followed:
(1) Only essential personnel should be allowed
at the crash site.
(2) All work performed at the crash site should
be performed upwind of the wreckage.
(3) Damaged composite parts from the
crash/fire shall be coated with the approved
fixant material, MIL-PRF-81309, Type II,
after the fire is out and the wreckage has
cooled.
(4) Personnel performing operations which gen-
erate dust or loose fibers (such as cutting
composite surfaces or moving wreckage)
shall wear the PPE as recommended in
table 2-1.
(5) Fire-damaged parts inducted into repair
facilities and awaiting repair disposition
shall have fire-damaged areas contained
by wrapping the affected area with 0.006
inch thick plastic sheet, A-A-3174. Tape
the sheet in place with aircraft preservation
tape, SAE AMS-T-22085, Type II; ensure
tape only contacts non fire-damaged areas.
If this is not possible, completely bag the
part.
2-10. EMERGENCY AND FIRST AID PROCE-
DURES. Accidental chemical spills, runaway exother-
mic reactions and heat blanket fires are some of the
potential emergencies that can be encountered during
the repair process. Always refer to the material spe-
cific MSDS for emergency and first aid procedures.
Some general guidelines for dealing with these types
of emergencies are listed below.
a. Accidental Spills/Leaks. If accidental contact,
inhalation or ingestion occurs proceed as follows:
(1) Eyes. Immediately flush with large amounts
of low pressure water for a minimum of 15 minutes.
Remove any contact lenses to ensure thorough flush-
ing. Seek immediate medical attention.
2-9
TM 1-1500-204-23-11
(2) Skin. Promptly flush with running water.
Wash with soap and water. If an allergic reaction is
encountered, seek medical attention. Do not clean
up resin on skin with solvents as they will crack the
skin and cause a path for resin entry.
(3) Inhalation. Remove the person to fresh
air at once. Seek prompt medical attention.
(4) Ingestion. The guidelines for ingestion vary
depending upon the materials ingested. Some specify
large quantities of liquid be given to dilute the ingested
material as well as inducing vomiting. Guidelines for
other materials recommend vomiting not be induced.
The specific material’s MSDS should be consulted for
the correct procedures. Seek medical attention.
b. Runaway Exothermic Reaction. Do not han-
dle containers with materials undergoing a runaway
exothermic reaction. Exothermic emissions can be
toxic and extreme temperatures can be generated.
Do not approach the container or attempt to control
the reaction. Do not breathe toxic gases. Depart the
area immediately. Do not return until the reaction is
complete and the workspace has been ventilated to
remove toxic exothermic reaction products.
c. Heat Blanket Fires. Turn off electrical power to
the hot bonder. Avoid breathing smoke and gasses.
If fire persists, extinguish with dry chemical or carbon
dioxide fire extinguisher while someone calls the fire
department. Depart the area as soon as practical.
Ventilate the workspace before returning to work.
2-11. COMPOSITE REPAIR ENVIRONMENTS. The
bottom line for successful composite repairs is to start
with good materials; store these materials properly,
keep the repair surfaces and materials clean and dry,
and cure the materials correctly. Failure to keep the
repair surfaces and materials clean and dry will result
in repairs that are cosmetic only. Cosmetic repairs will
not be able to carry the intended structural loads and
will fail. Meeting this basic requirement for successful
repairs may mean a dedicated facility, a portable
enclosure (containment bag, tent or other structure)
or more crude temporary protective measures.
a. Structural Repair in a Controlled Environ-
ment. The ideal environment for performing bonded
structural repairs is controlled to minimize the effects
of dust, dirt, temperature, humidity, and traffic flow.
Adherence to these recommendations will prevent
degradation of the strength of repairs. The criteria
listed in this chapter, adapted from typical manufac-
turing requirements, are recommended for a general
repair facility.
2-10
b. Structural Repair in an Uncontrolled Environ-
ment. In some cases, such as deployed environ-
ments, the control of environmental conditions and
reduction of contaminants may not be possible due
to time or cost constraints. Compromises to environ-
mental and contaminant control measures to satisfy
near term needs will generally increase future mainte-
nance requirements (i.e., replacement of poor quality
repairs). Repair quality and safety of flight are directly
proportional to the level of environmental and con-
taminant control exercised in the repair facility.
c. On-Aircraft Repairs. When performing on-air-
craft repairs, it is not always feasible to remove
damage or perform surface preparation for bonding
in a separate facility.
2-12. DAMAGE REMOVAL. When performing
machining operations, removing damage, or drilling
fastener holes; use a portable vacuum cleaner with
a HEPA filter to collect the dust at the source of
generation. When preparing surfaces for bonding,
cover them immediately following the preparation step
by taping clean barrier material over the prepared
surface. Prepare repair materials in the environmen-
tally controlled area described above and transport
to the aircraft in a sealed bag. Expedite the layup of
the repair materials, heat blanket and vacuum bag
to minimize environmental exposure.
a. Preparation Area. Extremely hot conditions
will severely shorten the work life of two-part resin
systems. When possible, repair the aircraft during a
more hospitable time of day, for example at night in
high temperature conditions or during the day during
cold conditions. If repair must be conducted during
hot conditions in the sun, use a sun shield, tarp,
or other covering. In cold weather, you may need
to erect a tent around the portion of the aircraft to
supplement heat with a ground vehicle or power cart;
being careful to keep the power cart exhaust from
contaminating the bonding surface.
(1) Environmental Enclosures. When remov-
ing a component or hangering the aircraft is not an
option, environmental enclosures may be required for
flight line repairs. Erect an enclosure around the
repair site to aid in dust containment where feasible.
Enclosures with supplemental heating or air condi-
tioning may also be necessary in extreme weather
conditions. Hot bonders will not reach the required
cure temperature when used in extremely cold con-
ditions.

NOTE
Care must be taken when attempting repairs in
blackout conditions when deployed. Use hand
held white lights in a shelter with the doors
closed or covered to prevent light escaping.
Ply orientations, repair markings, and damage
locations must be easily visible under blackout
lighting before a repair is conducted. If
blackout lighting does not provide adequate
visibility to conduct a repair, wait until daylight
to repair the aircraft.
(2) Lighting. Lighting intensity at the work
plane should be 75 foot candles or greater.
Graphite/carbon dust is electrically conductive
and can short out electrical and electronic
equipment. It can also corrode aluminum
aircraft structure.
(3) Contamination and dust control. Ade-
quate dust control equipment should be provided
to decrease worker’s exposure to contaminants and
reduce housekeeping requirements. Downdraft work
stations are recommended. At a minimum, portable
vacuums should be used during or immediately after
any dust generating activity. Since carbon dust is
conductive, sanding or grinding of carbon should not
be accomplished adjacent to circuit breakers, elec-
trical shop equipment or electronics. If the carbon
workload is great enough, a separate room may be
justified to prevent migration of carbon dust through-
out the shop. If a separate room is used, locate
circuit breakers outside the room.
2-13. BONDING/LAYUP AREA. Bonding and layup
areas should be located in a separate room, away
from other maintenance activities (especially ones that
produce dust, fumes, release agents or other contam-
inants). This room should be sized to accommodate
the largest removable composite part from the weapon
system with additional area for movement of parts
and personnel. To facilitate easy access, the bond-
ing/layup area should have both a rollup door for large
parts and a traditional man door for personnel. When
separate rooms are not possible, the bonding/layup
section of the repair facility shall be thoroughly cleaned
prior to use; damage removal/preparation and other
dust producing activities shall be stopped 30 minutes
prior to bonding/layup.
a. Design Criteria. Bonding/layup rooms should
be designed to meet ISO Class 9 particulate count
TM 1-1500-204-23-11
(International Organization for Standardization Speci-
fication ISO 14644 Cleanrooms and Associated Con-
trolled Environments Part 1: Classification of Air Clean-
liness). Related design information can be found
in Federal Aviation Administration’s Advisory Circular
number AC145-6, Repair Stations for Bonded Com-
posite and Bonded Aircraft Structure; ISO 14644 Part
4, Cleanroom Design and Construction; MIL-HDBK-
1028/5 Environmental Controls Design of Cleanroom.
NOTE
Care must be taken when attempting repairs
in blackout conditions when forward deployed.
Use hand held white lights in a shelter with
the doors closed or covered to prevent light
escaping. Ply orientations, repair markings,
and damage locations must be easily visible
under blackout lighting before a repair is
conducted. If blackout lighting does not
provide adequate visibility to conduct a repair,
wait until daylight to repair the aircraft.
(1) Lighting. Light fixtures should be recessed
or flush mounted. Lighting intensity at the work plane
should be 75 foot candles or greater.
NOTE
Both 120 volt (20 amp) and 240 volt (30 amp)
outlets should be available to power hot bon-
ders (both current and future equipment). Hot
bonders require a lot of electricity, especially
for cures that require large heat blankets or
high temperatures; therefore, each outlet that
will power a hot bonder must be on a sep-
arate circuit. In some cases, a dual-zone
hot bonder will have two different incoming
power cords which will need to be plugged
into outlets on separate circuit breakers.
(2) Enclosure. The area should be completely
enclosed in order to restrict the movement of con-
taminates into the bonding area.
(3) Air filters. Incoming air should be filtered
to reduce particulate contaminants. Filters in the air
supply system should be disposable. Multiple banks of
traditional air filters are an affordable and appropriate
substitute for HEPA filters; unless otherwise specified
in system specific technical data or by the unit.
Recommend MERV 11 rated filter for the final filter;
such as the 3M Ultra Allergen filter. (Note: 3M uses
a system different than the MERV system to rate
their filters, so you will not find “MERV 11” written
on the Ultra Allergen filter, but it is equivalent to the
MERV 11).
(4) Temperature and Humidity. The area’s
temperature and humidity should be controlled to
2-11
TM 1-1500-204-23-11
provide the conditions necessary for successful com-
posite fabrication. See the shaded area in figure 2-3
for industry standard environmental allowables. Air
Figure 2-3. Temperature and Humidity Allowables for Bonding and Layup
(5) Air Conditioning System. If the air condi-
tioning system is inoperable or not able to maintain
the required temperature and humidity requirements,
repairs to primary structure or critical safety item com-
ponents must be terminated until the environment can
be restored.
(6) Temperature and Humidity Recording
Equipment. Temperature and humidity recording
equipment should be located in the area so confor-
mance to environmental requirements can be routinely
monitored.
(7) Air Pressurization. Air pressurization
capable of maintaining a slight positive pressure (0.05
inch of water) should be provided to prevent dust
and dirt from entering the bonding/layup area.
2-12
conditioning controls must not be relaxed for bonded
repairs on primary structure or critical safety item
components.
(8) Dirt traps. The area should be free of
ledges, overhangs, protrusions or other dirt traps as
much as practical. Walls, ceilings, service plumbing,
and furniture should be smoothly finished and painted.
Plumbing lines, electrical conduit, and other installa-
tions necessary to service the equipment should be
mounted outside the area or enclosed in order to
minimize dirt traps. Light fixtures should be recessed
or flush mounted.
(9) Floors. Floors shall be covered with either
a vinyl or other composition material. Concrete floors
shall be sealed with latex, epoxy, or polyurethane or
covered with vinyl tile then sealed and waxed.
(10) Central Vacuum. A central vacuum sys-
tem with a HEPA filter should be included in the
bonding/layup area to facilitate proper housekeeping.
A variety of vacuum accessories should be available,
including an attachment for vacuuming floors.

(11) Walls. Walls should be painted with a
durable, lightcolored, semigloss or gloss paint to
promote easy cleaning.
(12) Ceiling. Ceiling may be a suspended
ceiling with sound absorbing tiles. Sound absorbing
tiles will compensate for all the other hard smooth
surfaces in the room, thus eliminating the echoing
and lowering the overall sound levels.
b. Enclosure. A layup area, fully enclosed and
environmentally controlled for the preparation of adhe-
sives and patch materials for subsequent bonding, is
mandatory. The intermediate level layup area should
contain a local exhaust hood for mixing adhesives and
resins to remove hazardous vapors. Processes or
operations which produce uncontrolled spray or fumes
are not permitted in the controlled area. This area
may be used for curing repairs and drying compo-
nents. Curing repairs and drying may be performed
outside the layup area provided that the repair is
vacuum bagged.
c. Ventilation. Adequate ventilation is a primary
consideration for a composite repair facility. Each work
TM 1-1500-204-23-11
area should have general ventilation providing from
3 to 5 air changes per hour. Additionally, there is a
need for local exhaust ventilation for specific operations
(provisions for adequate makeup air are required to
ensure the proper function of the local exhaust and
general ventilation system). If air is recycled back
into the work area, filtration is required to remove
particulates and organic vapors. Air recycled in the
machining area either from the general ventilation
system or dust booth must be equipped with a HEPA
filter. Recycled air is not recommended in the layup
area. Fresh air supply must be filtered to remove
particulates and must be located away from fume
producing activities (i.e. do not locate fresh air supply
where diesel engines routinely idle, or near fume hood
exhausts).
d. Treatment Area. A separate metal treatment
area for cleaning, degreasing, surface preparation and
priming is recommended. At the intermediate level,
this should be performed in a local exhaust hood to
remove hazardous vapors. Metal treatment may be
performed in the local exhaust hood of the layup area
as long as the process is not performed simultaneously
with material preparation or layup operations.
2-13
TM 1-1500-204-23-11

Table 2-1. Personal Protective Equipment, Equipment/Facilities and Personal Hygiene for Working with
Advanced Composite Materials

WORK ACTIVITY PPE EQUIPMENT/FACILITIES

Handling Damaged Composite None
Parts a. Leather palmed gloves

b. Goggles
Damage Removal/ Machin-
ing/Drilling/ Sanding Composite a. Respirator with 0.3 micron HEPA a. Vacuum cleaner with 0.3 micron
Parts filter HEPA filter

b. Leather or plastic gloves b. Dust collection booth with 0.3

micron HEPA filter (if applica-
c. Goggles ble)
d. Long sleeved, loose fitting c. Emergency eye wash station
coveralls, taped closed at the within 100 feet
wrist
Handling pre-preg/ Uncured Film
Adhesives a. Plastic gloves Well ventilated area

b. White cotton gloves (worn over

plastic gloves)

c. Long sleeve coveralls

Mixing/Handling Liquid and Paste
Adhesives a. Plastic gloves a. Local exhaust hood for mixing

b. Face shield or splash goggles b. Well ventilated area for appli-

cation
c. Long sleeve coveralls taped
closed at wrist c. Emergency eyewash/ deluge
shower within 100 feet
d. Rubber coated apron
Working with Solvents
a. Work inside a chemical hood a. Well ventilated area
when applicable or use a respi-
rator with a chemical cartridge b. Emergency eyewash/ deluge
if PEL is exceeded shower within 100 feet

b. Splash goggles or face shield

c. Rubber coated apron

d. Long sleeve coveralls taped

closed at wrist

e. Gloves appropriate for chem-

ical(s) used (e.g. polyethyl-
ene, nitrile, or butyl rubber).
Consult the solvent MSDS for
proper protection.

2-14
 TM 1-1500-204-23-11

Table 2-1. Personal Protective Equipment, Equipment/Facilities and Personal Hygiene for Working
with Advanced Composite Materials — Continued

WORK ACTIVITY PPE EQUIPMENT/FACILITIES

Handling Fire Damaged Composite
Parts a. Respirator with 0.3 micron HEPA Vacuum cleaner with 0.3 micron
filter HEPA filter

b. Leather palmed gloves

c. Goggles

d. Long sleeved, loose fitting,

disposable coveralls, taped
closed at the wrist

NOTE

1. Wash hands, face, and arms with soap and water before and after breaks and at end of
shift.
2. Dispose of coveralls after each shift.
3. Dispose of gloves after each use.
4. Cleanup residual adhesive from work area, tools and PPE. Vacuum dust and debris frequently
and at the end of each shift.

2-15/(2-16 blank)

CHAPTER 3
REPAIR EQUIPMENT, TOOLS AND SUPPLIES
3-1. GENERAL. This chapter describes the shop
tools, hand tools, vacuum bagging consumables, and
ancillary supplies that are necessary for composite
repairs. A complete list of tools, equipment and
consumable items can be found in Appendix B.
3-2. SHOP TOOLS. This paragraph identifies the
tools found in the composite shop set or at intermediate
level shops. Refer to TM 1-1500-204-23-10, Chapter
3 for more information regarding shop tools.
a. Downdraft Table. A downdraft table is an
efficient and economical device for protecting workers
from harmful dust caused by sanding and grinding
operations. The tables are also useful housekeeping
tools as the majority of particulate material generated
by machining operations is immediately collected for
disposal. Downdraft tables should be sized and
maintained to have an average face velocity between
100 and 150 cubic feet per minute (ft³/min) across
the top surface. The table will draw contaminants like
dust and fibers away from the operators’ breathing
zones. Downdraft tables should be monitored and
filters changed on a regular basis to provide maximum
protection and particulate collection. The further work
is performed away from the top of the table the less
useful the downdraft feature will be. Downdraft tables
are available in a full range of sizes to fit every space
and need.
b. Drill Press. Standard, manual drill presses of
the type found in most sheet metal or wood shops are
generally adequate for composites. More sophisticated
types may be utilized depending on the system specific
requirements. A 1/2 inch chuck is suitable for most
operations.
c. Refrigerator. Refrigerators are used to store
laminating resins and paste adhesives and should be
kept near 40 °F. A household refrigerator should be
sufficient except where special storage needs exist.
If flammable resin storage is required, the refrigerator
must be designed for flammables in accordance with
National Fire Protection Standard 30. Consult with
the local safety office to determine specific refrigerator
requirements. The refrigerator temperature should be
monitored and recorded.
d. Circular or Table Saw. Ensure the proper blade
is installed in the saw prior to cutting cured composites
TM 1-1500-204-23-11
or other material. The blade must be in good condition
and have the correct cutting geometry for the material
being cut. Machine and blade suppliers can provide
useful handbooks on saw operations.
e. Bandsaw. When machining cured composites
on a bandsaw, a low speed should be used with
the appropriate blade for the specific material being
cut. When cutting expanded honeycomb, a highspeed
bandsaw must be used to overcome the tendency for
the material to be pushed away from the blade. The
best cutting performance can only be achieved if the
guides and blade tension are properly adjusted. The
blade must be in good condition and have the correct
cutting geometry for the material being cut. The saw
blade must be sharp and in good condition. The throat
of the saw table must be in good condition as well.
A piece of wood can be used as a sacrificial throat.
Saw speed should be relatively high and feed rates
should be determined by the laminate configuration,
thickness, and the complexity of the cut. Machine
and blade suppliers can provide useful handbooks on
bandsaw operations.
(1) Bandsaw Blades. To cut solid composite
materials, the saw blade must be abrasive carbide
grit or diamond grit and in good condition. Do not use
tooth-type blades except for cutting aramids, in which
case you install the blade so the teeth point up. Saw
speed and material feed rates should be relatively
low. A noncontaminating wax or liquid cutting lubricant,
such as water, will prolong blade life. Feed rates
are affected by laminate configuration, thickness, and
complexity of the cut; consult the blade manufacturer
to determine proper speed and feed rates for your
application. Preferably an alternating toothed blade
designed for aramid cutting with 14 teeth per inch
should be used (see figure 3-1). Cutting expanded
honeycomb, either aluminum or aramid, is usually
done with a special high speed bandsaw with a blade
speed of 16,000 feet per minute. DuPont has provided
special instructions for cutting aramids. Honeycomb
blades should not be used to cut anything else as
the blade teeth will be blunted and the special tooth
offset will not provide enough clearance to remove
scarf when cutting solid materials.
3-1
TM 1-1500-204-23-11
Figure 3-1. Alternating Tooth Bandsaw Blade for
Cutting Aramid Laminates
f. Layup Tables. Tables used for composite mate-
rial cutting and layup should be sturdy enough to sup-
port the materials being cut as well as any associated
tooling. The table tops should consist of a material
that does not produce foreign particulates when cutting
and can be readily cleaned. Two types of table tops
that have been found to provide satisfactory perfor-
mance are glass tops and self-healing urethane tops
(sometimes called Mochathane®). Glass tops made
from tempered glass 1/2 inch thick (or two layers of
1/4 inch) provide a good cutting and layup surface.
Due to the risk of fracture, care must be exercised to
not drop objects on the glass top. Urethane tops are
typically 1/4 inch thick and are not easily damaged
by dropped tools.
g. Compressed Air Supply. Shop air should be
maintained at or near 100 psi and have sufficient flow
capacity to operate all air tools that are expected to
be operated simultaneously. Shop air should be clean
and oil free to prevent contamination of the composite
surface.
h. Vacuum Pump. A vacuum pump rated at a
minimum of 3 ft³/min flow rate and an ultimate vacuum
of 15 torr (0.3 psi absolute) or less is needed to
provide adequate vacuum levels for repair operations.
Permanent or portable vacuum pumps are available
and should be sized and selected in accordance with
facility requirements. For permanent installations, the
3-2
number of vacuum ports connected to the pump
should be determined by peak usage.
i. Portable Vacuum Cleaner. Vacuum cleaners
can be used to assist in collecting dust from sanding
and grinding operations as well as for general shop
cleanup in a repair facility. If no dust collection
system is attached to a tool, the nozzle of a portable
vacuum cleaner can be held near the waste source
to eliminate or greatly reduce the amount of dust
produced during the operation. Vacuum filters should
be changed frequently to prevent clogging. Some
filters are a high efficiency particulate air (HEPA) filter
that is 99.97% efficient at the 0.3 micron level.
3-3. HANDHELD TOOLS. The following paragraphs
give the requirements for handheld tools required to
sand, grind, cut, machine, drill, countersink, and ream
advanced composite materials. Some of these tools
and equipment are unique to composites and the
procedures used are sometimes unique in order to
produce high-quality repairs. The use of improper
tools, equipment, and/or procedures will damage repair
areas. It is common practice in a structural mainte-
nance shop to sand and/or oil the bare metal surfaces
on tools to remove/prevent rust; however, the oil can
easily be transferred to the technician’s hands and
then to the surfaces being repaired and the materials
used for the repair. To prevent oil contamination, a
dedicated composite tool kit with unoiled tools should
be kept in the composite repair facility. If air tools
are used, they should have a rear exhaust capture
device to prevent air line oil from contaminating the
part.
a. Router. A router is a portable, high speed
cutting tool equipped with a base and a guide. It may
be used for machining both skin and core material.
Normally, the router is used with a template that
ensures a smooth and regular cut. A router is often
used for irregular holes or on round holes where
access to the back side is limited and the material
cannot be backed up to prevent splintering. A router
is preferred for core removal operations. Routing is
done using a vacuum to draw off loose material.
(1) Template. When a router is used for dam-
age removal, a template should be fabricated to guide
and control the tool accurately and ensure uniform
and neat cuts. The template should be configured to
take into account the setback of the router guide and
the required depth of penetration. If the part surface
is curved, the template must be fabricated from a
flexible material. Templates may also be necessary
to control the depth of the damage removal. If only
the skin is to be removed, the template must follow
the contour of the skin. The router should be set to
cut through the skin only, leaving the adhesive on

the core. If the core is to be removed through to the
opposite skin of a nonuniform thickness sandwich,
the core near the opposite skin should be cut by
hand with a core knife. The skin-to-core bond can be
easily broken with peeling action. Cutters 1/4 inch in
diameter may be preferred to 3/8 inch cutters because
of easier tool handling. Tungsten-carbide tools can
be used for most applications.
b. Drill Motor. Drill motors come in many vari-
eties. A 3500 rpm drill motor has been found to per-
form best when drilling advanced composites. When
drilling through composite structures containing alu-
minum skins, a 2000 rpm drill motor works best. Both
straight and 90 degree drill motors are required for
access to different areas.
c. Die Grinder. The die grinder is a high-speed
motor with either a 90 degree or inline head. When
it is equipped with a silicon-carbide abrasive disc, it
is useful for the removal of partial thickness damage
to composite laminates and tapering (scarfing) the
perimeter of the damage removal areas. The die
grinder is also used for partial depth removal of
damaged core.
d. Kett Saw. The kett saw equipped with a dia-
mond cutter blade is the quickest way to cut damaged
laminates. The tool is easy to control, produces uni-
form cuts, and has a rapid material removal rate.
The main disadvantage of the kett saw is that its
use is limited to straight cuts or cuts with very slight
curves. Diamond coated tools are needed for boron
and some carbon configurations.
e. Reciprocating Saws. Saws that reciprocate
the blade, commonly known as saber saws or Sawza-
lls®, should be avoided because the constant changing
blade direction imposes forces on the surface plies
that tend to delaminate composites. These saws can
be either air or electric powered. Feed rates should
be slow to prevent heat buildup and the tool must be
held firmly to prevent loss of contact between the foot
and the material being cut. These saws are suitable
for cutting mishap damaged parts into manageable
sizes for containment and removal from the mishap
site.
f. Sander. Sanding can be performed either by
hand or with power tools such as a pneumatic right
angle die grinder, Dual Action (DA) sander or jitterbug
type sanders. Only currently approved paint removal
(and primer removal) method for composite field repair
is sanding. Perform this method either by hand or by
using a dual action/orbital sander. Use of other types
of powered sanders is prohibited since there is a high
potential for laminate damage. Use care during paint
removal to prevent sanding into the laminate. It is
TM 1-1500-204-23-11
impossible to remove paint without sanding into some
of the load carrying fibers; however, the amount of
fiber damage should be kept to an absolute minimum.
Chemical paint strippers are unsatisfactory for paint
removal as they attack the matrix material in composite
laminates causing degradation.
NOTE
Hot bonders or other heat curing equipment
must meet Class I Div II per 29 CFR 1926.449
for operation within 5 ft of aircraft fuel tanks
Radios interference may cause hot bonder
errors. Exercise care using radios when
conducting bonding operations.
g. Hot Bonders. A hot bonder is a programmable
heat and vacuum control unit, usually used in con-
junction with a heat blanket to perform an elevated
temperature vacuum bagged repair. Hot bonders con-
trol curing temperatures according to a programmed
cure cycle by regulating the electrical power applied
to the blanket at set times, temperatures, and rates.
The hot bonder receives temperature information from
thermocouples (TC) that monitor repair area temper-
atures. Vacuum capability is provided through either
the use of a vacuum pump and regulator or a venturi
system with manual adjustment of the vacuum level.
Temperature and vacuum alarms are used to indicate
that an out-of-specification condition exists during the
cure. The user sets the temperature and vacuum
alarm limits when programming the hot bonder. Also,
a printer that records the temperatures, vacuums, and
any out-of-specification condition that occurs through-
out the cure is useful for quality record purposes.
Aircraft hot bonders typically come with one or two
heating zones. Each zone has the capability of con-
trolling the temperature and vacuum separately from
one another, such that two hot bonded repairs may
be conducted simultaneously. The use of a dedicated
circuit is recommended for each hot bonder zone to
ensure adequate power exists to operate the heat
sources.
h. Heat Blankets. A heat blanket is a portable
heat source normally used with vacuum bagged
repairs. Figure 3-2 illustrates several types of heat
blankets. Heat blankets are typically regulated by a
heat control unit. This may be done automatically with
a hot bonder. Folding heat blankets around sharp
corners during use and/or storage can stretch or break
the wire heating elements within the blanket. To min-
imize damage, store blankets flat or loosely rolled.
Heat is transferred from the blanket via conduction.
Consequently, the heat blanket must conform to and
be in 100 percent contact with the repair area. This
is usually accomplished using vacuum bag pressure.
Lack of contact between the heat blanket and the
area to be cured will result in inadequate heating.
3-3
TM 1-1500-204-23-11
For example, excessive height in a core plug being
bonded into place causes a gap at the edges of the
core plug and correspondingly inadequate heating at
the plug’s edge. In addition, heat loss occurs around
the outer perimeter of the heat blanket causing the
Figure 3-2. Heat Blanket Configuration
(1) Standard Heat Blankets. Standard heat
blankets can be used for most field repairs up to
400 °F. These consist of electrical heating elements
embedded between plies of silicone material. They
are available in standard sizes and use a constant
watt density across the blanket, typically 5 watts per
square inch. These heat blankets are flexible and
can usually be formed to part contours of 0.50 inch
or larger.
(2) Special Heat Blankets. Special heat blan-
kets are available and may be required to provide
even heating of repairs. The shaded watt density
blanket provides extra heat near the edge band; it is
good for repairs near the edge of a panel or where
there is lack of space for the heat blanket to overlap
the repair. A multizone heat blanket can be designed
for specific applications requiring unique shapes or
watt densities to overcome heat sinks (see paragraph
6-18g, Thermal Survey). Some blankets have varying
watt density, some have separate heating zones, and
some incorporate a vacuum capability. Heat blankets
for hazardous locations (flight line) may include over
temperature safety devices and faulty circuit sensors.
See the system specific technical manual to verify if
a special heat blanket is required for your repair.
(3) Heat Blanket Testing. While some equip-
ment is available commercially that “tests” heat blan-
kets, most defects can easily be detected using a
common multimeter. When the NiChrome wire ele-
ments in a heat blanket become stretched and thin, or
when they break it changes the overall electrical resis-
tance of the blanket. All heat blankets are stamped
at the bus area with the manufacturer’s name, and
3-4
temperatures on the outer portion of the repair area
to be less than the center. A shaded watt density
heat blanket can minimize the temperature variation
by providing higher heat capacity at the edges.
the voltage and wattage of the blanket. Using this
information we can calculate its nominal resistance.
The formula for calculating the resistance (R) of a
circuit is: R=V² ÷ W, where V is voltage and W is
watts. Therefore, if a heat blanket’s markings say
that it is rated for 120 volts and 720 watts, we can
calculate the nominal resistance as follows: R = 120
²÷ 720 R =14,400÷720 R = 20 Ω All other things
being equal, the resistance through this heat blanket
should be 20 ohms, or 20Ω. If we allow a ±5%
deviation for normal wear and tear we can then say
that this heat blanket should have a resistance range
of 19Ω to 21Ω. It is recommended that the range
be calculated for all heat blankets in the shop and
written on them at the bus with indelible ink. That
way, technicians need only perform a quick resistance
check on any heat blanket to verify that it will operate
satisfactorily prior to running a cure.
i. Thermocouples. A thermocouple (TC) is a
thermoelectric device used to accurately measure
temperatures. They may be connected to a simple
temperature reading device or, more often, they are
connected to a hot bonder, oven or other type of
controller which regulates the amount of heat applied
to the repair area. TCs consist of a wire with two
leads of dissimilar metals; the metals are joined at one
end. Heating the joint produces an electric current;
this current is converted to a temperature reading with
a TC monitor. Select the type of wire (typically J)
and the type of connector (standard or miniature) that
are compatible with the local temperature monitoring
equipment (hot bonder, heat gun, etc.). TC wire
is available with different types of insulation; check
the manufacturer’s product data sheets to ensure the

insulation will withstand your highest cure temperature.
Teflon® insulated wire is generally good for 390 °F
and lower cures; Kapton® insulated wire should be
used for higher temperatures. Most TCs used for
bonding are the J-type, which use one iron and one
constantan wire. If no guidance exists, TCs should
be between 10 and 50 feet long. See Chapter 6
for more information on inspecting and using TCs.
Table 3-1. Thermocouple Identification
Outer Sheath (Optional)
J Positive (Iron)
Negative (Constantan)
(1) Locally manufactured TC. Both, welded
and twisted TCs, may be locally manufactured. Fol-
low the instructions below to locally manufacture a
welded or twisted TC.
(a) Welded TC. Welded TCs (see figure
3-3) are less prone to problems and shall be used
when available. The thermocouple being welded is
inserted into the chamber and creates an arc when
the TC contacts the graphite powder. Oxygen in
the chamber is quickly consumed by the arc which
provides a clean weld with minimal soot or ash on
the weld itself. Follow these steps to manufacture
a welded TC using an Applied Heat Model A–300
Thermocouple Welder:
1 Attach AC power cord to the face
plate of the A-300 Welder. Attach the
other end to 120 V power source.
2 Remove the nylon plug from the weld
chamber and allow it to dangle over
the edge where it will not be in the
way.
Do not knick the wires as this will cause the
wire to break at the nick when flexed.
3 Strip wires approx. 3/4" or 2 cm.
4 Twist wires tightly at least 6 turns.
5 Trim twisted pair so that 3 turns
remain.
6 While holding the Press to Weld but-
ton down, slowly insert the TC into
TM 1-1500-204-23-11
TC wire color codes vary by nation; always check
the label to ensure you are using the correct type.
The industry standard is ASTM E 230 and is shown
in table 3-1. Sometimes, the TC wires used in the
composite industry are supplied without the outer
sheath to minimize the potential for vacuum leaks.
If the wire color is not visible, the iron wire can be
determined since it is magnetic.
USA Thermocouple
USA Thermocouple Color Extension Color
Brown Black
+ White + White
- Red - Red
the weld chamber until an arc occurs.
Hold approximately 2 seconds.
Do not touch the bead when inspecting the
weld. Metal will be hot and can cause burns.
7 Withdraw the TC from the chamber
and inspect the weld. Reinsert if nec-
essary to obtain a satisfactory weld.
8 Completed weld should appear as a
bead connecting the two wires of the
thermocouple. The size of the bead
may vary and is not critical to the
proper function of the thermocouple.
9 When finished, replace nylon plug
and disconnect from power.
Figure 3-3. Welded Thermocouple Wire
(b) Twisted TC. Twisted TCs (figure 3-4) do
not form as reliable a junction as a welded TC and
their reliability decreases with repeated use. When
necessary, a twisted TC shall be made following these
steps.
1 Overlap the bare ends of the two TC
wires 1/4 inch and at 90 degrees to
each other.
3-5
TM 1-1500-204-23-11
2 Tightly twist the wire four to five times
and cut off the excess wires to make
contact for the first time.
3 Insure the TC is reading ambient
temperatures and reacts to a temper-
ature change such as holding it in
your hand.
Figure 3-4. Twisted Thermocouple Wire
j. Vacuum ports. Use one vacuum port for each
10 ft2 of bagging material. Use one additional vacuum
port for vacuum gauge. Ensure the ports are placed
over the breather cloth. An extra piece of breather
cloth should be placed under the port, especially for
high temperature or autoclave cures. If necessary,
create an air path by placing a strip of breather cloth
from the vacuum port to the breather cloth on the
repair. Additional information on vacuum bagging can
be found in Chapter 6.
k. Heat Lamps. Heat lamps are heating devices
that utilize infrared light emission to radiate heat from
the lamp to the part when surface contact with a heat
blanket is not possible. Heat lamps are used to heat
components to assist in flow of injection adhesives
as well as to reduce the gel time of paste adhesives
and wet layup patches. They are not to be used for
curing wet layup patches or patch bond adhesives
and are limited to temperature applications of 160
°F or below on advanced composite parts. Individual
heat lamp elements can be arranged in a housing
with a reflector to provide a uniform heating area for
3-6
4 Verify proper operation of the TC prior
to bonding.
5 Log the information with a data
recording system (often, but not
always, this is part of a hot bonder or
oven) or by hand.
highly contoured sections or non-contact cures where
a heat blanket is not practical. It is difficult to control
the heat applied with a heat lamp during extremes in
temperatures or windy conditions. Use of heat lamps
in these conditions shall be avoided.
(1) Heat Lamp Variables. Variables that effect
part temperature when using heat lamps are discussed
below:
(a) Lamp Distance. When the heat lamp is
moved away from the surface, a larger area is heated
but the temperature is reduced. When the heat lamp
is moved closer to the surface, a smaller area is
heated and the temperature is increased. (See figure
3-5 View A). Adjust the distance from the surface to
ensure required surface temperature is obtained.
(b) Airflow. Airflow across the surface has
a significant cooling effect. (See figure 3-5 View B).
If required, block the airflow by erecting a temporary
shelter with materials on hand, such as sheet metal,
vacuum bag film, etc.

(c) Impingement Angle. The angle of the
heat lamp should be perpendicular to the surface, or
the part will heat unevenly (see Figure 3-5 View C).
(d) Heat Sink. The presence of clamps or
substructure members may create a heat sink drawing
heat away from the part. (See Figure 3-5 View D).
Reposition heat lamp or add additional heat lamps
as required to obtain the required temperature.
(e) Curvature. A curved surface will heat
unevenly, as shown in figure 3-5 View E. Place
additional heat lamps over the repair area to obtain
the required temperature.
(f) Shadow. The presence of obstructions
can cast a shadow on the repair area causing uneven
heat distribution (see figure 3-5 View F). Reposition
heat lamp or add additional heat lamps as required
to obtain the required temperature.
(g) Emissivity. Emissivity of the surface
effects surface temperature. A shiny or light color
surface has a low emissivity, which results in a cooler
surface temperature when heated, as opposed to a
dark surface which has a high emissivity and will
result in a higher surface temperature when heated.
(h) Heat Reflection. The presence of vac-
uum bag material (i.e. breather cloth) can insulate
and reflect energy away from the part being heated.
(i) Ambient Temperature. Temperature the
ambient temperature is warm, it will take less energy
to heat the part than if the ambient temperature is
cool. Adjust the heat lamp placement accordingly.
TM 1-1500-204-23-11
(2) Using Heat Lamps. The following are the
steps to take when using heat lamps:
(a) Perform Thermal Survey. Before
using heat lamps for a repair process,
a heat survey shall be performed on
component(s) as described in Chapter
6.
(b) Place heat lamp(s) in the same posi-
tion as determined by the heat survey
in Chapter 6 to obtain the required tem-
perature.
(c) Using high temperature tape, tape ther-
mocouple sensors or thermocouples
in the repair area at the minimum and
maximum temperature, as determined
by the heat survey in Chapter 6. To
ensure the thermocouple accurately
measures the surface temperature of
the part, use tape approximately the
same color as the part surface to secure
the thermocouples.
(d) Connect the thermocouple to a tem-
perature measuring device. (The hot
bonder controller can be used for tem-
perature measuring). Check to ensure
proper operation.
(e) Power on heat lamp(s) and continually
monitor the temperature to ensure the
required temperature is achieved.
3-7
TM 1-1500-204-23-11

Figure 3-5. Heat Lamp Temperature Affects (Sheet 1 of 2)

3-8

Figure 3-5. Heat Lamp Temperature Affects (Sheet 2 of 2)
l. Heat Guns. Many times the complexity of a
surface or the materials being used will negate the
use of heat blankets for curing. When a heat blanket
cannot be used to heat the surface of a repair, hot
air may be utilized. For small areas that only need to
be warmed, a handheld heat gun may be adequate.
Larger areas or higher temperatures require other
controlled hot air generators. Using a hot air tent
rather than a heat blanket also assists in controlling
heat loss by conduction as a larger area is usually
heated than with a heat blanket or lamps. Small,
handheld heat guns can be used to warm resins,
pre-pregs, and part or aircraft surfaces to improve
material handling. When using a heat gun, the hot
air should not be exhausted directly on the part or
material. To minimize the potential of overheating,
the part should be heated indirectly. A tent of Mylar
can be used to improve heating effectiveness and
evenness. If the heat gun does not have an integral
TM 1-1500-204-23-11
temperature control, the temperature control on a hot
bonder can be used.
m. Double Vacuum Debulk (DVD) Tool. The DVD
tool removes entrapped air (porosity) from wet layup
laminates. The finished structural properties of a DVD
produced repair patch are better (lower porosity and
higher fiber volume) than a standard vacuum bagged
wet layup patch, but not as good as an autoclave
cured pre-preg repair. See Chapter 7 for details on
the DVD process. The resin used in this technique
must have a fairly long pot life due to the use of
heat and the time required to perform the process.
Hysol EA9390 resin has proven to be one of the few
laminating resins capable of meeting this requirement.
After the dry cloth has been impregnated with EA9390
resin, the plies cut, and the plies flat ply collated, it is
debulked using a double vacuum bag debulking tool
(figure 3-6). For this technique a rigid box (figure 3-7)
is placed over the vacuum bag (inner vacuum bag)
3-9
TM 1-1500-204-23-11
containing the wet layup laminate and heat blanket.
The outer vacuum bag is placed over the box and
vacuum applied. This second vacuum bag and rigid
box relieve the compaction pressure on the laminate
induced by the initial vacuum bag, while maintaining
vacuum on the inner bag. With vacuum applied to both
bags, the laminate is heated to the debulk temperature
and held for a specified time. This allows trapped
gases to be removed without being trapped by the
compressing (inner) vacuum bag. Next, compaction
of the laminate is accomplished by venting the outer
Figure 3-6. Double Vacuum Debulk (DVD Tool Schematic)
3-10
vacuum bag to the atmosphere so that only the inner
vacuum is applied to the repair patch. Following
debulking and compaction, the laminate is removed
from the debulking tool and formed to a tool or part
surface. A vacuum bag is then applied over the
laminate (and heat blanket if applicable) and vacuum
applied. Heat is then applied to cure the laminate
using an oven or heat blanket. Chapter 7 details the
DVD procedures. Appendix B lists the NSN for the
DVD tool.

Figure 3-7. Rigid Box Construction
3-4. CONSUMABLE MATERIALS. Consumable
materials are single use products. The following con-
sumable materials are used in the repair of advance
composite structures:
a. Vacuum Bag Materials. The following para-
graphs discuss selection of materials used in vac-
uum bagging. When selecting bagging materials, the
most important factor is matching material temperature
capability to the expected cure temperatures. Typical
material temperature capabilities are provided in table
3-2. If you have special needs, contact engineering
or the bagging film manufacturer for guidance.
(1) General. Vacuum bag materials are usually
nylon materials that form a barrier and isolate the
composite material from the local atmosphere. Once
this is accomplished and the air is drawn out of the bag
using a vacuum pump, the earth’s atmosphere exerts
pressure on the laminate (approximately 14.7 psi at
sea level) which aids in the removal of porosity and
volatiles. Vacuum bag materials must be non-porous.
If they are to come in contact with the resin, they
must be compatible with the resin system in use.
Several bagging materials are commercially available.
For most field repair applications using a 350 °F or
less curing system, nylon film of 2 to 5 mils thick is
sufficient. Underneath the bag; the bleeder, release
TM 1-1500-204-23-11
films, and breather are selected to maximize air and
volatiles escaping the repair while also only allowing
a certain amount of resin to leave the patch. Release
films allow the bagging materials to be removed after
cure. Peel ply is used for surface preparation for
subsequent bonding.
(2) Peel Ply. Peel plies are used to provide
a surface that is ready for bonding; however, further
surface preparation, such as scuff sanding, may be
required. The material is peeled from the repair after
the repair is cured. Peel plies are manufactured
from polyester, nylon, Fluorinated Ethylene Propylene
(FEP) or coated fiberglass. They can be difficult to
remove if overheated. Some coated peel plies can
leave an undesirable contamination on the surface.
The preferred peel ply material is polyester which has
been heat-set to eliminate shrinkage and scoured to
eliminate contaminates. Follow your specific repair
guidelines for the selection of peel ply and any
subsequent surface preparation procedures; if in doubt
after the removal of the peel ply, scuff sand and
perform a water break test (refer to the Glossary for
Water Break Test).
(3) Release Film. Release fabrics and films
are also referred to as separator film, parting film or
release fabric. They are sometimes referred to by
3-11
TM 1-1500-204-23-11
the material they are made from, such as Polyvinyl
Fluoride (PVF), FEP or Polytetraflouroethylene (PTFE
or Teflon®) coated fiberglass. Both the films and
the fabrics are available in porous or non-porous
forms. The non-porous release films and fabrics are
interchangeable; their purpose is to stop resin flow
from the bleeder plies into breather plies. Porous or
perforated release films and fabrics have small holes
which allow excess resin to bleed out. The size and
distance between perforations, in combination with the
bleeder cloth used, directly affects the resin content
of the cured component; therefore, you must use the
type specified for your particular repair. The ability
of the thinner films to stretch can make them difficult
to apply to flat surfaces without wrinkles.
(a) Porous or Perforated Release Film
Porous release film, also known as porous parting
film, or separator, is placed between the repair plies
(or peel ply, if used) and the bleeder cloth. Gas flow
and resin bleed out through the film, and the bleeder
plies are prevented from bonding to the repair plies
during the cure cycle.
1 Bleeder. Bleeder cloths can be made
from woven or nonwoven cotton, polyester or fiber-
glass. They absorb the surplus resin from the repair.
When a specific number and type of bleeder cloth
is called for in a repair, it must be used to ensure
the resin-to-fiber ratio meet the repair requirements.
Too few plies of bleeder cloth may result in too much
resin in the repair; too many plies of bleeder cloth
may result in not enough resin.
2 Caul Plates. Caul plates are smooth
metallic or plastic plates used in a composite layup
or on a repair part to distribute pressure and to
provide a smooth surface on the finished laminate.
Caul plates maintain contour with the assembly tool
to fix the part details in place. They also support the
bag over an area where the vacuum bag pressure
may cause local crushing at vulnerable edges. Metal
caul plates, usually aluminum or copper, are used to
distribute the temperature from the heat blanket more
evenly over the repair. The caul plate should be the
same size as the heat blanket. Sharp edges can
puncture the vacuum bag and a non smooth surface
can create resin rich areas.
3 Breather. Breather material allows air
inside the vacuum bag to be removed and thus enables
atmospheric pressure to be applied to the area. It is
made of a loosely woven or nonwoven material; it does
not come in direct contact with the part or repair area.
Fiberglass cloth or commercially available breather
materials may be used. The commercially available
breather cloths have been designed for improved
airflow over fiberglass cloths. Breathers have been
3-12
tailored to meet composite part manufacturer’s needs
and are available in different weights (thickness) and
different levels of conformability. For most field repair
applications, 4 ounce polyester breather is sufficient.
NOTE
Only use flashbreaker tape inside the vacuum
bag. Other tapes will contaminate the bonding
area.
4 Tapes. There are two types of tapes
used in vacuum bagging Flashbreaker tape and vac-
uum bag sealant tape.
a Flashbreaker Tape. Flashbreaker
tapes are used to hold thermocouples and other
materials in place inside the vacuum bag. Flash-
breaker tapes are usually made from 2 to 5 mils thick
polyester film and have either a silicone or rubber
adhesive on one side; the rubber adhesive is pre-
ferred if there will be subsequent bonding operations.
They are available in a variety of widths and typically
have a 1 year shelf life. Because the flashbreaker
tape is not part of the completed repair, the shelf life
is not critical and the tape can be used as long as it
has sufficient tack. For field repairs, 1 inch wide, 2
mils thick flash tape with silicone adhesive is usually
sufficient.
b Vacuum Bag Sealant Tape. Vac-
uum bag sealant tape is used to seal the vacuum bag
to the part or tool surface. Sealant tape is usually
made of a synthetic rubber material, available in a roll,
1/8 inch thick and 1/2 inch wide. It is available with
different amounts of tack or stickiness. Most have a
shelf life of 9 months to 1 year, after which they lose
their tackiness. For field repairs, a sealant tape with
good or excellent tack is recommended. Duct seal is
not recommended because it is susceptible to leaks
and contamination.
NOTE
Do not use nylon vacuum bag material for
storing frozen materials; this material does
not provide an effective water vapor barrier.
Nylon has a tendency to dry out in low humidity
environments; this will degrade the bagging
film and shorten its shelf life. It absorbs
moisture from the air making it more pliable
and less likely to crack. In low humidity
environments, such as a desert, do not use
brittle material as it may rip or tear.
5 Vacuum Bag Film. Vacuum bag film
is an impermeable plastic film such as nylon or PVF
that covers the repaired area or completely envelopes
the entire part (and the tool if used). It is sealed
 TM 1-1500-204-23-11

at the edges so that vacuum can be applied. The wrinkling when handling the bagging material. Use
bagging film most typically used is 2 to 4 mils (0.05 caution when using sharp edged tools to avoid cutting
to 0.1 mm) in thickness. Thicker films reduce the the bagging film.
likelihood of punctures on complex shapes. Avoid

Table 3-2. Material Temperature Capabilities

Application Material Maximum Temperature 1

Polyethylene <120 to 250 °F

Vacuum Bag Nylon <400 °F

Polyimide <800 °F

Low Temperature <180 to 250 °F

Sealant Tape 2 General Purpose <400 °F

High Temperature <800 °F

Polyester <400 °F
Breather/Bleeder Nylon <450 °F

Fiberglass <900 °F

Polyvinyl Chloride <180 °F

Polyvinyl Alcohol <250 °F

Release Film
Nylon <400 °F

Fluorinated Polymer Films <450 °F

Polyimide <700 °F

Polyester <400 °F

Nylon <400 °F
Peel Ply Coated Fiberglass <550 °F

Aramid <800 °F

Fiberglass <900 °F

3-13
TM 1-1500-204-23-11

Table 3-2. Material Temperature Capabilities — Continued

Application Material Maximum Temperature 1

Polyester <400 °F

Nylon <400 °F
Flashbreaker Tape
Coated Fiberglass <550 °F

Polyimide <800 °F

1 Maximum temperature values reflect industry averages for each material type and are listed for reference
purposes only. Use only vendor supplied material data when selecting materials for a given cure
temperature.

2 Sealant tapes are made from a wide variety of materials and blends of materials. For simplicity, they
are listed by temperature application rather than specific chemical makeup.

6 Fasteners. Composite fasteners are 2. Large footprint - the

specifically designed to ensure the structural integrity backside needs a large
of a composite repair. Use fasteners that are elec- shop head or footprint to
trochemically compatible with the composite structure prevent pulling through.
being repaired. For example, in carbon/epoxy, gal- 3. Limited torque - over-
vanic corrosion of the fasteners can be avoided by torqueing fasteners
using fasteners made of titanium (preferred), monel or damages composites.
Corrosion Resistant Steel (CRES). Cadmium plated 4. For sandwich panels,
or aluminum, fasteners are not compatible. Refer to limited or adjustable
TM 1-1500-204-23-10, Chapter 7 for additional infor- clamp-up force; this pre-
mation on conventional fastening systems or consult vents the core crushing.
system specific technical manuals for information not
covered in this technical manual. (2) Selection. There are few rules
of thumb that can be applied to fastener selection
a Background. Engineers consider for composite parts.
many different factors when selecting fasteners for
a particular application. These factors must be 1. Consult the system spe-
addressed for all the materials the fastener goes cific technical manual. If
through. These factors include, but are not limited information is not given
to, the following: in the technical manual,
request an engineering
• Strength - lap/shear/tension/bearing disposition. Compos-
ite fasteners are specif-
• Corrosion potential ically designed for this
application to insure the
• Removable or permanent structural integrity of the
repair.
• Access for fastener installation and/or removal 2. Use fasteners that are
electrochemically com-
(1) Features. Features common to patible with the com-
most fasteners used in composites include: posite structure being
repaired. For exam-
1. Nonhole filling – fas- ple, in carbon/epoxy,
teners traditionally used galvanic corrosion of
for metal repairs that the fasteners can be
expand to fill the hole avoided by using fas-
will damage composite teners made of tita-
parts. nium (preferred), monel

3-14

or Corrosion Resistant
Steel (CRES). Do not
use cadmium-plated or
aluminum fasteners.
3. Install fasteners wet with
MIL-PRF-81733 sealant.
4. Ensure the proper torque
is used on all fasteners
or bolts.
5. Use 100 ° or 130
° countersink tension
head fasteners when
the countersink is in
the carbon/epoxy lam-
inate. The head of
a tension fastener is
20-40% larger than the
head of the same diam-
eter shear fastener.
The larger head helps
prevent fastener pull
through and provides a
larger bearing surface.
The 130° is used for
very thin laminate appli-
cations.
6. Exercise caution to
insure the proper coun-
tersink is used for the
different countersink fas-
tener angles.
(3) Patch and Fastener Installa-
tion. Once fastener holes in the metal or composite
repair plate and the composite skin are drilled (or
reamed) to full size, the plate can be installed on
the skin with mechanical fasteners. See Chapter 6-8
for drilling instructions. A variety of fastener types
may be used to affect the repair. Different installation
and inspection procedures are required for the differ-
ent type of fasteners. This section briefly describes
the different fasteners commonly used in a bolted
composite repair and the installation and inspection
requirements for each type fastener. Also listed are
some general guidelines and practices that can be
applied to composite bolted repairs. Refer to TM
1-1500-204-23-10 Chapter 7 for more information on
these and other fasteners.
b Fastener Types. There are many
factors to consider when selecting fasteners for a par-
ticular application. These factors must be addressed
for all of the materials the fastener penetrates. They
include: strength (lap/shear/tension/bearing), corrosion
potential, permanence, and accessibility.
(1) Hi-Lok® Fasteners. Hi-Loks®
are two piece fasteners using a threaded pin and
TM 1-1500-204-23-11
a collar. Advantages of Hi-Lok® fasteners include
their light weight, high fatigue resistance and high
strength. Another advantage for using Hi-Loks® is
the fastener cannot be over torqued. The collar has
a regulated break off groove which shears off at a
predetermined torque, leaving the lower portion of the
collar seated with the proper torque without additional
torque inspections.
(2) Blind Fasteners. Blind fasten-
ers are designed for applications where only one
side of the repair area is accessible. These fasten-
ers are secured in place by a collar that deforms
and bears up against the backside material. If the
backside material is composite, a Composi-Lok® or
Composi-Lok® II must be used. The Composi-Lok®
fasteners have a larger upset surface or footprint
when installed. This larger bearing area helps pre-
vent localized delamination around a fastener hole and
increases the resistance to “tipping.” Figure 3-8 shows
some basic design differences between the Visu-Lok®
(Jo-Bolt) and Composi-Lok® fastener. Part numbers
and other descriptive information are listed in table
3-3 for both conventional blind fasteners and Com-
posi-Lok® blind fasteners. These are for illustrative
purposes only. Consult the system specific technical
manual for proper fastener selection.
(a) Visu-Lok®. This blind fas-
tener, commonly called a Jo-Bolt, is for installation
where the backside material is metal. The fastener
consists of a preassembled nut, threaded bolt and
sleeve.
(b) Visu-Lok® II. The Visu-Lok
II® is similar to the Visu-Lok® except a drive nut
is located on the stem of the fastener. This feature
reduces logistical elements since only two nose pieces
are required to install all diameters and head styles.
(c) Composi-Lok®. Composi-
Loks® are specifically designed for fastening car-
bon/epoxy composite joints with one side access. The
Composi-Lok® is similar in design to the Visu-Lok®.
However, once installed, the sleeve upset is larger,
distributing the bearing loads over a larger area.
(d) Composi-Lok® II. The
Composi-Lok II is similar to the Composi-Lok® except
a drive nut is located on the stem of the fastener. As
with the Visu-Lok II® fastener, the drive nut reduces
installation time and reduces the tooling required.
With two nose adaptors, all diameters and head
styles can be installed.
3-15
TM 1-1500-204-23-11

Figure 3-8. Blind Fastener Differences

3-16
 TM 1-1500-204-23-11

Table 3-3. Mechanical Fasteners

NOMENCLATURE / DESCRIP-
TION PART NUMBER VENDOR / CAGE CODE
Structural Screw Flush, Sealing Hi-Shear Corp
HT271A4
Head Titanium, 1/4" Dia 73197
Composi-Lok® Blind Bolt Flush, Monogram Aerospace Fasteners
MBF 2012-06
Titanium, 3/16" Dia 98524
Composi-Lok® Blind Bolt Hex Monogram Aerospace Fasteners
MBF 2011-06
Head, Titanium, 3/16" Dia 98524
Composi-Lok® II Blind Bolt Hex Monogram Aerospace Fasteners
MBF 2111-06
Head, Titanium, 3/16" Dia 98524
Hi-Lok® Pin Flush, Shear Head, Hi-Shear Corp
HL 11V6
Titanium, 3/16" Dia 73197
Hi-Lok® Pin Protruding, Tension Hi-Shear Corp
HL 12V6
Head, Titanium, 3/16" Dia 73197
Hi-Lok® Pin Flush, Tension Head, Hi-Shear Corp
HL 13V6
Titanium, 3/16" Dia 73197
Hi-Lok® Collar Hi-Shear Corp
HL570-6MC
73197
Visu-Lok® Blind Bolt Flush, Tension Monogram Aerospace Fasteners
PLT 170-06
Head Titanium, 3/16" Dia 98524
Visu-Lok® Blind Bolt Protruding, Monogram Aerospace Fasteners
PLT 270-06
Shear Head, Titanium, 3/16" Dia 98524
Visu-Lok® Blind Bolt Protruding, Monogram Aerospace Fasteners
PLT 1058-06
Tension Head, Titanium, 3/16" Dia 98524
Visu-Lok® II Blind Bolt Flush, Monogram Aerospace Fasteners
PLT 5170-06
Tension Head Titanium, 3/16" Dia 98524
Visu-Lok® II Blind Bolt Protruding, Monogram Aerospace Fasteners
PLT 5270-06
Shear Head, Titanium, 3/16" Dia 98524
Visu-Lok® II Blind Bolt Protruding, Monogram Aerospace Fasteners
PLT 5470-06
Tension Head, Titanium, 3/16" Dia 98524

c Fastener Installation Tools. The
type of fastener used in composite repair determines
which tools are required. Specialty fasteners may
require specialty tools. These fasteners require spe-
cialty tools installation.
(1) Installation of Hi-Loks® Fas-
teners. Hi-Loks® are designed to be installed with
either specially designed Hi-Lok® tooling or standard
hand or power tools with Hi-Lok® adapters. Refer
to TM 1-1500-204-23-10, Chapter 7 or the system
specific technical manual for additional information on
Hi-Lok® installation with these additional provisions.
Figure 3-9 demonstrates the use of Hi-Lok® specialty
tooling.

3-17
TM 1-1500-204-23-11

(2) Installation of Blind Fasteners.

The tooling required for installing Visu-Lok® or Com-
posi- Lok® blind fasteners is listed in Tables 3-4
through table 3-7. Also, extensions may be added to
the pneumatic tool if additional length is required. Fig-
ure 3-10 shows the extensions available. Numerous
measurements around the fastener hole are needed.
Use a fastener grip gauge (figure 3-11) to measure
material thickness to determine blind bolt length.

Figure 3-9. Hi-Lok® Installation: Hand Tooling

Figure 3-10. Pistol Extension Assemblies

3-18
 TM 1-1500-204-23-11

Figure 3-11. Blind Fastener Grip Length Gauges (Sheet 1 of 2)

3-19
TM 1-1500-204-23-11

Figure 3-11. Blind Fastener Grip Length GaugesBlind Fastener Inspection (Sheet 2 of 2)

Table 3-4. Composi-Lok® Installation Tooling

MRC550 CLOSE QUARTER PNEUMATIC INSTALLATION TOOLING

FASTENER WRENCH NOSE ADAPTER

DIAMETER ADAPTER FLUSH 100° HEX LOW PROFILE FLUSH 130
5/32 (-5) MRCBC-5 MRCF-5 MRCP-5 MRCA-5 MRCR-5
3/16 (-6) MRCBC-6 MRCF-6 MRCP-6 MRCA-6 MRCR-6
1/4 (-8) MRC-8 MRCF-8 MRCP-8 MRCA-8 MRCR-8
MP550BF PNEUMATIC INSTALLATION TOOLING

FASTENER WRENCH NOSE ADAPTER

DIAMETER ADAPTER FLUSH, 100° HEX LOW PROFILE FLUSH, 130°
5/32 (-5) MPBF-5 MPFBF-5 MPPBF-5 MPRBF-5 MPRBF-5
3/16 (-6) MPBF-6 MPFBF-6 MPPBF-6 MPRBF-6 MPRBF-6
1/4 (-8) MPBF-8 MPFBF-8 MPPBF-8 MPRBF-8 MPRBF-8
5/16 (-10) MPTBF-10 MPTFBF-10 MPTPBF-10 MPTRBF-10 MPTRBF-10
3/8 (-12) MPTBF-12 MPTFBF-12 MPTPBF-12 MPTRBF-12 MPTRBF-12
MHC75 CLOSE QUARTER HAND TOOLING

FASTENER WRENCH NOSE ADAPTER

DIAMETER ADAPTER FLUSH, 100° HEX LOW PROFILE FLUSH, 130°
5/32 (-5) MHCBF-5 MHCF-5 MHCP-5 MHCR-5 MHCR-5

3-20
 TM 1-1500-204-23-11

Table 3-4. Composi-Lok® Installation Tooling — Continued

MRC550 CLOSE QUARTER PNEUMATIC INSTALLATION TOOLING

FASTENER WRENCH NOSE ADAPTER

DIAMETER ADAPTER FLUSH 100° HEX LOW PROFILE FLUSH 130
3/16 (-6) MHCBF-6 MHCF-6 MHCP-6 MHCR-6 MHCR-6
1/4 (-8) MHC-8 MHCF-8 MHCP-8 MHCR-8 MHCR-8
5/16 (-10) MHC-10 MHCF-10 MHCP-10 MHCR-10 MHCR-10
3/8 (-12) MHC-12 MHCF-12 MHCP-12 MHCR-12 MHCR-12
MH75 HAND TOOLING

FASTENER WRENCH NOSE ADAPTER

DIAMETER ADAPTER FLUSH, 100° HEX LOW PROFILE FLUSH, 130°
5/32 (-5) MHBF-5 MHF-5 MHP-5 MHR-5 MHR-5
3/16 (-6) MHBF-6 MHF-6 MHP-6 MHR-6 MHR-6
1/4 (-8) MH-8 MHF-8 MHP-8 MHR-8 MHR-8
5/16 (-10) MH-10 MHF-10 MHP-10 MHR-10 MHR-10
3/8 (-12) MH-12 MHF-12 MHP-12 MHR-12 MHR-12

Table 3-5. Composi-Lok® II and IIa Installation Tooling

MRC550 CLOSE QUARTER PNEUMATIC INSTALLATION TOOLING

FASTENER DIAMETER WRENCH ADAPTER NOSE ADAPTER
5/32 (-5) MRCBF-5 MRCPDN-1
3/16 (-6) MRCBF-6 MRCPDN-1
1/4 (-8) MRC-8 MRCPDN-2
MP550BF PNEUMATIC INSTALLATION TOOLING
FASTENER DIAMETER WRENCH ADAPTER NOSE ADAPTER
5/32 (-5) MPBF-5 MPPBF-8
3/16 (-6) MPBF-6 MPPBF-8
1/4 (-8) MPBF-8 MPPBF-8
5/16 (-10) MPTBF-10 MPP-12
3/8 (-12) MPTBF-12 MPP-12
MHC75 CLOSE QUARTER HAND TOOLING
FASTENER DIAMETER WRENCH ADAPTER NOSE ADAPTER
5/32 (-5) MHCBF-5 MHCPDN-1
3/16 (-6) MHCBF-6 MHCPDN-1
1/4 (-8) MHC-8 MHCPDN-2
5/16 (-10) MHC-10 MHCPDN-3
3/8 (-12) MHC-12 MHCPDN-3

3-21
TM 1-1500-204-23-11

Table 3-5. Composi-Lok® II and IIa Installation Tooling — Continued

MRC550 CLOSE QUARTER PNEUMATIC INSTALLATION TOOLING

FASTENER DIAMETER WRENCH ADAPTER NOSE ADAPTER

NOTE

MHC75A hand tool assembly for -5 and -6 fasteners

MHC75B hand tool assembly for -8 and above.
MH75 HAND TOOLING
FASTENER DIAMETER WRENCH ADAPTER NOSE ADAPTER
5/32 (-5) MHBF-5 MHPDN-1
3/16 (-6) MHBF-6 MHPDN-1
1/4 (-8) MH-8 MHPDN-2
5/16 (-10) MH-10 MHPDN-3
3/8 (-12) MH-12 MHPDN-3

Table 3-6. Visu-Lok® Installation Tooling

MRC550 CLOSE QUARTER PNEUMATIC INSTALLATION TOOLING

FASTENER WRENCH NOSE ADAPTER

DIAMETER ADAPTER FLUSH 100° HEX LOW PROFILE FLUSH 130
5/32 (-5) MRC-5 MRCF-5 MRCP-5 MRCA-5 MRCR-5
3/16 (-6) MRC-6 MRCF-6 MRCP-6 MRCA-6 MRCR-6
1/4 (-8) MRC-8 MRCF-8 MRCP-8 MRCA-8 MRCR-8
MP550BF PNEUMATIC INSTALLATION TOOLING
NOSE ADAPTER
FASTENER WRENCH
DIAMETER ADAPTER REDUCED
FLUSH, 100° HEX MILLABLE
FLUSH, 100˚
5/32 (-5) MP-5 MPF-5 MPP-5 MPA-5 MPR-5
3/16 (-6) MP-6 MPF-6 MPP-6 MPA-6 MPR-6
1/4 (-8) MP-8 MPF-8 MPP-8 MPA-8 MPR-8
5/16 (-10) MP-10 MPF-10 MPP-10 --- MPR-10
3/8 (-12) MP-12 MPF-12 MPP-12 --- MPR-12
MHC75 CLOSE QUARTER HAND TOOLING
NOSE ADAPTER
FASTENER WRENCH
DIAMETER ADAPTER REDUCED
FLUSH, 100° HEX MILLABLE
FLUSH, 100˚
5/32 (-5) MHC-5 MHCF-5 MHCP-5 MHCA-5 MHCR-5
3/16 (-6) MHC-6 MHCF-6 MHCP-6 MHCA-6 MHCR-6
1/4 (-8) MHC-8 MHCF-8 MHCP-8 MHCA-8 MHCR-8

3-22
 TM 1-1500-204-23-11

Table 3-6. Visu-Lok® Installation Tooling — Continued

MRC550 CLOSE QUARTER PNEUMATIC INSTALLATION TOOLING

FASTENER WRENCH NOSE ADAPTER

DIAMETER ADAPTER FLUSH 100° HEX LOW PROFILE FLUSH 130
5/16 (-10) MHC-10 MHCF-10 MHCP-10 --- MHCR-10
3/8 (-12) MHC-12 MHCF-12 MHCP-12 --- MHCR-12

NOTE

MHC75A hand tool for -5 and -6 fasteners.

MHC75B hand tool for -8 and above.

MH75 HAND TOOLING
NOSE ADAPTER
FASTENER WRENCH
DIAMETER ADAPTER REDUCED
FLUSH, 100° HEX MILLABLE
FLUSH, 100˚
5/32 (-5) MH-5 MHF-5 MHP-5 MHA-5 MHR-5
3/16 (-6) MH-6 MHF-6 MHP-6 MHA-6 MHR-6
1/4 (-8) MH-8 MHF-8 MHP-8 MHA-8 MHR-8
5/16 (-10) MH-10 MHF-10 MHP-10 --- MHR-10
3/8 (-12) MH-12 MHF-12 MHP-12 --- MHR-12

Table 3-7. Visu-Lok® II Installation Tooling

MRC550 CLOSE QUARTER PNEUMATIC INSTALLATION TOOLING

FASTENER DIAMETER WRENCH ADAPTER NOSE ADAPTER
5/32 (-5) MRC-5 MRCPDN-1
3/16 (-6) MRC-6 MRCPDN-1
1/4 (-8) MRC-8 MRCPDN-2

MP550BF PNEUMATIC INSTALLATION TOOLING

FASTENER DIAMETER WRENCH ADAPTER NOSE ADAPTER
5/32 (-5) MP-5 MPP-8
3/16 (-6) MP-6 MPP-8
1/4 (-8) MP-8 MPP-8
5/16 (-10) MPTBF-10 MPP-12
3/8 (-12) MPTBF-12 MPP-12

MHC75 CLOSE QUARTER HAND TOOLING

FASTENER DIAMETER WRENCH ADAPTER NOSE ADAPTER

3-23
TM 1-1500-204-23-11

Table 3-7. Visu-Lok® II Installation Tooling — Continued

MRC550 CLOSE QUARTER PNEUMATIC INSTALLATION TOOLING

FASTENER DIAMETER WRENCH ADAPTER NOSE ADAPTER
5/32 (-5) MHC-5 MHCPDN-1
3/16 (-6) MHC-6 MHCPDN-1
1/4 (-8) MHC-8 MHCPDN-2
5/16 (-10) MHC-10 MHCPDN-3
3/8 (-12) MHC-12 MHCPDN-3

MH75 HAND TOOLING

FASTENER DIAMETER WRENCH ADAPTER NOSE ADAPTER
5/32 (-5) MH-5 MHCPDN-1
3/16 (-6) MH-6 MHCPDN-1
1/4 (-8) MH-8 MHCPDN-2
5/16 (-10) MH-10 MHCPDN-3
3/8 (-12) MH-12 MHCPDN-3

d Fastener Removal Tools. Fasten-
ers are removed using specialty hand tooling or com-
mon hand tools. Common hand tools used to remove
fasteners are a hex Allen wrench, pliers, and drill. See
paragraph 7-7 for fastener installation and removal
instructions.
(b) Non-Porous Release Film. Non-porous
release film, also known as non-porous parting film
or separator, goes between the bleeder plies and
breather plies. It stops resin flow from bleeder
plies into the breather cloth layers. It is spliced or
otherwise overlapped wide enough to prevent bleed
through of the resin or adhesive into the breather
plies. Non-porous release film also prevents excess
resin from bleeding onto heat blankets and caul plates
when they are used.
b. Drill Bits. Carbide or diamond-coated drill bits
shall be used for drilling composite structures. Carbide
and diamond-coated drill bits minimize backside dam-
age to composites. If possible, use a backup plate
when drilling. Standard twist drill bits or standard high
speed steel (HSS) drills shall not be used for drilling
composite structures because they dull immediately,
generate excessive heat, cause ply delamination, fiber
tear out, and unacceptable hole quality. Positive rake
drill bits induce ply outer delamination around the
hole. If a twist drill is used, the tip must be ground
so the flute rake is parallel to the bit centerline. See
Volume 9 Chapter 4 for drill terminology.
(1) Drill Reamer. A straight-fluted carbide drill
reamer (i.e., ST1257B, shown in figure 3-13 and figure
3-12 ) has been found to cut high quality holes, with
minimum backside breakout, in carbon/epoxy and
fiberglass materials. These last significantly longer
than any other bit except for diamond-coated drills and
countersinks. Drill reamers are expensive; however,
they can be sharpened by tool manufacturers. The
sharpening process will render them about 0.001
inches smaller than their original diameter. Before
using sharpened reamers, ensure the smaller diameter
will be within tolerance for the fasteners you are
installing. Diamond-coated drill bits last the longest
and are the preferred drill bit for drilling holes in boron
reinforced composites.

Figure 3-12. Typical Drill Reamer

3-24
 TM 1-1500-204-23-11

Figure 3-13. Typical Drill Reamer Diagram (ST1257B Shown for Reference)

(2) Dagger, Spade, & Brad Point Bits. A dag-

ger, spade or brad point bit are best for drilling aramid
materials as it minimizes fiber fuzz (see 3-14, figure
3-15, and figure 3-16). Carbide or Cobalt is gener-
ally the drill material of choice as they hold a sharp
cutting edge significantly longer than HSS.

Figure 3-14. Dagger Bit

(a) Spade Bit. The spade type drill was

originally developed specifically for reinforced solid
laminates and honeycomb sandwich panels with clean
entrance and exit surfaces without sacrificial backing.
It can easily be sharpened.

Figure 3-15. Spade Drill for Aramid Laminates

(b) Brad Point Twist Drill. The brad point

twist drill was developed for the wood working industry.
The sharp knife edge cuts the outer hole diameter
with a knife action, the brad point provides good
centering, and the flute-ended cutting surface shears

3-25
TM 1-1500-204-23-11
the laminate in plane. Generally, a sacrificial backup
is not necessary but may improve the exit hole quality.
Figure 3-16. Brad Point Bit for Aramid or
Fiberglass Laminates
(3) Eight-Faceted Drill . Eight-faceted drill bits
are used to drill holes in hybrid metal/composite repairs
(see figure 3-17).
Figure 3-17. Eight–faceted Bit for Hybrid
Metal/Composite Repairs
(4) Drill Bushing and Guide. The preferred
method for drilling holes in laminate materials is
to use a drill bushing and guide to stabilize drill
bits to prevent wobble and ensure holes are drilled
perpendicular to the surface. Also, firmly clamped
backup material on the exit side must be used. Do
not force feed the drill bit through the composite
as damage (delaminations and splintering around the
hole) may result when the drill bit breaks through
the exit side of the structure. The drilling process
must also be performed incrementally, beginning with
a pilot hole. Thus, several sizes of drill bits are
required for a drilling operation (e.g., pilot holes, 1/64th
undersized, and final hole size). Do not continue to
use a drill bit that has become dull. When this
happens, the drill motor will slow down, much more
force and energy is required and the drill bit will
most likely snap, and the resin can overheat. All of
these symptoms can damage, sometimes severely,
the composite structure. As soon as any of these
symptoms begin, stop and replace the drill bit with a
sharp one. Appendix B lists the recommended drill
bits. Generally, a highspeed, low-feed method works
best. If too much pressure is applied at high speeds,
the excessive heat generated can damage the resin
causing delamination or fracturing.
(5) Portable Drill Stands or Drill Guides. To
obtain good quality holes, portable drill stands or drill
guides should be used. Drill motors equipped with
feed rate limiting surge control are recommended. A
steady pressure should be maintained to keep the
drill cutting at a constant rate.
3-26
(6) Preferred Method for Drilling Holes. Wh-
en drilling without depth sensors, extra care is needed
to control hole depth. The following precautions should
be observed to delaminations, splintering, or fuzzing
around holes.
(a) The drill should be turning before it con-
tacts the laminate and also as it is being
withdrawn from the completed hole.
(b) Reduce pressure and avoid tilting the
drill, driving the drill chuck into the work
or ramming the drill point into hidden
material.
(c) Just before the drill breaks through the
back of the material, pressure must be
reduced to prevent splintering or fuzzing
of fibers on the back face of the lami-
nate.
(d) When drilling or reaming, backup mate-
rial should always be used to prevent
delamination, splintering or fraying.
Several backup materials have been
used successfully, including fiberboard,
wood, and fiberglass laminates. Clamp
the part securely to prevent gaps
between the laminate and the backup
material or between multiple layers
being drilled.
(e) Clean debris from bits and holes to
reduce out of tolerance holes.
(f) Dull or chipped drills affect the size and
quality of holes and can cause over-
heating.
c. Router Bits. Router bit material and cutting
surface design varies depending upon the fiber used
in the laminate. Router bits made from carbide
or diamond coated routers are required. Special
angle grinds are available for aramids, carbon, and
fiberglass. Boron requires diamond-coated router bits
and a supply of approved coolant, either water or
alcohol based. Aramid routing is done with a split
helix router bit with either two or four helical flutes.
Pin router tables should use a 1/4 inch bit with a
template or guide system. Cut in the direction the
cutter turns and keep the cutter clean and sharp (see
figure 3-18).
 TM 1-1500-204-23-11

machining boron/epoxy laminates. Use with a 0

degree router motor and template.

(3) Aramid/Epoxy. The 1/4 inch diameter solid

carbide straight flute router bits, Fullerton series 1900-
250, are used for machining Aramid/Epoxy laminates.
They should be used with the 0 degree router motor
and a template for routing operations. The design
of this cutter results in fuzzing of the edge requiring
additional rework after machining to remove the fuzz.

(4) Carbide Router Bits. Carbide router bits

are provided for machining carbon/epoxy laminates,
but are not the preferred cutter. They are brittle
and can break during machining operations or when
dropped. They dull more quickly than diamond plated
cutters.

d. Reamers. Reamers are for final sizing of

drilled holes. High speed steel reamers are not
recommended for any composite as the cutting edge
will break down rapidly. Solid carbide reamers are
recommended for most applications. Reaming boron
requires diamond-coated reamers.
Figure 3-18. Split Helix Router Bit for Trimming
Aramid Composites e. Countersinks. Four flute solid carbide, carbide
tipped, and polycrystalline diamond insert type coun-
tersinks with pilots should be used for all composites
(1) Carbon/Epoxy. The abrasive nature of
except for aramids where fuzzing is not allowed. To
carbon fibers results in excessive tool wear unless
prevent fuzzing, aramids require a special grind on
the proper cutter material is used. Diamond
the carbide to shear the fibers. The flutes for aramid
coated/impregnated cutters are used for machining
countersinks should be two very sharp flutes with
laminates containing carbon fibers to reduce wear
sickle shaped cutting edges. A tool of this type with
and heat buildup during machining operations. The
a positive rake in the radial direction will prevent
diamond router bit is made by coating high speed
peripheral fuzzing. See figure 3-19 for aramid coun-
steel shank material with industrial diamonds.
tersink geometry. Micro stop tooling is required to
control depth.
(2) Boron/Epoxy. The 80 grit, diamond
coated, 1/4 inch diameter router bits are used for

3-27
TM 1-1500-204-23-11
Figure 3-19. Countersink for Aramid Laminates
f. Abrasives. Abrasives are miniature cutting sur-
faces combined to form a tool. They are derived from
abrasive grains. Abrasive grains are hard crystals
either found in nature or manufactured. The most com-
monly used abrasive materials are aluminum oxide,
Silicon Carbide, cubic boron nitride, and diamond.
Other materials such as garnet, zirconia, glass, and
even walnut shells are used for some applications.
Fiber reinforced abrasive cutoff wheels that
have been fractured can explode when run
up to a high rpm.
(1) Cutoff Wheels. Cutoff wheels for compos-
ites are of two main types: fiber reinforced abrasive
wheels and steel wheels with the edge coated with
diamond grit. The fiber discs can wear rapidly and if
3-28
they bind in the cut, fracturing of the disc can occur.
Diamond cutoff discs are priced much higher than
fiber reinforced abrasive but if used properly can last
for years.
(2) Coated Abrasive Discs. Coated abrasive
discs (see figure 3-20) have an abrasive mineral
bonded to a paper or fiber backing. Aluminum oxide
and silicon carbide are the two abrasives most com-
monly used for aerospace applications. Silicon carbide
is the preferred type of abrasive media because it
stays sharp longer than the aluminum oxide. Coated
abrasive discs are the most frequently used discs for
machining composite repair joints. These discs are
usually mounted on a 90 degree die grinder motor
for use but other tools may be used when conditions
merit. Various grit sizes are required (80 to 150
grit for rough sanding and 150 to 240 grit for finish
sanding).

Figure 3-20. Coated Abrasive Disc
NOTE
Grinders (straight and 90º) must be used with
caution if used for paint removal. The use
of non-oscillating grinders to remove coatings
can remove too much material resulting in
substrate damage. The use of Scotchbrite®
or similar “buffing” disks is necessary to
reduce this possibility. Orbital type sanders
and hand sanding are the recommended
methods for paint removal. Always refer to
the applicable technical manual for proper
equipment selection.
(3) Abrasive Sleeve and Sanding Drums. The
drum consists of a 1.5 inch diameter by 1 inch long
rubber drum and an abrasive sleeve which fits over
the drum. The rubber drum absorbs shock loads
and reduces vibration during machining. It is used
freehand with a 0 or 90 degree router motor.
(4) Sanding Disks and Disk Holders. The
sanding disks and holders have a locking feature that
allows the disks to be positively locked in place during
sanding. Disks use aluminum oxide or silicon carbide
abrasive material in various grits. Disks and disk
holders are available in all three tool sets. Sanding
disks are also used for honeycomb core machining.
They can be used freehand with a 0 or 90 degree
router motor.
TM 1-1500-204-23-11
(5) Vacuum Type Sanding Disk, Disk Holder
and Dust Collection Shroud. This system uses a 90
degree router motor, 3 inch disks and disk holders
both with 6 spaced vacuum collection holes. Used
in conjunction with the dust collection shroud, the
dust collection system (see Chapter 7) and a 1⁄2
inch 80 psi (100 psi maximum) air pressure line,
this unit captures dust at the point of generation. It
has the disadvantage of being unwieldy due to the
attachment of the extra vacuum collection hose to
the dust collection shroud.
(6) Arbors. An arbor in this application is a
shaft on which a revolving cutting tool is mounted.
Arbors are used for mounting, cutting, and grinding
wheels.
g. Hole Saw. Diamond abrasive hole saws, used
between 100 to 500 rpm, are the best choice for
cutting fiberglass, boron, and carbon reinforced com-
posites. Traditional hole saws work well on aramid
reinforced composite materials only when used in
the reverse cutting direction. When using a hole
saw, the drill motor should be operated as suggested
in this paragraph. When drill motors are used for
damage removal, they are most often used with a
diamond-coated hole saw for carbon, fiberglass, and
boron materials. A toothed hole saw run in reverse
is appropriate for cutting aramids and polyethylenes.
A hole saw can easily remove damage from 1 to 3.5
inches in diameter in a very neat, uniform manner.
The material being cut should be well supported and
firmly backed up with wood or an aluminum plate to
prevent backside breakout. Hole saws may also be
used to cut through core for damage removal, but
only when the damage removal cut is to be made
perpendicular with the skin. When using a hole saw
and access to the backside of the structure exists,
do not cut the hole all the way through the skin of
sandwich structure unless a backup material is used.
Failure to use a backup material has a high poten-
tial for causing additional damage on the backside
of the structure. The backside skin can easily be
delaminated and separated from the core. If access
to the backside skin from the outside is not possible,
extreme care must be taken to minimize any damage
to the backside skin. Slowing the feed rate down
considerably near the moment of penetration can min-
imize the damage potential. Figure 3-21 shows a hole
saw and guide bushing assembly.
3-29
TM 1-1500-204-23-11
Figure 3-21. Hole Saw and Guide Bushing
(1) Use of Hole Saws/Roto-Bores. The follow-
ing practices are recommended with the use of hole
saws and roto-bores on carbon composite materials:
(a) The speed of the motor should remain
between 150 and 250 rpm.
(b) The tool should be kept perpendicular
to the surface to allow the hole to be
machined uniformly.
(c) The cutter should be dipped in water
prior to for lubrication and cooling.
(d) Light feed pressure should be applied.
(e) A backup should be used or the hole
should be cut from both sides.
(f) Fuzz accumulated around the hole
should be removed by light wet sand-
ing.
(g) Inspect hole to ensure no edge delam-
inations exist or additional backside
damage has been created during the
cutting operation. If additional damage
exists, consult system specific technical
manual for damage assessment.
3-30
3-5. MISCELLANEOUS TOOLS AND SUPPLIES-
. The following tools and supplies are not found in
repair tool kits, but are necessary in the repair of
composite structures.
a. Scissors. Scissors for composite material cut-
ting generally come from industrial scissor manufac-
turers. Composite materials are abrasive and require
the scissors to have either hardened stainless steel,
carbide, titanium nitride or ceramic coatings to improve
wear resistance. Scissors that cut aramids have a
shearing edge on one blade and a serrated or grooved
surface on the other. These serrations hold the mate-
rial from slipping. Sharp blades should always be
used as they minimize fiber damage. When scis-
sors with serrations are sharpened, only the shearing
blade is ground, thus maintaining the fiber holding
serrations. Cutting uncured materials with serrated
scissors gums up the serrations causing them to be
ineffective. Always clean the scissor serrations imme-
diately after use. The most commonly used are 10
and 12 inch scissors.
b. Scales. An electronic toploading scale with a
minimum 500 g capacity and 0.1 g resolution is needed
for repair operations. Local usage may require larger
capacities. An adequate number of scales should be
available for peak usage needs.
c. Mixing Cups. Mixing cups must be wax free
and clean. Wax free food grade and/or paint mixing
cups are appropriate. To aid in thorough mixing and
avoid uncontrolled exotherms, short cups with a large
diameter should be used as opposed to tall cups with
a narrow diameter.
d. Knives. Utility knives are commonly used for
cutting pre-pregs and wet laminates. Utility knives
with quick change, retractable blades are preferred
because blades must be changed often. Quick change
retractable utility knives provide increased productivity
and enhanced safety.
e. Honeycomb Core Cutters. Two types of cutters
are provided to cut core. One type cuts parallel to
the cell axis and one type is used to machine the
core flush with mating part surfaces. Honeycomb
core cutters are shown in figure 3-22.

Figure 3-22. Honeycomb Core Cutters
(1) Core Slicer. This cutter is made from steel.
It is used to slice replacement core sections from
core kit material. The slicer cuts parallel to the cell
axis. It requires frequent sharpening during use to
cut effectively and prevent tearing of the thin core
foil material.
(2) Core Knife. The core knife is sharp on one
edge only. It must be sharpened along its end and
opposite side to allow core slicing operations. It also
requires frequent sharpening during use.
(3) Burr Special (Rotary File). The burr spe-
cial is an inverted cone shaped rotary file. It is
used with a 0 degree router motor and router holder
to machine core flush with part mating surfaces. It
allows clean honeycomb core cuts without core roll
over or tearing.
(4) Core Cutter. This piece of equipment is a
fly cutter used to undercut honeycomb core.
(5) Internal Cutter. An internal cutter can be
made from an Allen wrench. To create an internal
cutter, sharpen the short leg of the wrench so that
TM 1-1500-204-23-11
when rotated it will cut and push the core material
1/4 inch beyond the void to leave a clean hole.
f. Resin Injection Equipment. Three types of
equipment are commonly used for resin injection: a
hypodermic syringe and needle, a SEMCO sealant
gun and a vacuum cup. In addition, material manu-
facturers may package their products in premeasured
cartridges with static mixing tips that are dispensed
with hand operated guns.
(1) Hypodermic Needles. Hypodermic needles
are used for manual injection of liquid resin into
delaminations and disbonds open to the edge of
the part. The syringe assembly consists of a barrel,
stopper and plunger rod. The needles come in various
diameters. The smaller diameters are more readily
usable for injecting edge delaminations. However,
needles smaller than 0.022 inch outside diameter (24
gauge) are not practical to use as they require a
significant amount of force to get resin through them
and they bend easily during use. The needles are
non-sterile and for industrial use only. See figure
3-23.
3-31
TM 1-1500-204-23-11

Figure 3-23. Industrial Hypodermic Syringe and Needles

(2) Sealant Gun. Sealant guns, such as the
SEMCO Model 250, are used for pressurized injection
of liquid resin into delaminated and disbonded areas.
The gun is used with a regulated pressure source. The
regulated pressure source is mandatory to prevent
damaging assemblies during the injection process.
This equipment consists of the sealant gun, disposable
cartridge, cartridge nozzle, and metallic retainer barrel
and air hose. The cartridge and retainer barrel
come in various sizes. However, the 2 1/2 ounce
size is recommended for injection repair applications.
Nozzles come in various orifice sizes and lengths. The
1⁄16 inch orifice nozzle is recommended for injection
repairs which utilize 1⁄8 inch diameter injection holes.
This allows sealing of the nozzle in the injection hole
during the injection process. See figure 3-24.

Figure 3-24. SEMCO Model 250 Sealant Gun

(3) Vacuum Cup. These are used for vacuum the disbond or delamination is too close to the edge of
injection of liquid resin in fastener hole delaminations, the part to allow injection holes to be drilled, or when
edge delaminations and disbonds. It is useful when little or no airflow is possible. The equipment can be

3-32

locally fabricated from plastic pipe, a clear Plexiglas
plate, vacuum bag sealant tape, the connector from
a vacuum valve assembly and a piece of threaded
Figure 3-25. Vacuum Cup
g. Wiping Cloths. Wiping cloths must be low lint
and manufactured from material free of contaminates
such as cotton seed oil, fabric sizing, flame retardant
chemicals, and silicone. Cloths conforming to AMS
3819, Class 1, 2 or 3, Grade A and Federal Spec-
ification CCC-C-46 Type 1, Class 7, have passed
solvent extraction, linting, and silicone contamination
tests and are acceptable. Do not use other types,
classes or grades for adhesive bonding applications.
NOTE
Isopropyl alcohol must be reagent grade or
technical grade due to the unacceptable water
content in lesser grades.
h. Solvents. Always use the purest grade of sol-
vent available; order of preference is: reagent grade
(A-A-59282); technical grade (same as commercial
grade); and general purpose. Acetone and isopropyl
alcohol are suitable solvents for surface preparation
for adhesive bonding of advanced composites. Methyl
Ethyl Ketone is suitable; however, it is being phased
out due to environmental concerns. Only use wash
bottles designed for the particular solvent being used.
Other types of plastic bottles may leach plasticizer
out and contaminate the bonding surface.
i. Kraft Paper. Kraft paper is used to protect
precured patches and parts from contamination. The
TM 1-1500-204-23-11
pipe. Wrap all male fitting threads with pipe sealing
tape, A-A-58092. See figure 3-25.
paper must not be coated with wax or oil. Barrier
paper or vacuum bagging materials may be used in
lieu of kraft paper.
NOTE
Desiccant can be reactivated by drying in an
oven at 150 to 200 °F until the color change
is reversed.
j. Moisture Indicator. The moisture indicator is
used to determine if a part is dry following the
composite honeycomb sandwich part drying cycle
specified in Chapter 6. It uses a color changing
desiccant to indicate the presence of moisture. The
indicator consists of vacuum valve couplings, an
airline filter, color changing desiccant and rymple
cloth. It is essential that the desiccant consist of
calcium sulfate containing cobalt chloride as this is
the ingredient that causes the blue to pink color
change indicating the presence of moisture. Use of
a desiccant material without cobalt chloride will result
in a false dry indication. The desiccant must be fresh
and blue in color prior to use. Replace the desiccant
after each use. Maintain the desiccant in a moisture
proof sealed container. See figure 3-26.
3-33
TM 1-1500-204-23-11
Figure 3-26. Moisture Indicator
k. Adhesive Comb. The adhesive comb, figure
3-27, is used to remove excess adhesive from bonding
surfaces. The comb remains perpendicular to the
Figure 3-27. Adhesive Comb
Do not use oil based coolant. Do not use any
type of coolant when holes will penetrate into
bonded honeycomb or foam core structure.
l. Coolant. Coolant can be used in conjunction
with the cutting tool to ease the cutting process by
removing debris and reducing heat buildup. A high
pressure, light spray mist of water or air can be
3-34
surface as it is drawn across the surfaces containing
paste adhesive.
used when drilling and reaming laminates alone or in
combination with metallic substructure. Non-oil based
lubricants such as BOE-LUBE, cetyl alcohol, and
oil-free Freon may be used when authorized by the
system specific technical manual. Coolant becomes
more important as the thickness of the laminate
increases. The composite should not exceed 140
°F during drilling or machining. Often, holes can be
drilled successfully on thin carbon laminates without
the use of coolant. Coolant use is mandatory when
 TM 1-1500-204-23-11

machining boron fiber reinforced materials. Do not use

coolant when cutting or drilling honeycomb structures.

3-35/(3-36 blank)

CHAPTER 4
COMPOSITE MATERIALS
4-1. COMPOSITE MATERIALS. To produce the
required strength characteristics, advanced compos-
ites rely on a combination of matrix type, fiber type,
ply orientation, and processing method. All fibrous
materials are characterized as having strength par-
allel to the fiber direction and a lack of strength
perpendicular to the fiber direction. Plywood was the
first practical laminated composite material, formed
by laying plies in two directions. Fiberglass brought
improved structural strength to this class of materials.
The much stiffer fibers of boron and carbon have
given composite materials structural properties supe-
rior in several ways to the metal alloys they have
replaced. The term ADVANCED applies to these and
other composites, which have fibers of high stiffness
and strength. The development of advanced compos-
ite materials has been accompanied by a substantial
improvement in the theory required for an adequate
understanding of laminated composites. This theory
may be applied equally well to fiberglass composites.
The same is true of research in composite repair
technology. In this manual, the adjective ADVANCED
will be implied, although the adjective may not be
used. This manual refers specifically to composite
materials with fibers oriented in selected directions
rather than those composites with fibers of random
orientation, though at times random fibrous materials
would also be utilized in particular systems.
a. Thermoset and Thermoplastic Materials. The-
re are both thermoset and thermoplastic matrix mate-
rial systems being used in the construction of advanced
composite parts. Thermoset materials are systems
that take a permanent set or shape when cured. Cure
temperatures range from room temperature to 350
º F for polyesters, vinylesters, epoxies, and cyanate
esters, around 450 º F for Bismaleimide (BMI) mate-
rials, and close to 700 º F for polyimides. Cure
pressures are usually less than 100 pounds per square
inch (psi). Thermoplastic materials are noncuring sys-
tems that can be reshaped or reformed after the part
has been processed or consolidated. Reshaping is
TM 1-1500-204-23-11
accomplished by reheating the part until the material
softens and applying pressure to produce a newly
molded shape. Thermoplastics are consolidated at
temperatures up to 800 º F and pressures up to 200
psi. Continuous length fiber/thermoplastics are not
common, but are seen at times. Refer to system
specific repair manuals for repairs to thermoplastic
systems.
b. Advanced Composite Structure. A structure
constructed by combining fibers in specific orientations
with a resin to form a solid shape. Structures made
exclusively from chopped fiber are not considered to
be advance composite structures; however, chopped
fibers could be part of an advanced material system.
c. Pre-preg. Pre-preg material is the basic build-
ing block of most advanced composites. It consists of
fibers preimpregnated with a partially cured (B-staged)
matrix material. It is supplied by a pre-preg manufac-
turer in thin sheets in two different forms, unidirec-
tional pre-preg (fibers all in one direction) and woven
pre-preg (fibers woven into a specified weave style).
The fibers in both of these forms are continuous.
d. Laminate. Considering its light weight, a lamina
(ply) of fiber reinforced composite is remarkably strong
along the fiber direction. However, the same ply is
considerably weaker in all off fiber directions. To
address this issue and withstand loadings from multiple
angles, aircraft structure is manufactured by laminating
plies of composite, usually pre-preg. Plies are cut
to the required orientation and shape and stacked
together in specified directions to obtain the required
stiffness and strength. To obtain repeatable laminate
properties, approved manufacturing operations must
be followed to exacting detail. This stack up is then
cured using heat and pressure to form a solid laminate.
Process control is essential for manufacturing basic
structural materials such as aluminum or composite
laminates. See figure 4-1 for laminate details.
4-1
TM 1-1500-204-23-11

Figure 4-1. Laminate

e. Sandwich Construction. An advanced com- structural properties of sandwich construction. The

posite structure consisting of two face skins sep-
arated by a lightweight core material is known as
sandwich construction. This construction is capable
of the highest strength to weight and rigidity to weight
ratios presently obtainable by ordinary design meth-
ods. Designers of missiles, air and spacecraft, and
ground support equipment rely heavily upon the unique
flexibility and versatility of sandwich construction can
solve many design problems. Specific design require-
ments can be matched through proper selection of
skin and core materials as well as their thickness,
density, and orientation in relation to the sandwich
construction span. See figure 4-2 and figure 4-3 for
sandwich construction details.

Figure 4-2. Sandwich Construction

4-2
 TM 1-1500-204-23-11

Figure 4-3. Structural Property Comparison

4-2. FIBERS. The primary function of the fibers is to
carry load and to provide the required part stiffness.
Carbon, boron, fiberglass and aramid (Kevlar®) are
the most common fibers in use on aircraft. Individual
fibers are bundled together into groups. These groups
are called strands for fiberglass products and tows
for carbon. Larger fiber groups consisting of multiple
strands or tows are called yarns when twisted or
rovings when not twisted. Strands, tows, yarns,
and/or rovings are combined in different ways to
make different types of fabric. The fabric may be
coated or left unfinished. Some fabrics, such as
fiberglass, require a finish to bond properly to the
resin matrix. The type of finish used depends on the
resin type to be used (i.e., epoxy, polyester, phenolic).
Finish should not be confused with the size (or sizing)
applied to the fibers during the weaving process. See
figure 4-4 for fiber terminology.

Figure 4-4. Fiber Terminology

4-3
TM 1-1500-204-23-11
a. Carbon. Carbon and graphite fibers are made
from organic materials. The two major types of carbon
are pitch based or those derived from synthetic fiber
precursors. The fibers are manufactured by heating
these precursor filaments in a controlled atmosphere
to drive off hydrogen and other non-carbon atoms.
Depending on processing, the strength and stiffness
of the fibers can be modified. Carbon fibers and
graphite fibers differ in the temperature at which the
fibers are made and heat treated, and the amount
of residual carbon left behind. Carbon fibers typically
are heated to about 2400 °F and are 93 to 95%
carbon, while graphite fibers are heated to between
3450 to 5450 °F and are more than 99% carbon.
This results in different properties for each mate-
rial. Due to these different properties, carbon fibers
are not necessarily interchangeable, similar to differ-
ences between 2024-T3 and a 7075-T6 aluminum
alloys. While they’re both aerospace grade aluminum
alloys, they have very different strength and stiffness
properties and are not generally considered inter-
changeable. The most desirable property for high
performance structures is the stiffness to weight ratio.
Fiber bundles (tows) are identified by the number of
fibers in the bundle by thousands. For example, 12
K tow contains 12,000 fibers. Carbon is available
in any fabric form listed in paragraph 4-3. Carbon
fibers are always dark gray or black in color. They
are moderately flexible. Carbon fibers have a high
potential for causing galvanic corrosion when used
with metallic fasteners and structures.
b. Aramid. Kevlar® is DuPont’s trademark name
for aramid fibers. This type of fiber is produced
from two liquid chemicals using a complex process
resulting in spun filaments. Aramid is an organic fiber
that is 43 percent lighter than and twice as strong in
tension as glass. One of the outstanding properties
of aramid is toughness; therefore, it is often used
for ballistic protection and body armor. Aramid fibers
are generally weak in compression and difficult to
cut due to fuzzing. Bundles of aramid fibers are not
designated by the number of fibers but by the weight.
The weight term (denier) is defined as the weight in
grams of 9000 meters of filament. Aramid fibers are
available in any fabric form listed in paragraph 4-3.
Aramid is naturally yellow in color and darkens when
exposed to ultraviolet (UV) radiation with degraded
properties.
c. Fiberglass. Fiberglass is made from glass mar-
bles melted and spun or extruded through tiny holes
into fibers. Glass is an inorganic material that will not
burn and will not support combustion. These fibers
normally appear white and any color may be added
during manufacture. Glass fibers are very flexible
and may be woven, draped or formed to almost any
contour. The most common types of fiberglass are
S-glass and E-glass.
4-4
d. Quartz. Quartz fiber is similar to fiberglass but
is far less “visible” to radar, a property known as
transmissibility. Because of this, the primary use of
quartz is the construction of radomes. Quartz is
also used for high temperature applications in the
neighborhood of 700 º F. These fibers are clear but
appear white and may be dyed any color during
production. Quartz fibers are available in any fabric
form listed in paragraph 4-3.
e. Boron One of the stiffest and strongest rein-
forcing fibers is boron. The boron fiber is 0.005 inch
in diameter. It is made by chemical vapor deposition
of elemental boron onto a cleaned 0.0005 inch diam-
eter tungsten filament. The boron fiber has a high
bending stiffness and cannot be bent around an object
any smaller than the diameter of a dime. Due to this
relatively high bending stiffness, boron fibers cannot
be woven into cloth or used for complex contoured
parts. Boron’s high tensile and compressive strength
plus its lack of galvanic corrosion potential makes the
fiber very popular for repairs to cracked metallic struc-
tures. Boron is only available as pre-impregnated,
unidirectional tape.
f. Polyethylene. This fiber is sold under the trade-
mark Spectra® or Dyneema®. The fibers are the
same as those found in plastic milk containers but
are processed to align the molecular structure. The
material is used in composite armor. Polyethylene is
naturally clear but appears white and may be dyed
any color during production. These fibers are avail-
able in any fabric form listed in paragraph 4-3. To
make polyethylene fibers bondable, they are usually
corona treated. The treatment strips electrons to cre-
ate more chemically bondable sites.
4-3. FIBER FORMS. Most composite materials are
available in two basic forms: unidirectional materials
or woven fabrics.
a. Fabrics. Most fabrics are classified by their
areal weight, usually in ounces per square yard or
grams per square meter. The areal weight is based on
the fiber, tow size and weave density measured in tows
per inch or centimeter. Repair fabrics will be specified
not only by the fiber type, tow size and weave style,
but also the areal weight. Differences in areal weight
affect the structural performance composite. Two
fabrics with the same fiber, tow size and weave style
are not necessarily interchangeable due to differences
in areal weight. Additionally, a single ply of fabric has
strength in not just one, but two directions (See figure
4-5). This is due to the simple fact that weaving is
the interlacing of yarns, or tows in a distinct pattern,
usually at 90º to each other. The fabric’s integrity
is maintained by the mechanical interlocking of the
yarns. Drape (the ability of a fabric to conform to a
 TM 1-1500-204-23-11

complex surface), surface smoothness, and stability weaves. The following is a description of some of
of a fabric are controlled primarily by the weave style. the more commonly found weave styles.
See table 4-1 for a qualitative comparison of different

Figure 4-5. Warp vs. Fill Fibers in a Roll of Fabric

4-5
TM 1-1500-204-23-11

Table 4-1. Qualitative Comparison of Fabrics

Property Plain Twill Satin Basket Leno Mock Leno

Good Stability **** *** ** ** ***** ***
Good Drape ** **** ***** *** * **
Low Porosity *** **** ***** ** * ***
Smoothness ** *** ***** ** * **
Balance **** **** ** **** ** ****
Symmetrical ***** *** * *** * ****
Low-crimp ** *** ***** ** **/***** **
***** = excellent, **** = good, *** = acceptable, ** = poor, * = very poor

(1) Plain Weave. Each warp yarn passes alter- the pattern repeats. A 4 X 4 Twill weave is also
nately under and over each fill yarn. The fabric is available. See figure 4-7.
symmetrical, with good stability and reasonable poros-
ity. Plain weave is the most difficult to drape, and the
high level of fiber crimp imparts relatively low mechan-
ical properties compared with the other weave styles.
With large fiber bundles, this weave style gives exces-
sive crimp and, therefore, it is not usually used for
heavy fabrics (over 24 ounces per square yard). See
figure 4-6.

Figure 4-7. Twill Weave (2X2 Twill Shown)

(3) Harness Satin Weave. Harness Satin

Figure 4-6. Plain Weave
(2) Twill Weave. One warp yarn is alternately
woven over and under two fill yarns in a regular
repeated manner offsetting the over and under pattern
by a single yarn with each pass. This produces a
distinctive visual effect of a broken diagonal rib in the
fabric. Superior drape properties are seen in the twill
weave over the plain weave with only a small reduction
in stability. With reduced crimp, the fabric also has
a smoother surface and slightly higher mechanical
properties. Twill is classified by the number of fill
yarns crossed under and over by the warp fiber before
weaves were first produced in China over a thou-
sand years ago. The weave style was designed to
enhance the appearance of silk making it appear to
shimmer in the light. This is accomplished by limiting
the interlacing of warp and fill yarns to a fraction
of that seen in plain weave fabrics. For example, if
we follow a warp yarn (horizontal) in figure 4-8, we
see that it interlaces (goes under) only one fill yarn
every three it goes over. Three plus one equals four,
thus this weave style is known as a four-harness
satin weave. Weaving a fabric in this way creates
a material on which we see three-times as much of
the warp yarns on one side of the fabric as we do
on the other. This is referred to as the “warp face”
of the fabric. Conversely, on the other side of the
fabric we see three times as much of the fill yarns
traveling at 90 degrees to their counterparts. Harness
satins typically available for use in composites are
four-harness, five-harness, and eight-harness satins
(figure 4-8 ).

4-6

Figure 4-8. Satin Weave (4 & 8 Harness Satin Shown)
Having so many yarns running straight and
parallel gives the surface its distinct shimmer, but it
also helps improve the overall strength of the material
when used in composite laminates. Another advantage
to harness satins is an increase in a property known
as “drape”. Plain weave fabrics exhibit poor drape
properties and often have to be relief-cut when used to
make parts with complex shapes in order to get them to
lay flat and avoid wrinkles. Relief-cuts are generally
undesirable as they tend to weaken the structure.
On the other hand, satin weaves are known for their
exceptional drape properties and are the fabrics of
choice for parts having compound curves or complex
TM 1-1500-204-23-11
shapes. Generally speaking, the higher the “harness
number, the more drapability a fabric will have. For
example, an eight-harness satin will usually conform
to more complex geometries than will a four-harness
satin.
The use of harness satins poses a small prob-
lem when trying to design a symmetric laminate. Con-
sider an eight-harness satin fabric, it is essentially row
upon row of warp yarns only loosely interlaced with
the fill yarns running the opposite direction (only every
eight yarn). The net result of this is a fabric that, in
and of itself, is not symmetrical. This is of particular
4-7
TM 1-1500-204-23-11
concern when working with carbon fiber laminates.
If care is not taken when designing laminates using
harness satins, the thermal stresses generated during
Figure 4-9. Example Satin Weave Showing Alternating Warp and Fill Faces Used for Lamination
b. Unidirectional Materials. Unidirectional materi-
als fall into one of two categories; unidirectional tapes,
and unidirectional fabrics.
(1) Unidirectional Tapes. Unidirectional tapes,
or uni-tapes, come in a variety of widths to suit the
manufacturer’s needs. The thickness of a ply of carbon
unidirectional tape is usually expressed as a function
of its areal weight per square meter. For instance,
Grade 145 uni-tape weighs 145 grams per square
meter and its cured thickness is approximately .006”.
Carbon uni-tape is generally available in Grades 95,
145, 160, 180, and 190. Since there are no cross
fibers at all in uni-tape it is usually only available in
pre-preg form.
4-8
the cure cycle may cause the part to warp and twist
severely. See figure 4-8 and figure 4-9.
(2) Unidirectional Fabric. A unidirectional
(UD) fabric is one in which the majority of fibers run
in one direction only. Unlike unidirectional tapes, a
small amount of fiber or other material may run in
other directions in order to hold the primary fibers in
position. These cross fibers afford some structural
properties, but their primary contribution is that they
make it possible to deliver unidirectional fabrics as
dry broadgoods. In unidirectional fabric construction;
there are various methods of maintaining the primary
fibers in position in a unidirectional including weaving,
stitching, and bonding. Some weavers of 0/90-degree
fabrics term a fabric with only 75 percent of its weight
in one direction as a unidirectional, while for others
the unidirectional designation only applies to those
fabrics with more than 90 percent of the fiber weight
in one direction. True unidirectional fabrics offer the
 TM 1-1500-204-23-11

ability to place fiber in the component exactly where

it is required and in the optimum quantity desired.
UD fibers are straight and uncrimped. This results
in the highest possible structural properties in fabric
composite construction. As with other fabrics, the
surface quality of a unidirectional fabric is determined
by two main factors: the combination of fiber bundle
size and thread count of the primary fiber as well
as the amount and type of the secondary fiber. The
drape, surface smoothness, and stability of a fabric
are controlled primarily by the construction style, while
the areal weight, porosity, and (to a lesser degree)
wet-out are determined by the number of fibers per
inch or centimeter.

(3) Braids. Braiding is a system of three or

more yarns intertwined in such a way that no two
yarns are twisted around one another. In practical
terms, braid refers to a family of fabrics continuously
woven on the bias. There are four main braid forms
and four main braid architectures available. The acute
angle measured from the axis of the braid to the axis
of the bias yarns is called the braid angle. This angle
is also referred to as the fiber angle or the bias angle.
The braiding process allows for the introduction of
axial yarns between the woven bias yarns. These
axial yarns are not crimped by the weaving process.
See figure 4-10.

Figure 4-10. Braid

(a) Braid is most commonly manufactured

and used as a freestanding, tubular
fabric with a constant braid angle for a
given diameter. In this form, it is sup-
plied on reels or festooned in cartons.
In composite manufacturing, tubular
braids are typically expanded open dia-
metrically, applied to a molding tool or
core, snugged down (using the Chi-
nese finger trap effect), impregnated
with resin, and then consolidated. For
pultrusion, tubular braids are continu-
ously fed over a die mandrel to produce
hollow cross sections. Flat braids are
used primarily for selective reinforce-
ment, such as tabbing in boat building
and strengthening specific areas in pro-
truded profiles.

4-9
TM 1-1500-204-23-11
(b) Braided fiber architecture resembles a
hybrid of filament winding and weaving.
Like filament winding, tubular braid fea-
tures seamless fiber continuity from end
to end of a part. Like woven materials,
braided fibers are mechanically inter-
locked with one another. The combi-
nation, however, is quite extraordinary.
When functioning as a composite rein-
forcement, braid exhibits remarkable
properties because it is highly efficient
in distributing loads. Because all the
fibers within a braided structure are
continuous and mechanically locked,
braid has a natural mechanism that
evenly distributes load throughout the
structure.
(c) With regard to strength and stiffness,
properly molded biaxial braided com-
posites exhibit properties that are
essentially identical to unidirectional
tape laminates of the same orienta-
tion and fiber volume. Because of
the load distributing feature inherent
in braided reinforcement, there is no
design strength reduction due to fiber
crimp. This phenomenon is limited to
triaxial constructions that have signifi-
cant fiber volume in the axial direction.
The laid in axial yarns force added crimp
in the bias yarns, causing the biases to
lose in plane properties. The axial fibers
also tend to inhibit the distribution of
loads within the laminate, yielding lower
breaking strength. However, triaxial
constructions are very cost effective in
a myriad of applications because the
automated formation of complex net
shape preforms frequently affords more
savings than the additional cost asso-
ciated with the fiber needed to meet
design loads.
(d) Braid’s efficient distribution of loads
also makes braided structures very
impact resistant. Since all the fibers in
the structure are involved in a loading
event, braid absorbs a great deal of
energy as it fails. This is why braid is
used for energy absorbing crash struc-
tures, ballistic applications, and fan
blade containment in aircraft engine
applications.
(e) Braided structures are also excellent
with regard to fatigue. Like a filament
wound structure, braided fibers are
4-10
coiled into a helix. The difference, how-
ever, is the mechanical interlocking. As
a structure is exposed to high fatigue
cycles, cracks will propagate through
the matrix of filament wound or unidirec-
tional pre-preg laid up structures. While
micro cracking will occur in a braided
structure, the propagation is arrested
at the intersections of the reinforcing
yarns. This is why braid is the reinforce-
ment choice for aircraft propellers and
stator vanes in jet engines.
(f) Braid greatly improves interlaminar
shear properties when nested together
with other braids. While interlaminar
adhesion is no different from other rein-
forcement products, the layers move
together. As a result, it is very rare for
cracks to form and propagate between
layers of braided reinforcement. Since
braids are woven on the bias, they
provide very efficient reinforcement for
parts that are subjected to torsional
loads. Braid is an ideal reinforcement
for drive shafts and other torque trans-
fer components such as flanged hubs.
(g) Since braiding is typically done with dry
fiber, resin transfer molding is used to
apply resin to the preforms. The braided
preform is placed in a closed die and
liquid resin is injected. Resin transfer
molding uses very low viscosity resins,
many times bismaleimide based, even
though the high temperature capability
of the resin is not required.
c. Filament Winding. Filament winding involves
wetting out a continuous tow of fiber as it is wound
around a mandrel. Each circuit of winding is at
prescribed angles to achieve the desired structural
properties. The mandrel rotates to insure coverage
around the part while the application head transverses
longitudinally. The fiber is wet-out just prior to being
wound. Cylindrical or spherical parts, such as pres-
sure vessels, are commonly manufactured by filament
winding. This type of construction is typical in rocket
motor casings and is usually found in aircraft appli-
cations on external fuel tanks and drive shafts.
d. Stitched Multiaxial Fabrics. In recent years,
multiaxial fabrics have begun to find favor in the
construction of composite components. These fabrics
consist of one or more layers of long fibers held in
place by a secondary, nonstructural stitching thread.
The main fibers can be any of the structural fibers
available in any combination. The stitching thread is
usually polyester due to its combination of appropriate

fiber properties (for binding the fabric together) and
cost. The stitching process allows a variety of fiber
orientations, beyond the simple 0/90 degrees of woven
fabrics, to be combined into one fabric. Multiaxial
fabrics have the following main characteristics:
(1) Advantages. The two key improvements
with stitched multiaxial fabrics over woven types are
better mechanical properties and improved compo-
nent build speed. Better mechanical properties result
from the fact that the fibers are always straight and
noncrimped, and that more orientations of fiber are
available from the increased number of layers of fab-
ric. Component build speed is improved because the
fabrics can be made thicker and with multiple fiber
orientations so fewer layers need to be included in
the laminate sequence.
(2) Disadvantages. Polyester stitching fiber
does not bond well to some resin systems, so the
stitching can be a starting point for wicking or other
failure initiation. The fabric production process can
also be slow and the cost of the machinery high. This,
together with the fact that more expensive, small, fiber
bundles are required to get good surface coverage
for the low weight fabrics, means the cost of good
Figure 4-11. Weave and Stitch Process
(b) Simultaneous Stitch. Simultaneous sti-
tch manufacture is based on the knitting process.
Fibers are drawn simultaneously along each axis/layer
until the required layers have been assembled, and
TM 1-1500-204-23-11
quality stitched fabrics can be relatively high com-
pared to wovens. Heavyweight fabrics, while enabling
large quantities of fiber to be incorporated rapidly into
the component, can also be difficult to impregnate
with resin without some automated process. Finally,
the stitching process, unless carefully controlled, can
bunch together the fibers, particularly in the 0 degree
direction, creating resin rich areas in the laminate.
(3) Stitched Fabric Construction. The most
common forms of this type of fabric are weave and
stitch, and simultaneous stitch.
(a) Weave and Stitch. With the Weave and
Stitch method, the +45 and -45 degree layers can be
made by weaving fill unidirectionals and then skewing
the fabric to 45 degrees. A warp unidirectional or a
fill unidirectional can also be used unskewed to make
a 0 and 90 degree layer. If both 0 and 90 degree
layers are present in a multilayer stitched fabric, this
can be provided by a conventional 0/90 degree woven
fabric. Because heavy rovings can be used to make
each layer, the weaving process is relatively fast, as
is the subsequent stitching together of the layers via
a simple stitching frame. See figure 4-11.
then stitched together, as shown in figure 4-12. Unlike
the weave and stitch method, each layer is unidirec-
tional rather than woven.
4-11
TM 1-1500-204-23-11
Figure 4-12. Simultaneous Stitch Process
4-4. LAMINATING RESINS AND STRUCTURAL
ADHESIVES. The material that binds and supports
the fibers in the laminate is called the matrix. We
use the term “laminating resin” to refer to any of the
two part, thermoset plastic resins that are typically
used as matrix materials in composite laminates.
a. Laminating Resins. While there are many
matrix resin chemistries available (see paragraph 4-5)
epoxy is by far the most common resin system found
in Army aviation. Epoxies used as laminating resins
tend to be fairly low viscosity (generally less than
5000 CPS) meaning they’re fairly “thin” or “runny”.
This is necessary in order to thoroughly saturate the
fibers and allow air and other gasses to escape as
the resin cures. This lower viscosity often affects the
resin’s adhesive characteristics to a small degree, but
it’s worth the trade off to get a high quality laminate.
b. Structural Adhesives. Superior adhesive prop-
erties are the primary consideration when making
structural adhesives. Thinner materials generally move
away from the bondline where it is needed. Higher
viscosity is almost always a feature of structural adhe-
sives when compared to laminating resins. Structural
adhesives are often thickened by the addition of
either fillers or a chemically reactive modifier. These
adhesives are used for adhesively bonding structures
together, bonding in core materials, as well as repair
patches. They are also used as a “liquid shim” in a
bonded or bolted structure to fill any gaps left during
assembly. Both laminating resins and structural adhe-
sives are two component systems that require careful
weighing and thorough mixing to ensure strength is
not compromised. Because of their different viscosi-
ties, laminating resins and structural adhesives are
4-12
not interchangeable unless specifically authorized by
engineering.
c. Crosslinking. Once mixed, two part thermoset
resin systems like epoxy undergo a chemical reaction
known as “cross-linking”. Cross-linking occurs at the
molecular level and binds the molecules of component
A with those of component B forming a solid over a
period of time. When the cross-linking is complete the
resin is said to be fully “cured”. Like most chemical
reactions, cross-linking can be accelerated with heat,
thus reducing the cure time. For example, an epoxy
that normally cures in 5 days at room temperature
(77 °F) may be fully cured in only 1 hour at 180 °F.
d. Fiber-dominated Properties. Fiber-dominated
properties are those physical properties of the lam-
inate that are governed by the properties inherent
in the fibers used, i.e. carbon fiber, fiberglass, or
Kevlar®. Tension and flexural strength are fiber-dom-
inated properties.
e. Matrix-dominated Properties. Just as we have
fiber-dominated properties in a laminate, we also
have matrix-dominated properties. Matrix-dominated
properties are those physical properties of the laminate
that are governed by the properties inherent in the
matrix used. Compression, shear, and interlaminar
shear are all matrix-dominated properties as is service
temperature.
f. Service Temperature. Whether used in man-
ufacturing or repair, one of the most important
matrix-dominated properties for selecting an epoxy
is the anticipated service temperature of the part.

Generally speaking, the fibers in most composite
laminates are capable of much higher temperatures
than matrix resins. For example, the very best epoxy
resins are only capable of temperatures around 400
°F, while the carbon fibers used to make a laminate
are capable of many times that. The service temper-
ature of any given resin system is determined in a lab
and has a relationship to the resin’s glass transition
temperature, or Tg. The Tg is the temperature at
which the resin goes from being a “glassy solid” to a
softer, rubbery solid. This is the point that the resin
begins to degrade and, in most cases, is permanently
compromised.
4-5. RESIN TYPES. The following paragraphs pro-
vide a general description of the types of resins and
adhesives; always refer to the manufacturer’s material
data sheet for specific information on the product you
are using.
a. Epoxy. Epoxy resins are probably the most
common two part system available. The majority of
advanced composite parts in aircraft applications use
epoxy resins as the matrix material. Epoxies generally
exhibit excellent physical properties, good adhesion,
low shrinkage, good impact resistance, and good
chemical and moisture resistance. Depending on the
actual composition, epoxy can be cured anywhere
between 70 and 350 °F with a corresponding range
of Tg from 200 to 400 °F. Table 4-2 provides shelf
life data for several common two part epoxies.
b. Bismaleimides. Bismaleimide resins are inter-
mediate service temperature polyimide resins. They
typically cure at 375 to 450 °F and have a service
temperature of 350 °F. Generally, they are used on
areas of the aircraft that experience operating tem-
peratures in excess of 250 °F but less than 350 °F.
BMI resins combine a number of unique features,
including excellent physical property retention at ele-
vated temperatures and in wet environments; almost
constant electrical properties over a wide range of
temperatures, and nonflammable properties. BMIs
have epoxy like processing characteristics yet have
a higher temperature use limit. One challenge when
repairing a BMI part is the very low viscosity the resin
reaches during cure. Special bagging precautions are
required to prevent over bleeding a BMI repair and
the high cure temperatures.
c. Polyimides. Polyimide resins used as matrix
materials are high service temperature resins. They
cure at 650 °F and have a service temperature of
550 °F. Polyimides are difficult to process due to
their complex cure chemistry, but they provide high
thermal stability, excellent mechanical properties, and
TM 1-1500-204-23-11
nonflammable characteristics. PMR polyimide materi-
als have seen very limited use as matrix materials and
have been used exclusively on engine components.
d. Cyanate Esters. Cyanate esters are a family
of high temperature thermosetting resins that bridge
the gap in thermal performance between epoxies and
polyimides. In the uncured state, cyanate ester resins
are prone to moisture absorption which adversely
affects the physical properties of the cured resin.
Many of the beneficial characteristics of cyanate ester
resins contrast with those of epoxies. Properties
of cyanate esters include lower moisture absorption,
higher diffusibility, low cure shrinkage, low coefficient
of thermal expansion, and low dielectric constant and
dielectric loss when compared to epoxy and BMI.
These attributes are particularly useful for structures
with stable moisture and thermal properties, radomes,
and low dielectric applications. Cynate ester repair
resins may also reach very low viscosities during cure
which require special bagging precautions to prevent
over bleeding the repair.
e. Vinyl Esters. Vinyl ester resins are thermoset-
ting resins that are a combination of polyester and
epoxy structures. Vinyl esters have the appearance,
handling properties, and curing characteristics of con-
ventional polyester resins. Corrosion resistance and
mechanical properties are improved over polyester
due to the epoxy structure in the resin.
f. Polyesters. Polyester resins are formed by the
reaction of dysfunctional acids and alcohols. While
common in the sporting goods and marine industries,
polyesters are rarely found in Army Aviation since they
lack the necessary strength and service temperature
properties. Polyesters are not acceptable substitutions
for epoxies. Polyesters also give off hydrogen cyanide
gas when burned and are therefore never used for
interior aircraft parts.
g. Thermoplastics. Thermoplastics are long
chained carbon molecules that do not crosslink like
thermoset resins. Most industrial plastics, such as
polyethylene, polycabonate, or acrylic, are thermo-
plastics and usually soften at lower temperatures
than thermosetting resins. Polycarbonate and acrylic
are commonly used for aircraft windows. Engineered
thermoplastics, such as polyetheretherketone (PEEK)
have not yet been used on Army aircraft for structural
applications. Temporary thermoplastic repair patches
which soften when mild heat is applied can be used
for secondary structure repair to provide an environ-
mental enclosure until a permanent repair can be
made.
4-13
TM 1-1500-204-23-11
4-6. SHELF LIFE. Material which exceeds its shelf
life must not be used. Shelf life extensions may be
granted if the material is laboratory tested. Often this
is not cost effective or practical for field units. Contact
engineering to determine if material that is beyond
its shelf live can be used. DoD databases may have
data to support extending the shelf life. Shelf life of
resins stored at room temperature can be assured
by avoiding excessive heat; i.e., store laminating
resins and paste adhesives in an air conditioned
4-14
room. In some cases, manufacturers offer extended
shelf life when their product is stored at reduced
temperatures; consult the manufacturer’s technical
data sheets and consider how the material was stored
(locally and within the greater supply system) before
altering storage temperature and/or shelf life based
on local storage temperature. Avoid storage at high
temperature to maximize shelf life. Table 4-2 lists the
shelf life for various epoxy adhesives.
 TM 1-1500-204-23-11

Table 4-2. Shelf Life Data for Common Two-Part Epoxy Adhesives

Material 90 °F 77 °F 40 °F 0 °F
Part A 1 month 3 months 12 months
EA956/EA9321
Part B 12 months 12 months 12 months
Part A 12 months
EA9309.3 NA
Part B 12 months
Part A 2 months 3 months 12 months 12 months
EA934NA
Part B 12 months 12 months 12 months 12 months
Part A 12 months
EA9394
Part B 12 months
Part A 12 months 12 months
EA9396
Part B 12 months 12 months
Part A 2 months 6 months 12 months
EA9390
Part B 12 months 12 months 12 months
Note: Values are based on the manufacturer’s material data sheets.

4-7. POT LIFE. The pot life of an adhesive is the
amount of time elapsed between the time a two part
adhesive is mixed and when the material hardens
into an unworkable state. Each adhesive has a
different pot life which must be taken into account
when accomplishing a repair. Table 4-3 lists pot life
data for common two part adhesive systems. The
pot life figures listed for any given resin system are
usually determined at room temperature. Since the
chemical reaction of crosslinking is accelerated with
heat, pot life is reduced at elevated temperatures.

Table 4-3. Pot Life Data for Common Two-Part Epoxy Adhesives

Pot Life @ 77 °F Maximum Amount to Mix (grams)

Material
(see Note 1) (see Note 2)
EA956 30 minutes 250
EA9321 40 minutes 450
EA9309.3NA 35 minutes 450
EA934NA 40 minutes 450
EA9394 90 minutes 450
EA9396 90 minutes 450
EA9390 120 minutes 250
Note:
1. At 90°F these times are reduced by 50%.
2. Maximum amount to mix to prevent excessive exotherm. Values are based on the manufacture’s material
data sheets.

4-15
TM 1-1500-204-23-11
4-8. PRE-PREGS. Pre-preg offers several advan-
tages over wet layup. These advantages often lead
to a stronger repair and consist of: exact resin mix
ratio, exact resin to fiber content ratio, and ease of
handling/cutting the material. The main disadvantage
to pre-preg materials is their refrigerated/frozen stor-
age requirement and short shelf life. Since frozen
storage of pre-pregs is required, they will typically be
used only for depot repairs and manufacturing. Refer
to the system specific DMWR for more information
on pre-pregs.
4-9. ADHESIVES. Film and foaming adhesives have
required a high temperature cure cycle. They also
require frozen storage and are typically limited to
depot repairs. Refer to the system specific DMWR
for more information on film and foaming adhesives
a. Film Adhesives. Film adhesives are used in
the construction of parts manufactured from advanced
composite materials to bond honeycomb core and/or
substructure members to laminate skins. These adhe-
sives may be cocured during the laminate curing
process or they may be secondarily cured after the
laminate curing process is complete.
b. Paste Adhesives. Compared to film adhesives
, paste adhesives have the advantage of lower tem-
perature cure cycles and are easier to store and ship.
However, they have lower strength, poorer bondline
thickness control, and higher overall repair weight
than film adhesives. The base resin of many paste
adhesives requires refrigerated storage to ensure its
shelf life is not compromised; however, there are
some paste adhesives that can routinely be stored at
room temperature for 6 months to a year. Selection
of an adhesive type is dependent upon the structural
application and repair type. For example, a paste
4-16
adhesive is unsuitable as a laminating resin or for
injection repair due to its high viscosity.
c. Foaming Adhesive. Foaming adhesives (core
splice adhesives) consist of a thin, unsupported epoxy
film containing a blowing agent. During the rise to
cure temperature, an inert gas is liberated causing an
expansion or foaming action in the film. The expansion
must be performed under positive pressure to prevent
over expansion and reduced strength. Following
expansion, the adhesive is cured into a strong, highly
structured foam. It is used as a lightweight splice
material for splicing honeycomb core repair sections.
4-10. CORE. Core materials are used in conjunction
with metal or composite skins to create sandwich
panels. In these constructions, the high modulus
skins carry tensile and compressive loads while the
low density core separates the skins and carries
shear loads. Thanks in part to their core materials;
sandwich panels offer the highest strength-to-weight
and rigidity-to-weight ratios available. Core materials
are typically thick, compared to the skins, and come
in a variety of materials and geometries. Honeycomb
core is the most common core material used for
aircraft parts.
a. Honeycomb. Honeycomb core is commonly
produced from aluminum, Nomex paper, plastic, and
composite materials and is available with several types
of cell geometry. This type of core is generally lighter
than solid cores, offers flexibility for forming to part
contours; and, depending on material, offers a wide
range of temperature, electrical transmissibility/shield-
ing, and heat transfer capabilities. See Figures 4-13
and 4-14 for core nomenclature and details on nam-
ing/numbering core products.
 TM 1-1500-204-23-11

Figure 4-13. Honeycomb Core Orientation and Nomenclature

Figure 4-14. Sample Vendor Callouts for Honeycomb Core

(1) Hexagonal honeycomb core (“hex-core”) is
the most common geometry available. This product
is primarily made by strip gluing sheets of material
together into a block and slicing the block into the
desired sheet thickness. The block is then mechani-
cally expanded into a sheet of honeycomb. An alter-
nate method of hexagonal honeycomb manufacturing
is the corrugation process. In this method, adhesive
is applied to corrugated sheets of material which are
then stacked into a block and cured. The corrugation
process does not require expansion and is often used
to produce higher density hexagonal honeycombs.
(2) Over expanded honeycomb core (“OX-
core”) is extended in the W direction to create rect-
angular, rather than hexagonal, cells. This cell shape
facilitates forming to contours in the L direction.
Shear properties are increased in the L direction
but decreased in the W direction when compared to
hexagonal honeycomb (see figure 4-15).

4-17
TM 1-1500-204-23-11
Figure 4-15. Overexpanded Honeycomb Core
(3) Flexible core cell configuration (“flex—cor-
e”) results in excellent formability in compound curva-
tures with reduced anticlastic (potato chip) curvature
and cell wall buckling. When formed into tight radii,
this type of core provides higher shear strengths than
Figure 4-16. Flexible Honeycomb Cores
(4) Honeycomb Core Selection. The following
criteria are applicable for repair core material selection.
(a) Strength. To achieve the same strength,
replacement core should be of equal or higher density
than the part being repaired, be constructed of the
same material and match the part ribbon direction.
When crossing a foam splice line, the replacement
core density should be equal to or higher than the
highest density on either side of the foam splice.
(b) Material. Never use non-metallic core as
a repair core material for metallic core. Some alu-
minum cores may be used as a replacement core
4-18
comparable hexagonal cores of equivalent density.
Flexible core is available in a variety of cell shapes
and can be manufactured in most of the materials
used for hexagonal honeycomb (see figure 4-16).
for other aluminum cores, but not vice versa. See
the system specific technical manual for core repair
requirements.
(c) Service Temperature. Aluminum core is
limited to 350 ºF. Some non-metallic core is limited
to temperatures no greater than 180 ºF. Glass fab-
ric reinforced polyimide core material has a service
temperature of 500 ºF.
(d) Corrosion Protection. When repairing
metallic honeycomb core, always use corrosion resis-
tant aluminum core as the replacement core material.

(e) Machinability. Small cell size (1⁄8 inch)
repair core sections are easier to machine than larger
cell sizes as the large cell size material tends to roll
over during machining.
b. Foam Cores. Foam cores include a wide vari-
ety of liquid plastic materials that are filled with
chemically released or mechanically mixed gas bub-
bles to produce rigid forms. Several types of
foam core are available including: Polyvinyl Chloride
(PVC), Polyurethane, Polyimide, and Polymethacrylim-
ide (PMI). Foam cores are sometimes used in place
of honeycomb core. Foam core is made by dispersing
gas or hollow spheres in the case of syntactic foams,
into a solid plastic material. There are two basic
types of foam core materials: closed cell and open
cell, both available in different densities. Closed cell
foam has cells that are predominantly non-intercon-
necting; whereas, open cell foams have cells that are
interconnecting. Closed cell foams tend to be heavier
than open cell, though they do not absorb liquids
and moisture as readily. Consult your system specific
technical manual for specific types and applications
used.
(1) Foam cores are often used in sandwich
panel applications in cases where mark off on the
exposed skin is not desirable (unlike honeycomb core)
and in sandwich applications with thin edges as
the foam can be formed and handled easier than
honeycomb. Closed cell foams are typically used in
applications requiring buoyancy, insulation, and are
excellent filler materials.
(2) The type used for a specific application
depends upon temperature, cost, structural, manufac-
turing, environmental, and electrical property consid-
erations. Typically, foam cores are less expensive
than honeycomb cores; however, in similar structural
applications they are heavier. The mechanical prop-
erties of foam cores vary in an approximately linear
fashion with material density. Foams tend to have
lower mechanical properties than honeycomb for a
given weight. Closed cell foams do not absorb mois-
ture and are an excellent choice for applications in
wet or humid environments. For example, epoxies are
typically less expensive but have lower temperature
capabilities than other types. Cyanate ester based
foams have excellent resistance to moisture intrusion
and have higher temperature capabilities, but they
are also much more costly than other types. Most
of the foam cores available today are environmen-
tally friendly in terms of by products produced during
cure, handling wastes produced, and excess product.
Rohacell is light, rigid, polymethacrylimide (PMI) foam.
Its high compression modulus makes it ideal for use
as a core in high strength composite structures.
TM 1-1500-204-23-11
(3) Types of Foam Core. There are four types
of foam core used in composite repair: Infusible core,
cure in-place core, pre-cured core, and X-Cor® and
K-Cor®.
(a) Infusible Core. Recent industry interest
in the resin infusion process has ushered in a new
variety of core materials. These cores are made
primarily from polyester and are available in several
geometries. Infusible cores are formed with channels
or holes through which resin can flow and are available
in several thicknesses and with many cell (or hole)
sizes.
(b) Cure In Place Core. The cured in place
type is either injected, troweled or in frozen sheet
form. The injected foam is either premixed or a two
part mixture which is injected into place. The troweled
type is typically a two part mixture. The sheet form
is similar in consistency to taffy. All forms expand in
place upon curing. The cure in place types of foams
typically require refrigerated storage for at least one
of the mixing components. The pre-cured foams are
supplied in either rough shape or standard blocks that
can be machined to shape as required. Many repair
scenarios use injected foam to fill a repair area. After
cure, the expanded foam is trimmed to match the part
contour. In addition, syntactic two part epoxy foams
can be mixed and applied in areas as filler. Some
of these products have the capability to be cured in
5 to 10 minutes and then sanded to contour.
(c) Pre-cured Core. Pre-cured foam comes
in sheets similar to honeycomb that can be cut and
shaped to fit each repair. A pre-cured piece of foam
can be placed in the repair area, similar to the core
plug method used to repair honeycomb core, and
bonded in place using an adhesive. In these repair
methods, an overlay patch is typically placed over the
repaired core area and bonded on with an adhesive.
(d) X-Cor® and K-Cor®. X-Cor® and K-Cor-
® are variants on pre-cured foam cores. The carrier is
a PMI foam that has had pultruded fiber pins, typically
carbon, inserted at prescribed angles and locations.
In X-Cor® the pins stick out from the surface of the
foam and interlock with the composite face sheets.
Since interlocking is essential to using X-Cor®, this
material is only used in manufacturing. Structures with
X-Cor® weigh less compared to honeycomb since the
adhesive used to bond the honeycomb in manufactur-
ing is not required. K-Cor® is a denser version with
a heaver PMI foam carrier, thicker pins, more pins,
and the pins have been folded over during manu-
facture. K-Cor® has better structural properties than
X-Cor® but is also considerably heavier. K-Cor® is
used when high out of plane loads are applied to
sandwich structure, such as from a flare dispenser.
4-19
TM 1-1500-204-23-11
K-Cor® requires an adhesive to bond the core to
the face sheets similar to a traditional honeycomb.
Figure 4-17 shows an example of X-Cor®.
Figure 4-17. X-Cor®
1 When removing damaged X-Cor®
and K-Cor®, the same techniques
are used when removing honeycomb
except that embedded X-Cor® pins
must be removed from the face sheet
with a pair of pliers.
2 Repairing X-Cor® and K-Cor® use
the same procedures as other sand-
wich parts. X-Cor® can be repaired
with a pre-cured foam sheet or tra-
ditional honeycomb. K-Cor® can
be repaired with K-Cor® or honey-
comb. Pre-cured foam usually does
not have the properties required to
repair K-Cor®.
3 Since X-Cor® and K-Cor® pin orien-
tation and number of pins can be tai-
lored to a specific part design, like the
ribbon direction in honeycomb, they
do have an orientation requirement.
4 Replacement cores for one part may
not be applicable to other parts on
the aircraft with X-Cor® and K-Cor®.
Always refer to the system specific
technical manual for replacement
core selection.
4-11. LIGHTNING STRIKE PROTECTION, ELEC-
TROMAGNETIC INTERFERENCE SHIELDING AND
ELECTRICAL GROUNDING. Since composites do
not conduct electricity like metals, additional materials
are required to protect against lightning strikes and
4-20
shield electronics from electromagnetic interference
(EMI). Fiberglass is not conductive at all and car-
bon fiber is not conductive enough. Lightning strike
protection is to prevent a catastrophic failure of the
composite. The most likely electrical material that will
require repair is the lightning strike mesh. However,
electrical grounding of avionics to the structure or
modifications to install new antennas may also require
these materials.
a. Lightning Strike Protection. Lightning strike
materials are typically an expanded perforated foil or
fine mesh of copper or aluminum. While aluminum is
considerably lighter than copper, it is not galvanically
compatible with carbon fiber. The additional protec-
tive layers that are required to isolate the aluminum
from the carbon make copper the preferred choice.
Aluminum wire mesh is commonly used on fiber-
glass components. In some instances, a conductive
paint or a metallized fiberglass pre-preg, such as
Thorstrand™, is used in manufacturing for lightning
strike protection. Lightning strike protection is typically
measured in pounds per square foot. Be very careful
handling the mesh as it is easy to tear and damage
it.
DO NOT use aluminum lightning mesh on
carbon fiber composite structure.
b. EMI Shielding and Electrical Grounding. Any
electronic components that must be grounded to the
aircraft may also require provisions in the composite
structure. Electrically conductive tapes may be applied
on top of the lightning strike mesh to ground antennas
installed on the exterior of the aircraft. Conductive
adhesives may also be used to connect composite
components to existing airframe components. Prior
to bonding, the metal components are conversion
coated to promote adhesion while permitting electrical
conductivity. However, care must be taken to insure
that an electrical path between carbon and aluminum
is avoided which will corrode the aluminum. Refer
to the system specific technical manual for detailed
electrical grounding requirements. In metal aircraft,
the structure provides shielding to protect avionics
and other electrical components from EMI. Composite
components generally provide shielding through the
lightning strike protection. Extensive damage to the
shielding may require repair even if the structure does
not. Some systems use electrically conductive tape
for battle damage and repair of composite components
just to address EMI for the electronics.

CHAPTER 5
TYPICAL DAMAGE AND ASSESSMENT
5-1. OVERVIEW. Most damage to aircraft occurs on
the ground during aircraft servicing, maintenance and
handling. Impacts from dropped tools, forklifts, main-
tenance stands, dropped panels and in flight foreign
objects are major causes of damage. This chapter
addresses the critical procedures for determining how
much damage has been sustained. It covers visual
inspection, tap testing, and Nondestructive Inspection
(NDI) techniques. Although visual inspection and tap
testing technically are structures NDI methods, this
document treats them as techniques to be used by
the composite technician, not the NDI technician. The
task of repair begins when it has been determined
that a structure has been damaged and the damage
is sufficient to require the structure to be repaired.
The existence of damage may be obvious for a skin
penetration, gouge or dent. Conversely, proper iden-
tification and classification of the damage may be
difficult owing to the brittle or elastic nature of com-
posite laminate materials. For example, fibers may
break upon impact but then spring back leaving little
visible indication of damage.
a. Steps to Identify Damage. There are three dis-
tinct steps involved in damage assessment. The first
step is to locate the damage. The second is to evalu-
ate the defect to determine such information as defect
type, depth, and size. This information is important
because the method of repair will vary depending
on this information. The third step is to reevaluate,
after defect removal (as applicable), to determine that
all damaged material has been removed. While the
search for improved methods is continuing, a sat-
isfactory job of field inspection can be done using
visual and tap test inspection techniques combined
with inexpensive, easy to operate, pulse-echo ultra-
sonic equipment.
b. Causes of Damage. Damage comes from a
great many causes, such as scratching, gouging,
impact, abrasion, erosion, local chemical attack or
overheating, may affect only a few surface plies over
a large area or a depth of many plies in a smaller area.
Failure to use protective devices, such as padded
fixtures and sacrificial plies, may cause additional
damage. Inadvertent or accidental impact may occur
during the handling of parts during maintenance. The
types of damage range from small surface scratches
to more severe defects that would include punctures.
Once damage is identified, the extent of damage
must be determined and then it can be classified
to determine the disposition of the defective part.
Improper damage removal and repair techniques can
TM 1-1500-204-23-11
impart greater damage than originally sustained to
the composite material.
c. Damage Growth Potential. Whenever damage
is left in disrepair, the potential for damage growth
becomes a concern. A large amount of research has
been directed toward the potential growth of unde-
tected small damages. Growth of damage between
advanced composite materials and metallic differ in
several ways. Cracking in metal is similar to delami-
nation in advanced composite structures. Penetration
damage becomes critical in advanced composites due
to the non-isotropic nature of the material design.
Keep in mind that the potential for damage growth is
peculiar to each component on each weapon system.
5-2. INSPECTION METHODS. The following nonde-
structive methods are used to inspect composite struc-
tures to evaluate damage. The ultrasonic inspection
techniques may also be used following a bonded
repair to evaluate the adequacy of the performed
repair. Detailed information on non-destructive inspec-
tion can be found in TM 1-1500-204-23-7.
a. Visual Inspection. Visual inspection will always
play a key role in determining the extent of structural
damage. Visual inspection has the distinct advantage
in that it is inexpensive, easy, and fast. Internal
flaws such as delaminations or disbonds are not
readily detectable and require the use of ultrasonic
or tap inspection techniques. In addition, closed
surface cracks and edge delaminations may not be
detectable. Visual inspection aids such as flashlights,
mirrors, borescopes, and magnifiers may be used to
increase access or detectably of the suspect area.
Photographs can be helpful in providing a record
of visual inspection results. Penetration damage is
readily apparent. The presence of dents requires a
closer look and can be aided by using a straight
edge over a suspected dent area and comparing
the suspected dent area with the surrounding part.
The presence of cracks and edge delaminations may
sometimes be detected by wiping the edge of the
part with a solvent. If the edge is delaminated,
the solvent will wick into the delaminated area. The
solvent will evaporate on the undelaminated edge area
leaving a “wet” mark along the delaminated edge.
NDI penetrants should not be used as they may
contaminate surface cracks or edge delaminations,
foiling subsequent repair attempts. Internal flaws
such as delaminations not open to an edge and skin
disbonds cannot be detected using visual methods.
If the inspection is performed in the presence of
hazardous conditions or materials, such as aircraft fuel
5-1
TM 1-1500-204-23-11
tanks, normal safety precautions apply. Personnel who
perform visual inspections should have good eyesight
and should be familiar with the appearance of the
defects they are expected to find. Also, surfaces to be
inspected should be clean and free of all conditions
that mask or obscure defects (e.g., dirt, paint, or
other coatings).
Sandwich structures with low density cores
are particularly sensitive to impact damage.
b. Tap Testing. Judicious tapping of suspected
locations, along with careful observation, are the
5-2
first approaches to damage assessment of bonded
structures. Tap testing is widely used to evaluate the
condition of laminated and bonded structures. The
method consists of lightly tapping the surface of the
part with a coin or other suitable object and listening for
variations in the sound. Acoustic impact NDI is useful
only when the part being investigated produces distinct
differences in sound when flaws are present. It has
relatively poor resolution capability and is affected by
ambient conditions (temperature, humidity, background
noise, etc.), changes in material density or thickness,
and the presence of structural discontinuities (cutouts,
reinforcements, fasteners, etc.). Figure 5-1 shows the
typical dimensions of a tap hammer.
 TM 1-1500-204-23-11

Figure 5-1. Inspection Tap Hammer Details

5-3
TM 1-1500-204-23-11
(1) Process. The acoustic response of the
damaged area is compared with that of a known
good area. An acoustically flat or dull response is
considered unacceptable. A dull sound is a good
indication that some delamination or disbond exists,
although a clear, sharp tapping sound does not nec-
essarily ensure the absence of damage, especially in
thick panels. The acoustic response of a good part
can also vary dramatically with changes in geometry,
therefore, the geometry and interior construction of
the part must be known before performing the tap
test. If results are questionable, the technician can
compare the results to a tap test of other like parts
which are known to be good or use another inspec-
tion method. The entire area of concern must be
tapped in order to map the damage. Where multiple
bondlines exist over the core, the core bond cannot
be evaluated. In a honeycomb structure, the farside
bondline cannot be evaluated. Thus, two side access
is required for a complete inspection of honeycomb
structures. Experience has shown that areas that
provide a defect indication do in fact contain defects.
However, areas that sound good by coin tap may
still contain disbonds and delaminations and must be
inspected using ultrasonic techniques. Surfaces to
be inspected should have all oil or grease removed
and should be dry. No peculiar safety precautions
are required.
NOTE
The following summary provides an overview
only and is not sufficiently detailed for per-
forming ultrasonic or radiographic inspection
of ACM.
c. Nondestructive Inspection Method (NDI) The
following paragraphs describe the various nondestruc-
tive test methods that can be used to inspect composite
parts and repairs for defects and damage. The actual
damage detection capabilities vary with defect size,
depth, and location; part geometry; type and setup
of inspection equipment; and the skill of inspection
personnel. Conditions favorable to accurate damage
detection include uniform, thin outer skins, lack of
obstructions, shallow defect location, and small total
part thickness. The primary NDI method to detect
defects is ultrasonic testing. This method provides
an accurate definition of the defect and allows evalu-
ation by comparison to a reference standard. These
methods, along with the equipment they require, are
outlined in TM 1-1500-335-23, Nondestructive Inspec-
tion Methods. Regardless of the specific equipment
available at a particular facility, an assessment of real
or suspected damage must be made and disposition
of the structure determined. System specific tech-
nical manuals will explain the use of peculiar NDI
equipment on a particular job.
5-4
(1) Ultrasonics. This method uses high fre-
quency sound waves, called ultrasound, transmitted
into the part by a transducer placed in contact with the
part. A liquid couplant is used to eliminate air gaps
between the transducer and the part as the air gaps
interrupt sound being induced into the part. An internal
defect, such as a delamination, interrupts the sound
traveling through the laminate and an indication is
received on the ultrasonic unit indicating the presence
of a defect. Interpretation of ultrasonic inspection indi-
cations requires a reference standard made from the
same material as the part being tested and contain-
ing flaws of known size and location for comparison
purposes. Two techniques are in use in the field,
pulse-echo ultrasonics and through transmission ultra-
sonics. Ultrasonics is effective in detecting internal
flaws in a variety of materials, including parts with very
thick sections. However, the flaws must be relatively
perpendicular to the ultrasonic beam to be detected.
A disadvantage of ultrasonics for the detection of
flaws in composite materials is the high attenuation
caused by absorption in porous resin and scattering
by the fibers. Hybrid configurations pose particular
problems because the abrupt variations in acoustic
properties from one material to another tend to mask
internal flaws. Complex part geometry (variable sur-
face contours, section thicknesses, wall thicknesses,
etc.) make ultrasonic inspection difficult. Interpreta-
tion of ultrasonic test responses requires a reference
standard of the same material containing flaws of
known size and location for comparison purposes.
For some types of tests, signal gates and sensitivi-
ties must be varied in the course of the test, placing
a high demand on operator skill.
(a) Pulse-Echo Longitudinal Wave Ultra-
sonics. This is the most common technique used in
the field. It makes use of a single transducer that
sends and receives sound energy perpendicular to the
entry surface. The sound energy is reflected back to
the transducer by the initial surface of the part, by the
backside surface of the part, by interfaces between
different materials (such as composite and adhesive
interfaces) and by locations of internal defects. The
amplitude of the reflected sound wave can be used
to measure the approximate size of an internal defect
and the travel time of the reflected wave to measure
its location from the surface of the article. When
this method is used by a skilled technician, a skin
delamination can usually be distinguished from a skin
to core or skin to substructure disbond.
1 Equipment Required. The equipment
required for pulse-echo ultrasonic testing includes a
pulsed ultrasonic generator, a transducer which acts
alternately as a transmitter and receiver, and a signal
processing and display device.

2 Limitations. The pulse-echo technique
suffers many of the limitations of the through trans-
mission ultrasonic technique, i.e., the need for cou-
pling to the test article, the insensitivity to flaws that
are non-perpendicular to the beam, the difficulty of
inspecting parts with hybrid configurations or complex
geometries, the need for reliable reference standards,
and the high dependency on operator skill. Pulse-echo
NDI has the added disadvantage that flaws located
close to the surface of the part are usually obscured
by near surface resolution losses. One advantage of
the pulse-echo method over through transmissions is
that the A-scan presentation can be used to reveal
both the presence of a defect and its location relative
to the surface of the part. It also has the advantages
TM 1-1500-204-23-11
of requiring access to only one side of the test article.
The major disadvantage of pulse-echo compared to
through transmission testing is that it is more affected
by the acoustic attenuation properties of composites.
Because the sound must traverse the material twice,
it is more likely that flaws will be obscured by reflec-
tion and scattering.
3 Test Display. The A-scan and C-scan
methods of presentation covered under through trans-
mission ultrasonics are also used to display pulse-echo
information. Figure 5-2 shows typical pulse-echo
A-scan presentation CRT displays for the defects
indicated.
5-5
TM 1-1500-204-23-11

Figure 5-2. Pulse-Echo Ultrasonic Inspection with A-Scan Presentation (Sheet 1 of 3)

5-6
 TM 1-1500-204-23-11

Figure 5-2. Pulse-Echo Ultrasonic Inspection with A-Scan Presentation (Sheet 2 of 3)

5-7
TM 1-1500-204-23-11
Figure 5-2. Pulse-Echo Ultrasonic Inspection with A-Scan Presentation (Sheet 3 of 3)
(b) Through-Transmission Ultrasonics. T-
his technique uses two transducers, one to transmit
sound energy and one to receive. Sound energy is
sent from one side of the part through the part to
the second transducer on the opposite side. Unlike
pulse-echo ultrasonics, sound does not have to tra-
verse the thickness of the part twice. A defect
encountered in the part significantly reduces the inten-
sity of the sound energy. This reduction in sound
energy intensity is used to detect the presence of
defects. It can be used to determine the area of a
defect.
1 Equipment Required. Required equip-
ment includes a pulsed ultrasonic generator, sending
and receiving transducers located on opposite sides
of the test article, and a signal processing and display
device. A coupling medium is required. For contact
testing methods, a thin layer of fluid is generally used.
This requires that the surface of the test article be
clean and relatively smooth.
2 Limitations. Through-transmission ultr-
asonics is usually more sensitive for flaw detection
in bonded assemblies. This technique is not able to
determine defect depth or type. In addition, it requires
5-8
access to both sides of the part and alignment of
the two transducers during inspection to ensure the
receiving transducer picks up the sound energy sent
by the transmitting transducer (see figure 5-3, View
B).
3 Test Display. Through-transmission
test results may be displayed in two basic ways
when using a display or permanent image recorder.
The A-scan presentation measures the amplitude of
the transmitted and received energy. It reveals the
presence of the flaws and provides some indication
of its relative size but does not locate its depth from
the surface of the part. See figure 5-3, View C for
typical through-transmission A-scan presentation CRT
responses for the defects indicated. The C-scan
presentation requires automated scanning of the test
article and the use of signal processing techniques.
A digital image display or paper recorder is used
to display ultrasonic test responses. The C-scan
provides a plan view of the article, revealing the area
of the flaw but providing no information relative to
its depth or distance from the surface. Successive
C-scans with signal gates set to various depths below
the surface may be used to locate the flaw in a
section.
 TM 1-1500-204-23-11

Figure 5-3. Through-Transmission Ultrasonic Inspection, A-Scan Presentation (Sheet 1 of 2)

5-9
TM 1-1500-204-23-11

Figure 5-3. Through-Transmission Ultrasonic Inspection, A-Scan Presentation (Sheet 2 of 2)

5-10

5-3. DAMAGE TYPES. Composite structures can be
damaged in many ways. Damage type must be
identified to determine a repair scenario. Six typical
types of defects are described in figure 5-4. Damage
incurred by composite materials is quite different than
that experienced by metallic materials. Composite
materials do not deform like metals. Composite
Figure 5-4. Types of Defects
a. Gouges. Partial thickness damage that results
in outer ply splintering, broken/removed fibers and
delaminations and the laminate has not been fully
penetrated (see figure 5-4).
b. Surface Scratch. A surface scratch does not
damage fibers or the internal structure of a composite
(see figure 5-4). Repair of such damage usually
requires only blending or refinishing.
TM 1-1500-204-23-11
materials either resist an impact force and spring
back or rupture. Due to the brittle nature of most
composite materials, these ruptures can occur at rather
low impact energies. The damage resulting from a
rupture produces cracks in the matrix, delaminations
between plies and broken fibers.
c. Delaminations. Delamination is the separation
of plies caused by impact, excessive heat, or inclu-
sion causing a void in the material (see figure 5-4).
Impact related delaminations tend to occur at multiple
depths throughout the thickness of the laminate. They
consist of inter and intraply matrix cracks which are
not always interconnected. Subsurface delaminations
and matrix cracks can exist without any indication
on the part surface. Laminates subjected to or sus-
pected of having been subjected to impacts from
5-11
TM 1-1500-204-23-11
foreign objects (such as maintenance stands, tool
boxes, dropped tools, etc.) must have the suspected
area inspected by an appropriate method (usually
ultrasonics). Inspect for the presence of subsurface
damage per paragraph 5-2 as well as the system
specific technical manual. Impact related delamina-
tion damage is the most common type of damage
experienced with composite materials.
d. Dent. A hollow or low place usually caused
by impact. It will usually have deformed fibers, but
no broken fibers on the impact surface (see figure
5-4). It is detectable by visual inspection or straight
edge comparison. If honeycomb core is present,
crushing of the core will exist beneath the dented
composite skin. The crushed core can be hidden
by the brittle composite materials separating in the
laminate, springing back and masking the buckled
core beneath. On solid laminates, the backside of
the dented surface will usually show significantly more
damage than the front side; therefore, technicians
should always examine both the front and back sides.
e. Disbonds. Disbond is adhesive failure at a
bondline. It occurs between a honeycomb core and
a face sheet or between adjacent bonded structures
(see figure 5-4). Skin to core disbonds and skin
to substructure disbonds occur as a result of core
corrosion or part exposure to temperatures at or
above the part cure temperature. They can also
be caused by impact forces if the adhesive used to
bond the core or substructure is more brittle than
the composite matrix material or due to inadequate
surface preparation or cure.
f. Cracks. Cracks are defects where one direction
is significantly greater than the other. Cracks include
both cracks through the matrix only and the matrix
and fibers. Cracks may only extend a few plies deep
and may not propagate deeper due to the different
orientation of the plies.
g. Puncture. A puncture is any penetration of a
structure (see figure 5-4). Composite skin penetration
damage is characterized by broken fibers, matrix
cracks and delaminations. This type of damage
usually results in subsurface delaminations and matrix
cracks larger than that apparent visually. Mapping of
these areas is required as described in paragraph
5-6. Visually apparent penetration damage on the
exit side is typically 3-5 times larger than entrance
side damage size.
h. Fastener Hole Damage. Gouging of counter-
sinks and areas surrounding fastener holes caused
by fastener drivers can occur during fastener removal
and installation. Repeated fastener removal and instal-
lation can result in excessive wear of fastener holes.
5-12
Delamination of fastener holes can be caused by over
torquing fasteners during installation and by gener-
ation of an excessive amount of heat when drilling
out damaged fasteners. Fastener holes may elongate
with repeated loading.
i. Edge Damage. Edge and corner damage to
panels result in edge delaminations and/or broken
off pieces sometimes requiring a rebuilding effort.
j. Heat/Burn Damage. Temperature exposure in
excess of the part cure temperature can degrade
matrix strength. This can be the result of a light-
ning strike or fire. Epoxy matrix materials that are
exposed to temperatures above their cure temperature
can experience a marked degradation in properties
and show little or no visual indication of damage to the
laminate. However, if the laminate is painted, discol-
oration of the paint system provides an indicator that
laminate damage may have occurred. Extreme expo-
sure, beyond 600 °F for example, may result in visual
blistering and pyrolyzation of the outer plies of the
laminate. For bonded composite assemblies, epoxy
adhesives degrade at lower temperatures than lami-
nate matrix materials. Advanced composite materials
and bonded composite assemblies exhibiting discol-
ored paint, coated with soot, or that are suspected of
being exposed to excessive temperatures may have
experienced heat damage. These advanced compos-
ite materials and bonded composite assemblies are
suspect. The matrix material beneath any blistered,
delaminated or pyrolyzed plies is suspect as well.
Any composite structure that is exposed to temper-
atures greater than design or maximum operating
temperature requires evaluation and disposition by
engineering to evaluate laminates, laminate to core
bonds, and laminate to substructure bonds. Even
though no NDI indications occur, any part suspected
of heat damage may have significant strength reduc-
tions. Composite materials exposed to aircraft fires
may experience pyrolyzation of the matrix material
on the outer plies, thus eliminating support for the
fibers, while the underlying plies experience blistering
and interply delamination. Although appearing intact,
the matrix material beneath blistered, delaminated or
pyrolyzed plies experiences a strength reduction and
requires evaluation and disposition. Perform NDI on
any area of the part subjected to temperatures exceed-
ing the service temperature of the part material.
k. Chemical Damage. Damage to the resin can
occur due to the effects of chemical attack. Com-
posite materials exposed to chemical paint strippers
experience a long term degradation of matrix strength
with no visual indication on the part surface. Chemical
paint strippers are not authorized for use on composite
materials. They require evaluation and disposition by
engineering. Composite materials exposed to most

other chemicals found in the maintenance environment
(cleaners, solvents, jet fuel, hydraulic fluid, engine oil,
etc.) show no effect due to exposure.
(1) Fluid Intrusion. This type of damage
occurs with honeycomb sandwich assemblies when
a leak path develops which allows fluid to enter the
honeycomb core cells. This can be detrimental to
weight and balance critical to rotor blades or flight
control surfaces, as well as causing material degra-
dation to both metallic and non-metallic honeycomb
core. Fluid intrusion is of major concern in performing
elevated temperature cures during bonded repairs.
Chapter 7 covers fluid removal and drying of core
prior to repair.
(2) Corrosion. Metallic structure, particularly
aluminum, may experience galvanic corrosion with
carbon fiber structure. This includes fittings, fasten-
ers, metallic core, and lightning mesh. Direct physical
contact is not required, just an electrical path between
the aluminum and carbon fiber. Aluminum must
be electrically isolated from the composite laminate.
Chapter 6 details isolation procedures. Indications of
corrosion include scale, cracking, pitting, material loss
or other corrosion by-products. TM 1-1500-344-23
provides additional information on corrosion.
5-4. DAMAGE CATEGORIES. Once the extent of
the damage is determined and prior to actually begin-
ning a repair, damage should be classified as (1) neg-
ligible, (2) repairable or (3) non-repairable. This clas-
sification requires experienced judgment and knowl-
edge of the strength and functional requirements of
the structure. Technical data that provides a zoning
system of the structure should be available in the
system specific technical manual. When specific dam-
age classification data is not available or the data is
questionable, additional technical data or engineering
must be consulted. The decision concerning disposi-
tion must be made with the specific requirements of
the aircraft or system in mind, as well as the partic-
ular parts involved, the limitations that can be placed
on the repaired aircraft, the degree of urgency, local
repair capabilities, availability of spare parts, and any
other circumstances impacting the situation. Three
types of damage are categorized below:
a. Negligible Damage. Damage which, because
of its size, nature and location that does not adversely
affect the structural integrity of the part is defined as
negligible. It may be allowed to exist without repair,
or may only require a cosmetic repair to be performed
to prevent further damage from occurring (such as
further stripping of outer ply material). Refer to the
system specific technical manual for further guidance
on what constitutes negligible damage.
TM 1-1500-204-23-11
b. Repairable Damage. This is defined not only
as damage requiring repair, but also damage that is
within the repair capability of the activity at which
the repair is to be performed. The location of
damage, complexity of the repair procedure, repair
weight limitations, availability of repair equipment and
materials, repair time/cost, spare part availability, etc.,
are all factors in deciding whether a part is beyond the
capability of maintenance (BCM) at that activity. Parts
that are BCM must be forwarded to the next higher
maintenance activity (NHMA). Refer to the system
specific manual for guidance on repairability due to
damage location and to provide specific repair weight
limits.
c. Non-Repairable Damage. Parts determined to
be non-repairable must be forwarded to depot level
for disposition.
5-5. DAMAGE ASSESSMENT METHODOLOGY. F-
our steps are involved in assessing damage: (1)
Locating damage, (2) characterizing the damage and
determining its extent, (3) zoning the damage on the
part being repaired and (4) re-evaluation of the dam-
aged area after damage removal.
a. Locate the Damage. This is usually performed
by visual inspection. However, caution must be
exercised as non-visible subsurface damage may
exist beneath impact areas and areas suspected
of having been impacted. Areas impacted (with
or without visual indication on the part surface) or
suspected of having been impacted must be further
evaluated for delaminations and matrix cracks. Use
the nondestructive inspection (NDI) methods listed in
paragraph 5-2 as well as the system specific technical
manual.
b. Characterize the Damage. Once the damage
has been located, the extent of the damage must
be determined and the damage characterized. The
depth of delamination and the presence of skin to
core or skin to substructure disbonds (if applicable)
should be determined to characterize the detected
damage. Determining the extent of damage and
characterizing the damage is an important part of the
damage assessment process, as it will have a direct
bearing on the repair procedures to be employed.
c. Zone in the Damages. After the damage has
been characterized and the extent determined, the
repair zone in which the damage is located is deter-
mined using the system specific technical manual.
Overlap of damage from one repair zone to another
requires the damage limits for the worst case zone
be used. If the damage limits for the repair zone in
which the damage is located are exceeded, the part
must be forwarded to the NHMA for repair. If the
5-13
TM 1-1500-204-23-11
damage lies in a nonrepairable zone, the part must
be forwarded to depot for disposition.
d. Reevaluate. Following damage removal, rein-
spect the damage area to ensure all the damage
was in fact removed. Current NDI methods used to
detect subsurface delaminations are capable of only
finding the first delamination nearest the surface on
which the probe was applied. Deeper delaminations
can be masked by the first delamination (see figure
5-2, View D). When the opposite side is accessible
a secondary inspection can be performed to deter-
mine the existence of additional delamination. After
removing what initially appears to be all the dam-
age present, it is necessary to re-inspect the area to
ensure no delaminations remain below the originally
defined damage.
e. Defect Mapping. The defect map is used to
determine the damage layout and extent of material
to be removed as described in Chapter 6. A Mylar
Figure 5-5. Defect Mapping of Damage Extent from NDI
5-14
map provides an aid when performing subsequent NDI
of the area after damage removal and after repair as
well as providing a permanent record of the defect
indications. Follow these steps to create a defect
map.
(1) Using the visual indication of damage as a
guide, mark a grid of 0.5 inch squares out to
a point at least 1 inch away from the edge
of the damage on the part surface using a
marking pen.
(2) Using one of the ultrasonic techniques listed
above; inspect each 0.5 inch square of the
marked grid.
(3) Mark the location of defect indications (and
depths if using the pulse-echo ultrasonic
technique) as indicated on the CRT on the
part surface using a marking pen (see figure
5-5).

(4) Mark the repair part with orientation marks.
Orientation markings are used as reference
points for placement of the repair materials
and other repair processes and for docu-
menting the damage.
(5) Create a repair template. Since surface
cleaning and paint removal processes can
remove orientation marks, a repair template
should be fabricated (see figure 5-6 and
figure 5-7). The template should include
the orientation lines, paint removal area
perimeter, damage removal perimeter, and
the repair patch details.
Figure 5-6. Damage Work Lines Drawn on Part Surface
TM 1-1500-204-23-11
(6) Tape a piece of Mylar over the damage area
and transfer the defect indication map to the
Mylar using a permanent marking pen. Mark
orientation lines on the part away from the
damage area.
(7) Transfer these lines to the Mylar to aid in
positioning the Mylar after the paint has
been removed from the part during the repair
process.
5-15
TM 1-1500-204-23-11
Figure 5-7. Typical Orientation Markings
f. Damage Orientation Marking. Follow these
steps to determine and mark damage orientation. The
following tools and equipment are required: pencil or
permanent marker, a straight edge, a compass or
circle template, and template film. Refer to Appendix
B for item description. Refer to figure 5-7 to view
typical orientation markings.
NOTE
Do not use wax, grease or oil-based markers
on composite materials. Do not use graphite
pencils on aluminum.
(1) Determine a basic reference direction to
be used for basic repair and NDI reference
coordinates. This is typically along a primary
load carrying member such as a spar, in the
0 degree direction; however, it may be arbi-
trary. Consult the system specific technical
manual or engineering authority for further
guidance.
(2) Using a straightedge and a pencil or marker,
draw an orientation line in the reference
direction through the repair zone. The orien-
tation lines should pass through the center
point of the repair area. When the repair
area is an odd shape, use your best judg-
ment when determining the center of the
repair area. The orientation lines should
extend far enough beyond the repair area to
ensure they are not removed by the surface
5-16
preparation process and will be visible upon
repair patch installation.
(3) Repeat the marking process for a 45 and 90
degree reference line.
(4) Using the pencil or marker and the appro-
priate marking aids (compass, straightedge,
etc.), mark the repair area with the dam-
age removal cutout line, scarf width line, and
coating removal perimeter (see figure 6-1 for
paint removal area).
(5) If a repair area template is used, draw tem-
plate location marks on the repair surface
using a pencil or marker. These marks
should be placed outside the repair area
where they are not likely to be removed.
The markings will be used for orienting the
template on the repair surface.
(6) Cut the template film large enough to cover
the entire repair area and include sufficient
area outside the repair zone for the place-
ment of template location marks. Center the
template over the repair area and tape in
place.
(7) Using the pencil or marker, transfer the tem-
plate location marks on the repair part to the
template film.
 TM 1-1500-204-23-11

(8) Trace the orientation marks and perime- d. Definitions.

ter markings onto the template film. Also
include an outline of any damage.
5-6. PLY ORIENTATION. To ensure the fibers in an
advanced composite laminate perform their function of
carrying load and providing part stiffness, it is essential
that the fibers (plies) be properly oriented within the
laminate with respect to the 0º fiber direction. In the
same way we would expect a map to tell us which
way is North relative to the features on the map, we
expect a part drawing to tell us which way is “0” or
“0º” on the part itself.
(1) Lamina. The lamina or ply is the single
layer in a laminate. Fibers in the ply are either
unidirectional (all fibers in the same direction) or
woven into cloth.
(2) Lamina Fiber Direction. The fiber direction
of a unidirectional ply is coincident with the fibers in
that ply (figure 5-8, View A). For woven cloth, the
fiber direction of the ply is the warp direction of the
weave (figure 5-8, View B).

a. Warp Fibers. When using unidirectional tape,

orienting each ply simply means lining up the fibers
in the ply with the orientation specified, be it 0, 90,
+45, -45, etc.

b. Woven Fabric. When using woven fabrics

which have fibers in both the warp and fill directions
we must understand that only the warp fibers are
used for orientation purposes. The warp fibers (yarns)
are those running the entire length of the roll of fabric
covered in greater detail in paragraph 4-3. In addition
the individual plies in a laminate must be placed in
the proper stacking sequence to ensure the required
laminate mechanical properties are obtained.

c. Determining Ply Orientation. “Reading” the

laminate is required when structural technical data
showing ply orientation at the damaged area is not
available. While the light reflecting from a sanded
surface can reveal the presence of plies of different
orientations, accurately determining the directions of
these plies is fairly difficult. The use of a magnifying
glass (8 to 12 power) is helpful. Using a needle to
pick out individual fibers should be used only as a
last resort. The ply direction in a scarfed surface
can also be read when the damaged material is
being removed; that is, the removed pieces can be
split apart to observe the direction of the fibers. A Figure 5-8. Ply and Ply Fiber Direction
group of plies lying together in the same direction
are not easily distinguished, but the length of the (3) Laminate 0 Degree Fiber Direction. The 0
scarf through each group of plies will reveal the degree laminate fiber direction is usually coincident
number of plies in the group. Wet sanding with 400 with the primary load direction of the part or patch.
rit sandpaper eases the reading of the ply orientation.
A reference system will be necessary to identify the (4) Ply Angles. The angle of each ply or lamina
actual ply layup of the laminate and subsequently the represents its orientation in degrees between the fibers
repair plies. An explanation of the standard reference in that ply (lamina fiber direction) and the 0 °Fiber
systems and notation is in paragraph 5-9. Document direction of the (laminate) part or patch. A 90 degree
the ply and reference orientation. ply is shown in figure 5-9, View A.

5-17
TM 1-1500-204-23-11

Figure 5-9. Fiber Orientations

(5) Positive and Negative Angles. Positive respect to the laminate 0 degree fiber direction (figure
angles are defined as being counter-clockwise from 5-10).
the 0 degree fiber direction when looking down on
the layup tool surface. Negative angles are clockwise
from the 0 degree fiber direction. Not all aircraft
manufacturers use this convention during fabrication
of parts. Use this convention for defining positive
and negative angles unless otherwise specified by
the system specific technical manual. A -45 degree
ply and a +60 degree ply are shown in figure 5-9,
View B and View C.

(6) Woven Material Ply Angles. The construc-

tion of many plain weave fabrics eliminates the need
for 90 degree ply designations as well as positive or
negative ply designations such as “+45 or -45”. For
example, the dry woven carbon cloth materials spec-
ified for repair patches in Chapter 7 of this manual
(SGP 196-P) has eleven 6k yarns per inch in the
warp direction, and eleven 6k yarns per inch run-
ning in the fill direction. The result is a fabric which
has essentially the same strength in both the warp
and fill directions. In this case, it is unnecessary
to differentiate a 0 ply from a 90 ply since they’re
essentially the same. Likewise, it is unnecessary to Figure 5-10. Typical Laminate
differentiate a +45 ply from a -45 ply. In laminates
made exclusively from these materials, it is common e. Lamination. During the lamination process, it is
to see only “0” and “45”, or “0/90”, “±45” to denote essential that the correct ply orientation and stacking
the ply orientations. When the laminate is made from sequence be maintained.
a combination of woven fabric and unidirectional tape
it is common to see a lowercase “w” or “f” after the (1) Ply Orientation Tolerance. Typical repair
ply orientation to distinguish that ply as being woven tolerance for ply alignment is ±3°. A ply misorientation
fabric as opposed to unidirectional tape. of 5° can result in a 20% reduction in strength while
a 10° misorientation can result in as much as a 50%
(7) Laminate. A laminate is made up of several reduction in strength. The system specific technical
laminas (plies) oriented in different directions with manual will list the required ply orientation tolerance.

5-18

(2) Stacking Sequence. Ply must be laid down
(stacked) in the proper sequence. Incorrectly stacked
ply can result in warped or bowed panels and prema-
ture failure when load is applied. Figure 5-11 provides
Figure 5-11. Stacking Sequence Effects
(3) Orientation Markings. Orientation mark-
ings are essential to proper repair ply layup. The
orientation marks used in this chapter may or may not
be used for the ply layup templates. When the repair
information calls out the orientation angle of each ply,
you must use the same coordinate system used by
the engineers to design the repair; this information
is found in the system specific technical manual,
repair drawings or Original Equipment Manufacturer
(OEM) drawings. If you are reading the laminate
to determine the orientation angle of each ply, and
have no guidance from the sources listed above, you
should orient the 0 degree direction of your coordinate
system along one of the fiber directions, usually the
fiber direction running the length or width of the part.
(4) Drawing Orientation. Drawings may show
ply layup orientation for the entire structure as if it were
TM 1-1500-204-23-11
a few examples of stacking sequence effects on a flat
laminate. In general, the upper half of the laminate
should be a mirror image of the lower half.
viewed from one side; or it may show cross sections
as referenced from the center of the structure or from
outer mold line to inner mold line. Technicians must
understand the orientation coordinate system used. If
no established orientation system is available, users
must establish a coordinate system.
f. Ply Cutting Template Manufacture. The first
element of patch preparation is generating a visual
aid in the form of a patch drawing or sketch. It
should include a coordinate system showing ply orien-
tation and shape, nearby fasteners, prominent aircraft
features, and overall dimensions of damage cutout,
scarf, and repair plies. An example is shown in figure
5-12 and figure 5-13. Manufacture the template from
suitable acetate, Mylar or other wax free material.
5-19
TM 1-1500-204-23-11

Figure 5-12. Patch Drawing Example and Typical Scarf Repair Stackup (Sheet 1 of 2)

5-20

Figure 5-12. Patch Drawing Example and Typical Scarf Repair Stackup (Sheet 2 of 2)
Figure 5-13. Scab Patch Ply Arrangement
NOTE
An intermediate template from vacuum bag
is not required if the part is relatively flat
and 0.040 inch thick acetate will conform to
surface.
Ensure patch templates used for layup and
alignment match the orientation and reference
lines on the structure being repaired include
ply orientation and stacking sequence on all
drawings and templates.
(1) Determine the number of plies, ply orienta-
tions and the ply stacking sequence from the
system specific technical manual. Deter-
mine the size of the plies from the system
specific technical manual. For patches,
determine ply size based upon the dam-
age cleanup hole shape and required patch
overlap. Refer to the system specific tech-
nical manual for guidance on determining
patch overlap requirements. Mark the ply
periphery on the part surface.
TM 1-1500-204-23-11
(2) Determine part 0 degree and other ply direc-
tions as specified in the system specific tech-
nical manual and mark on part near repair
area.
(3) Tape a piece of 0.002 inch thick vacuum bag
film over the part in the repair area. Slice
bag film as required to prevent wrinkling over
contoured areas.
(4) Place the bag film containing the ply periph-
ery trace on a flat surface.
(5) Place the acetate over the bag film and mark
ply cutting line(s) on the acetate from the
ply periphery trace(s). Include ply number,
orientation, and zero fiber reference.
(6) Cut the acetate along the ply cutting line
using scissors. The acetate will be used in
Chapter 7 to cut out the repair plies. Figure
5-14 shows a typical example.
5-21
TM 1-1500-204-23-11

Figure 5-14. Repair Ply Cutting Template (Example) (Sheet 1 of 3)

Figure 5-14. Repair Ply Cutting Template (Example) (Sheet 2 of 3)

5-22
 TM 1-1500-204-23-11

Figure 5-14. Repair Ply Cutting Template (Example) (Sheet 3 of 3)

5-23
TM 1-1500-204-23-11
5-7. LAMINATE ORIENTATION CODE. As men-
tioned in paragraph 5-6, to ensure the fibers in an
advanced composite laminate perform their function
of carrying load and providing part stiffness, it is
essential that the fibers be properly oriented. In
addition, the individual plies in a laminate must be
placed in the proper stacking sequence to ensure the
required laminate mechanical properties are obtained.
The laminate orientation code was created to simply
and clearly describe the layup of a laminate.
a. Reference Plane. The reference plane is
selected as either the bottom or top ply of the
laminate for the laminate orientation code. When the
laminate is symmetrical about the midplane, selection
of either the top or bottom ply as the reference plane
will yield the same results.
b. Reference Direction. Selection of the reference
direction or 0 degree is arbitrary. Standard convention
Figure 5-15. ASTM Standard for Measuring Ply Angles
(1) The ASTM-D-6507 and CMH-17 standards
measure positive angles in the counterclock-
wise direction when looking at the mold sur-
face, or tool. This is commonly referred to
as the counter-clockwise (CCW) warp clock
and can be thought of as looking from the
IML, or “bag side” of the part, outward as you
would when manufacturing a part and should
be placed on the inside, or bag side surface
5-24
is to select the 0 degree in the same direction as the
main load, the fiber in the top ply or the dominate
fiber direction in the laminate. When a set layup is
to be followed, system specific technical manuals or
drawings should be consulted for setting the reference
direction.
c. Angles. The angle of each ply or lamina rep-
resents its orientation in degrees between the fibers
in that ply (lamina fiber direction) and the reference
direction of the laminate.
d. Ply Orientation Convention Symbol. The ply
orientation convention symbol, or “warp clock” as it
is often referred to, is used in drawings to indicate
the reference, or 0 degree direction and to coordinate
the part drawing to a ply table or shorthand code
like the ones shown in figure 5-15.
of the part drawing at the location(s) where
the part is to be inspected during the man-
ufacturing process. Since fiber directions
can change, sometimes dramatically when
composite materials are applied to parts with
complex geometries, it is not uncommon to
see drawings with numerous warp clocks
illustrated on the part.

(2) The Clockwise (CW) warp clock can be used
any time the part is illustrated as viewed from
the OML, and can be thought of as looking at
the same warp clock from the opposite side,
or from the outside looking inward as seen
in figure 5-15. Note that in both cases the 0º
axis and the 90º axis remain the same, but
the 45º axes change sign.
Figure 5-16. Example Standard Code Element and
Laminate
5-8. STANDARD LAMINATE/ORIENTATION CODE-
. The Standard Laminate Code was originally formu-
lated specifically for unidirectional laminates; a modifi-
cation was subsequently established for woven fabric
and braided laminates. The standard code is used
to describe a specific laminate uniquely and is most
simply defined by the following detailed description
of its features.
a. Standard Code Elements. Each ply is denoted
by a number representing its orientation in degrees
between its warp direction and the reference direction.
Normally the angles are limited to between 90 and
90°.
Figure 5-17. Example for Positive and Negative Angles
TM 1-1500-204-23-11
(1) Individual adjacent plies are separated in
the code by a forward slash (/), if their angles are
different.
(2) The plies are listed in sequence from one
ply face to the other, starting with the first ply laid
up, with brackets indicating the beginning and the
end of the code.
(3) Adjacent plies of the same angle are
denoted by a numerical subscript.
(4) A subscript T to the bracket indicates the
total laminate is shown. If no subscript is present
on the brackets, the T is assumed to be there. See
figure 5-16.
(5) Positive and Negative Angles. When
adjacent plies are of the same angle but opposite
in sign, the appropriate use of the + and - signs is
employed. Each + or - sign represents one ply and
supersedes the use of the numerical subscript, which
is used only when the directions are identical. Signs
can be condensed to ± (plus minus) or a (minus
plus) sign with the sign that is on top representing
the first ply in the layup order. See figure 5-17.
In the fifth example illustrated, the latter code is
preferred because it can more easily accommodate
larger numbers. See figure 5-18. Note that, in
condensing the signs, the sign of the center ply of
an odd number is left uncombined.
5-25
TM 1-1500-204-23-11

Where an odd symmetric laminate has additional

plies of the same angle adjacent to the center ply,
a subscript is used with the over line to indicate the
number of half ply on either side of the center plane.
See figure 5-21.

Figure 5-18. Example for Accommodating Larger

Numbers

(6) Symmetric Laminates. Symmetric lami-

nates with an even number of plies still list the plies
in sequence, starting at one face, but stopping at the
plane of symmetry instead of continuing to the other
face. A bracket subscript S indicates only one-half
of the laminate. See figure 5-19.
Figure 5-21. Example Odd Symmetric Laminate
with Multiple Same Angled Plies

(7) Sets. Repeating sequences of plies are

called sets and are enclosed in parenthesis. A set
is coded in accordance with the same rules which
apply to a single ply. See figure 5-22 and figure 5-23.
Laminates are often composed of identical repeated
sets. When it is desired to refer to the laminate in a
generic sense or when the number of sets has yet to
be determined, as in the sizing stages of design, the
coefficient “n” will be used with the bracket subscripts
T and S instead of a numerical coefficient.
Figure 5-19. Example Even Symmetric Laminate
Symmetric laminates with an odd number of plies
are coded the same as even symmetric laminates,
except that the center ply, listed last, is over lined to
indicate that half of it lies on either side of the plane
of symmetry. See figure 5-20.

Figure 5-22. Example Sets for Symmetric

Figure 5-20. Example Odd Symmetric Laminate Laminates

5-26

Figure 5-23. Example Sets for Non-Symmetric Laminates
5-9. FABRIC/HYBRID LAMINATE/ORIENTATION
CODE. In general, fabric plies are followed by a
capital letter “F”. For example, “0F” indicates a ply of
fabric with its warp yarns traveling in the 0º direction.
If there is no capital letter after the ply it is assumed
to be unidirectional tape. If the entire layup contains
one type of ply, the capital “F” may follow the closing
bracket. This calls for caution when using the ± sign
since a “±45” indicates two unidirectional tape plies,
the first at +45 and the second at -45, whereas
“±45F” indicates a fabric ply in which the warp yarns
may travel at either + OR – 45. Additional consid-
erations need to be made if the fabrics used are
harness satin weaves (see paragraph 4-3) Harness
satins are, by nature, asymmetrical fabrics and are
therefore more prone to warping and twisting caused
by thermal stresses during the cure cycle.
a. Carbon Laminates. This is especially true in
carbon laminates cured at 350º F or higher. The key
to maintaining symmetry with harness satin fabrics
lies in identifying the warp-face of the material. The
warp-face is the side of the fabric on which we
see predominantly warp yarns. (See figure 4-8.) By
TM 1-1500-204-23-11
specifying that plies are to be laid up either “warp-face
up” or “warp-face down” on either side of the mid-plane
of the laminate, we can achieve perfect symmetry
and avoid thermal distortion. One popular way of
depicting this in drawings and shorthand code is to
place an arrow after harness satin weave fabric plies
indicating that the ply is to be installed warp-face up
(↑) or warp-face down (↓).
b. Hybrid Laminates. If more than one type of
material is used in a laminate, the material will need
to be designated for each material by the use of
augmented subscripts. For example, “G” or “FG”
may represent a fiberglass ply, “K” an aramid ply,
and “C” a carbon fiber ply. The augmented subscripts
will need to be defined in the document.
5-10. BRAIDING ORIENTATION CODE. The braid-
ing orientation code is used to describe the fiber
geometry of a two-dimensional braided preform. For
information beyond what is provided refer to ASTM
D 6507 – 11. The information in figure 5-24 is an
excerpt from CMH-17F.
5-27
TM 1-1500-204-23-11

Figure 5-24. Excerpt from CMH-17F

5-28

CHAPTER 6
REPAIR PROCESSES
6-1. SURFACE PREPARATION. Paint stripping of
composite parts has been a source of concern for
many years because the techniques used to strip
metal are usually too harsh to strip composites.
Stripping composites is normally accomplished by
power sanding to the primer then hand sanding
through the primer. Chemical paint strippers can
seriously damage epoxy matrix resins; their use is
prohibited on all polymer matrix composites. Some
abrasive blasting processes have great potential to
harm the matrix and fibers as well. The type of
blast media and pressure can affect the removal rate
and also can damage the surface of the composite
materials. Abrasive grit (sand) blasting and glass
bead blasting are never appropriate for composite
paint removal. Certain methods such as polymer
modified corn or wheat starch blasting, CO2 blasting
and plastic media blasting may be acceptable. These
methods should only be performed on large parts by
experienced personnel, and only when authorized by
the system specific technical manual or engineering.
Water jet blasters can severely damage a polymer
matrix material and must not be used on composites.
Laser stripping and flashjet methods are being used
more every day and have proven to be an effective
method in the removal of paint from a composite
surface. Consult with engineering prior to using other
paint removal procedures other than sanding.
6-2. PAINT REMOVAL PROCESS. Paint removal
(including primer) is required prior to patch installa-
tion because in adhesively bonded joints the paint
to laminate bond is considerably weaker than the
adhesive to laminate bond. In bolted joints the paint
to laminate bond is weaker than the sealant to lam-
inate bond. In cases where the paint may inhibit a
Figure 6-1. Paint Removal Zone
TM 1-1500-204-23-11
drying of moisture removal process, the paint should
be removed prior to conducting drying procedures.
a. Process Overview. Perform a solvent wipe prior
to removing paint to prevent driving contaminants and
oils into the composite. Paint and any other surface
coatings within the repair area boundary must be
removed prior to any surface repair activity. The
coatings should be removed from the repair area in
accordance with the procedures defined in the system
specific technical manual. During the paint removal
process, it is crucial that no additional damage be
caused by excessive material removal. Great care
must be taken to not sand into composite fibers
or remove excess material from metallic structures.
Generally, the only field authorized method for paint
removal from composite substrates is sanding. Pneu-
matic sanders are preferred for initial paint removal.
Other types of power sanders should not be used
because of the high potential for laminate damage.
Using a pneumatic sander, remove the paint until the
primer is exposed. Switch to hand sanding to complete
the paint removal process. The paint removal must
extend at least 1 inch beyond the repair area. Paint
must be removed from repair surfaces to ensure ade-
quate adhesion of bonded repairs and adequate friction
in bolted joints. The following methods will remove the
paint or surface coatings from Carbon/Epoxy (C/EP),
Boron/Epoxy (B/EP), Aramid/Epoxy (A/EP), Fiberglass/
Epoxy, and Carbon/ Bismaleimide (C/BMI) composites
in preparation for a bonded or bolted repair. Always
refer to the system specific technical manual for any
particular paint removal procedures. See figure 6-1
for a typical damaged area and paint removal outline.
6-1
TM 1-1500-204-23-11
b. Hand Sanding. Hand sanding with 180-grit
sandpaper on a soft sanding block removes paint
satisfactorily in many applications. However, a light
touch is needed and the sanding block must be
moved in a direction parallel to the surface fibers to
prevent damage to the surface ply. This technique
requires minimal preparation and cleanup time and
costs little. The removal rate is very slow and the
process is labor intensive. This is the preferred
method for sanding small areas.
c. Power Sanding. Paint removal can be per-
formed by a Dual Action (DA) or random orbital
sander; a jitterbug sander, or a 90° die grinder with
a 2 inch sanding mandrel and a Scotchbrite® pad.
As with hand sanding, care should be taken to sand
in the direction of surface fibers as much as possible
to avoid damaging them. Power sanding provides a
rapid means of paint removal. Extreme care must
be used to prevent gouging and/or damaging more
material than the needed repair.
Avoid breathing dust from sanding operations.
Use vacuum equipment when it is available.
Wear eye protection during all material removal
operations. As a minimum, wear a dust mask
and ensure adequate ventilation. Consult with
your local safety office for the appropriate per-
sonal protective equipment for your operation.
Use appropriate personal protective equipment
while removing and disposing of chromate
primer waste material in accordance with local
environmental regulations.
The use of chemical paint stripper is prohibited
as it attacks the composite resin system and
loss of structural integrity may occur.
DO NOT sand into laminate when removing
paint. When working on a carbon fiber lami-
nate, a black colored dust on the sand paper
indicates that sanding into the laminate has
occurred and carbon fiber is being removed.
If this occurs, the sanding process should
be stopped immediately. A loss of structural
integrity may occur if fibers are exposed or
damaged. Aluminum oxide and silicon car-
bide sandpaper can be used on all advanced
composite materials. Wet sanding shall not
be performed on a composite laminate.
6-2
Lightning strike protection (aluminum or copper
mesh, or aluminum foil) shall never extend
into the area under the repair patch. Loss of
structural integrity may occur.
Sand only in the direction specified in the
system specific technical manual. Incorrect
sanding may reduce the life of the component.
Rotor blades are typically sanded in the span
wise direction if allowed at all.
6-3. PAINT REMOVAL PROCEDURE. Follow these
steps for paint removal:
a. Preclean the repair area in accordance with para-
graph 6-5.
b. Apply masking tape to mask off the repair area
and to provide a paint removal boundary. The
paint should be removed from an area at least 1-2
inches larger than the repair area in all directions
(figure 6-1).
c. Remove paint by hand sanding or orbital sander
in accordance with the system specific technical
manual for your repair application.
d. Vacuum area frequently to reduce paint residue
buildup on the abrasive paper.
e. Visually inspect the abrasive paper frequently for
paint buildup and replace as required.
NOTE
Power sand only to the primer. The primer
is usually a different color. Hand sand to
the composite material using fine (240-grit or
finer) sandpaper.
f. When primer is visually detected on the part,
change to 240 grit or finer abrasive paper accord-
ing to the system specific technical manual and
continue hand sanding until the majority of the
primer has been removed. Some residual primer
may remain in peel ply impression recesses
on the laminate surface. It is permissible for a
residual haze of primer to remain on the laminate
surface. Sand cautiously to prevent laminate
damage: some composite parts are painted with
dark colored primers making primer detection
difficult, and some are painted without the use of
primer.
 TM 1-1500-204-23-11

Lightning strike protection (aluminum or copper

mesh, or aluminum foil) shall never extend
into the area under the repair patch. Loss of
structural integrity may occur.

g. In order to ensure optimum strength, repair plies

should be bonded only to the laminate substrate.
Composite structures often incorporate an alu-
minum foil, or an aluminum or copper mesh
below the paint and primer. If EMI/lightning strike
protection is present, it must be removed using
240 grit or finer abrasive paper or Scotchbrite
pad. Removal of EMI/lightning strike protection
should extend approximately 1/4 inch beyond
the largest repair ply.

h. Vacuum paint removal area to remove sanding

dust. Wipe area with clean, dry wiping cloth to
remove remaining sanding residue.

6-4. DAMAGE REMOVAL PROCESS. Damaged

material must be removed to sound material to affect
a structural repair. This means that damage must
be removed along with a minimum amount of good
material. First, use NDI to determine the damage
extent. Then, determine the cutout shape for remov-
ing damage. A circle is the most practical cutout
shape for damage; however, large damage often
cannot be confined to a circle without removing an
excessive amount of good material. Cutouts required
to remove large areas of damage may take any form
but should be a simple geometric shape which has
straight lines and smooth tapers and radii on the
damage boundary. However, maintain generous radii
at the cutout corners to prevent excessive stress
concentrations and the resultant overstress of the
repair joint. The cutout radius shall not be less
than 0.5 inch. When outlining the damage area,
use a permanent ink marker on light colored painted
surfaces or a white pen on dark surfaces. A correct
damage outline encompasses the damaged area and
a minimum amount of good material while maintaining
the minimum required cutout radius. For noncircular
damage, use a straight edge to draw straight lines
on the damage surface which will encompass the
damaged area as indicated by NDI. Connect the lines
using a circle with a radius not less than 0.5 inch.
A typical damage outline is shown in figure 6-2.
Figure 6-2. Damage Outlining
To avoid causing additional damage during
the damage removal process, use the correct
cutter type and the correct cutter feed/speed
for the composite material being machined.
NOTE
Refer to paragraph 6-8 for machining proce-
dures for composite materials and Chapter 4
for a description of the equipment used for
machining.
a. Damage Removal Tool Selection. Tool selec-
tion for damage removal is dependent on several
factors. Material type, damage size, depth, and
cutout shapes all affect tool selection. For partial
depth damage removal, use a dual action sander or
grinder with an abrasive disc. Full thickness mate-
rial removal requires a faster method of composite
machining. The most common of these tools are the
Kett saw, die grinder, and high speed router. In many
cases a combination of different tools is the most effi-
cient method for removing material. See Chapter 3
and table 6-1 for information on specific tools. Refer
to paragraph 6-8 for machining procedures for com-
posite materials.

6-3
TM 1-1500-204-23-11
Table 6-1. Ranking of Damaged Material Removal Techniques
Rank Damage
Large Damage
1 Kett Saw With Diamond-Coated Blade
Die Grinder With Abrasive Disc or Dual
2 Slight Curves
Action Sander
3 Router With Diamond-Coated Bit
Moderate Damage
1 Router With Diamond-Coated Bit
2 Dual Action Sander
3 Drill Motor With Diamond-Coated Hole Saw
Small Damage
1 Dual Action Sander
2 Drill Motor With Diamond-Coated Hole Saw
3 Die Grinder With Carbide Rotary File
b. Penetration Damage. Severe damage to the
laminate will require the removal of the full thickness
of the structure before a repair is applied. As with all
damage removal processes, it is desirable to remove
a minimum of sound material while removing all of
the damaged material. Careful NDI marking of the
damaged perimeter and tool control are required.
Proper selection of cutting tools and cutters is also
important. Refer to table 6-1 and Chapter 3 for
guidance on tool selection. For large damage removal
with long straight cuts, an Kett saw with a diamond-
coated blade is the fastest and most accurate method.
When a slightly curved section is reached, a diamond-
coated cut-off wheel mounted on a die grinder works
well. A hand operated cutting wheel is also adequate
for most thin laminates (up to 0.100 inch thick). Curves
with tight radii will require the use of a router motor
with a diamond-coated 1/4 inch bit. Moderate sized
damaged cutouts with only short straight sections
are best made with the router and diamond-coated
bit or a diamond-coated hole saw mounted in a
drill motor. Small damage, which fits easily within
a small circular cutout, is easily accomplished with
the diamond-coated hole saw motor combination. See
table 6-1 for a ranking of cutting methods for particular
applications.
6-4
Limitations
Straight Lines
Slower/Template Recommended
Template Recommended
Multiple Sizes Required
Multiple Sizes Required
Slow
Avoid breathing dust from cutting or machining
operations. Use vacuum equipment when
available. Wear eye protection during all
material removal operations. As a minimum,
wear a dust mask and ensure adequate
ventilation. Consult with your local safety
office for the appropriate personal protective
equipment for your operation.
Exercise care to avoid cutting excessive
undamaged plies or honeycomb core during
material removal. Loss of structural integrity
may occur.
(1) Template Method. A template works well
for stabilizing the router bit during the routing oper-
ation. Templates can be fabricated from aluminum
or fiberglass stock and should be a minimum of 1/8
inch thick. A 0 degree router motor, router attach-
ment and router guide are required for this operation.
The router setback distance shown in figure 6-3 must
be considered when making the template to ensure
the correct damage outline is attained. Adjust the
position of the router bit in the router assembly to
compensate for the template thickness and to achieve
the depth of cut desired. Firmly attach the template
to the part surface with tape to prevent movement
during routing. Then move the router guide along the
template edge to establish the damage cutout shape.
Templates are limited to fairly flat surfaces. A new
template must be manufactured for each nonstandard
damage shape encountered.

Figure 6-3. Router Template Fabrication
(2) Hand Routing Method. Hand routing oper-
ations can be performed without a template, using
either a 0 degree or 90 degree router motor. Remain
1/8 inch inside the damage outline while routing.
Then, finish sand the damage cleanup hole edge to
the damage outline. Use a 90 degree router motor,
a sanding drum with an 80 grit abrasive sleeve or a
1.0 inch diameter diamond coated router bit for finish
sanding of the damage cleanup hole edge.
c. Partial Thickness Damage. Partial thickness
damage (scratches, skin gouges, small near surface
delamination damage, and other similar types of dam-
age that penetrate partially through the skin thickness)
must be sanded down to undamaged material. After
determining the damage depth and damage outline,
sand down to the damage depth. Very shallow dam-
age can be removed by blending out the damage
TM 1-1500-204-23-11
using a hand sand method. Deeper damage will
require a sanding disc (80 to 120 grit) attached to a
die grinder or a small dual action sander. Sand care-
fully as the material is removed quickly. Care must be
taken to not remove excess material beyond the max-
imum damaged depth. Since multilevel delaminations
may be present, reinspect the area in question using
NDI after the damage is removed. If delaminations
are present in the skin below the original damage
area, remove them by sanding and reinspect using
NDI. Taper the edge of the partial thickness damage
removal area to provide a smooth transition between
the damage depth and the outer skin surface. Refer
to the system specific technical manual for the proper
taper to use for blending out the damage. The length
of the taper should be 10 times the damage depth
if a taper is not specified. (See figure 6-4).
6-5
TM 1-1500-204-23-11
Figure 6-4. Partial Thickness Damage Removal
d. Core Damage. The most important considera-
tion in the removal of damaged core is maintaining
a damage cutout that is parallel to the orientation of
the core cell axis. The cells of the core are nor-
mally oriented 90 degrees to the centerline of the
repair part. See figure 6-5 and paragraph 7-5 for
cell core axis illustrations. The parallel orientation of
6-6
the damage removal cutout is needed to minimize
the gaps between the replacement core plug and the
core remaining in the part. Damaged core may be
removed by sanding, routing, cutting with a core knife
or, in some instances, with a diamond-coated hole
saw.

Figure 6-5. Core Cell Axis Orientation
Exercise care to avoid cutting excessive
undamaged plies or honeycomb core during
material removal. Loss of structural integrity
may occur.
DO NOT delaminate opposite skin inner sur-
face when removing damaged core or damage
the adjacent core or skin when sanding. Loss
of structural integrity may occur.
NOTE
If the core is going to be potted rather
than replaced, core surface need not be
perpendicular to the core cell wall.
TM 1-1500-204-23-11
(1) If damage cleanup hole is 1.5 inches in
diameter or less, remove damage down
to undamaged core by sanding with a 90
degree router motor and a silicon-carbide
abrasive disc. Sand slowly and carefully to
minimize damage to the adjacent core and
to maintain a flat surface in the core cutout
which is 90 degrees to the core cell axis.
Vacuum clean the repair area.
(2) Using a core slicer or core knife carefully
slice down the core cell walls to separate the
core in the damage cleanup area from the
remaining part core section. Use the dam-
age cleanup hole in the skin as a guide. Slice
along the part core cell axis. Ensure core
slicer cutting edge is sharp. See figure 6-6.
6-7
TM 1-1500-204-23-11
Figure 6-6. Removal of Core With Core Knife
(3) If only one skin has been damaged, use the
core slicer to separate the core. Then, com-
pletely remove separated core in the dam-
age cleanup hole area down to the opposite
skin inner surface.
(4) Low density core can easily be removed
by causing cell wall failure using needle
nose pliers and a gentle pulling and twisting
motion. Be careful not to delaminate the
opposite side skin during removal. Use a 90
degree router motor and an 80 to 100 grit
abrasive disk to remove the core and adhe-
sive from the inner surface of the opposite
skin. It is acceptable to allow some adhe-
sive to remain on the inner skin surface to
avoid sanding into the laminate. If difficulty
in removing the core is encountered, employ
the procedures in step (b) below.
(a) High density core is sometimes diffi-
cult to remove. Remove only enough
6-8
adhesive to produce a smooth finish.
Remove by sanding with a 90 degree
router motor and an 80 to 100 grit abra-
sive disk. Use care during sanding not
to damage adjacent core areas or sand
into the opposite side skin. It is accept-
able to allow some adhesive to remain
on the inner skin surface to avoid sand-
ing into the laminate.
(b) An alternative method is to use a router
with a diamond-coated or carbide bit.
When this method is used, a depth
controlling fixture or template must be
used to control the depth of the material
removal. Template design must take
into account the cell orientation in order
to maintain a cut perpendicular to the
core cell axis. See figure 6-7 to view
template orientation and figure 6-8 for
typical router setup with the template.
 TM 1-1500-204-23-11

Figure 6-7. Template Orientation

Figure 6-8. Typical Router Setup With Template

6-9
TM 1-1500-204-23-11
(c) Vacuum core and sanding residue from
repair area. Wipe inner skin surface
using clean, dry cloth to remove remain-
ing sanding residue. Tape barrier mate-
rial or release film over the area to pre-
vent contamination.
(5) Vacuum core and sanding residue from
repair area. Wipe inner skin surface using
clean, dry cloth to remove remaining sand-
ing residue. Tape barrier material or release
film over the area to prevent contamination.
e. Defect Removal Assessment. When material
is removed in an attempt to remove a defect, the
part must be re-inspected to verify all the damaged
area was actually removed. Two considerations make
this necessary. First, most NDI methods, including
all ultrasonic and resonance methods, are capable of
finding only first layer damage. For example, deeper
delaminations are masked (covered) by the delami-
nation nearest the transducer or probe. Thus, after
removing what initially appears to be all the damage
present, it is necessary to confirm that no hidden
defects are present. Second, certain defects tend to
propagate during the material removal operations. For
example, delamination in a laminate skin may grow
larger during the sanding or grinding operation that
removes the delamination. Thus, material removal
in the vicinity of the original defect may not ensure
complete removal of all defects. For this reason, it
is important to inspect the material surrounding the
defect for additional damage prior to patch application.
6-5. CLEANING PROCESS. Proper preparation of
the repair area before any bonded repair process
proceeds is crucial in ensuring a quality bond is
achieved. Strength and durability of the bonded
patch will be adversely affected if the repair area
is not prepared properly. Poor surface cleaning and
improper vacuum sealing will greatly compromise the
ultimate strength of the repair. This section discusses
the materials and techniques for preparing composite
and metal surfaces for composite patches. If you
are preparing a metal surface for a composite patch,
you must use special surface preparation techniques
on the metal; refer to the system specific technical
manual. In some cases, system specific technical
manuals may omit the solvent wipe step; this step
should only be omitted when authorized by the system
specific technical manual or engineering authority.
Use solvents in a well ventilated area. Sol-
vents must be used only when wearing
approved health and safety equipment. Most
solvents are flammable and have low flash
6-10
points. DO NOT USE flammable solvents
near open flames. Inhaling solvent vapors
and mists may cause respiratory irritation.
In extreme cases, exposure can cause fluid
accumulation in the lungs and central ner-
vous system depression. In case of accidental
ingestion, a physician or local poison control
center shall be contacted immediately.
All surfaces must be wiped before solvent
evaporates. DO NOT leave solvent soaked
cloths on surfaces.
a. Surface Cleaning Requirements. Prior to the
part being processed for repair, the part surface
must be cleaned and dried to remove dirt, grease,
aircraft fluids, and Nondestructive Inspection (NDI)
couplant. This prevents potential contamination of the
repair adhesive bondline as well as contamination of
equipment and facilities. Hand sanding will remove
dry contaminants and improve the bonding surface.
Whenever possible, sand parallel to the fiber direction
with fine grit sandpaper. Cleaning solvents may
then be used to remove any remaining contaminants.
Always refer to the system specific technical manual
for any particular cleaning procedures.
(1) Wiping Cloths. Approved cloths are low
lint and are tested to contain a minimal amount of
contaminates; see Chapter 3 for selection of approved
cloths. Care should be taken to ensure the solvent
of choice does not affect the wipe cloth. Methyl Ethyl
Ketone (MEK) dissolves polyester blend cloths and
most other synthetic blend cloths, leaving a residue
on the surface that will affect the bond strength.
(2) Solvents. Solvents are used to clean an
area of dust, oils, adhesives, and other contaminants
prior to bonding or painting. See Chapter 3 for
selection of approved solvents and cloths. Care
must be taken to prevent these solvents from being
contaminated.
b. Wiping Process. Several applications of the
cleaning solvent should be used and applied each
time with a clean, dry, lint-free wiping cloth. Clean
an area at least twice the size of the repair. Use
one of the following methods:
(1) Method 1. Start from the center of the repair
area and wipe towards the outside. After one pass
has been made, fold or flip the rag so a clean
area of the rag will be used. Dry wipe before solvent
evaporates. Switch to clean cloths frequently. Repeat
until the entire area is clean before applying adhesive
or repair plies. Repeat the entire wiping process until

the rags show no signs of contamination. Allow the
surface to dry completely (usually 15 minutes after
solvent has evaporated) before applying adhesive or
repair plies.
(2) Method 2. Start from one side of the repair
and wipe straight across to the other side. After one
pass has been made, fold or flip the rag so a clean
area of the rag will be used. Dry wipe before solvent
evaporates. Switch to clean cloths frequently. Repeat
until the entire area is wiped. Repeat the entire wiping
process; however, wipe a slightly smaller area, being
careful not to pull contaminates from areas that were
not wiped. Repeat until the rags show no signs of
contamination. Allow the surface to dry completely
(usually 15 minutes after solvent has evaporated)
before applying adhesive or repair plies.
(3) Cleaning Procedures. Surface cleaning is
critical both before and after almost every step of the
bonded repair process. Pre-cleaning removes all the
gross oils, greases, dirt, etc., that might otherwise
contaminate the repair surface and any tool or mate-
rial used in subsequent process steps. Ground in
contaminants can be very difficult to remove; there-
fore, it is recommended to pre-clean all repair areas
per paragraph 6-5 before performing any machining
or sanding. Use the appropriate safety equipment as
described in Chapter 3. Use only approved solvent
and wiping cloths as specified in the system specific
technical manual.
Do not wash composite parts with high pres-
sure washers. Damage to the part will result.
Do not dip the wiper cloth into the solvent
container or hold the cloth to the container
opening when dampening the cloth. This
can contaminate the solvent remaining in the
container. The preferred method is to squirt
or pour the solvent onto the wiper cloth.
NOTE
This cleaning process is not to be confused
with the surface cleaning process for final
bonding. The cleaning process for final bond-
ing may differ from the procedure outlined.
Follow the cleaning procedure recommended
in the system specific technical manual and
the particular bonding application.
(a) Precleaning. When the repair is being
performed adjacent to dirty or greasy areas, it is good
practice to wash a large surface area around the repair
using water and the appropriate aircraft cleaner. If
TM 1-1500-204-23-11
the part is removable, wash the entire part, including
any grease fittings. This will help contaminants from
inadvertently migrating into the repair zone. Water
washes should not be performed in areas with skin
damage over core or areas where water intrusion
and part drying may be difficult. Use the following
procedure for cleaning the repair area:
1 Visually inspect part for skin pene-
trations, openings or edge delamina-
tions.
2 Mask all penetrations and openings
using water, vapor proof barrier mate-
rial and pressure sensitive tape.
3 Clean the part using a detergent
cleaning compound. Apply cleaner
solution to the part using wiping cloths
(AMS 3819B).
4 Scrub the solution into stubborn areas
using a nonmetallic bristle brush or
Scotch Brite pad (white) until the sur-
face deposits are loosened. Do not
damage outer surface ply fibers near
panel edges or in fastener hole coun-
tersink areas.
5 Rinse part with fresh water and dry
with clean, dry, lint-free wiping cloths
(AMS 3819B). Do not use a com-
pressed air supply to dry part as
contamination and/or damage to the
composite laminate may result.
6 After part is dry, remove the mask-
ing material carefully to prevent
pulling fibers out of the laminate.
Remove any remaining contamina-
tion (grease, oil, etc.) left on the part
following detergent cleaning using
lint-free wipes and solvent per para-
graph 6-5.
(b) Solvent Wipe. Perform the following
steps for cleaning the repair area:
1 While wearing the required safety
equipment, pour or squirt solvent
onto a lint-free cloth. Wipe using the
processes outlined in paragraph 6-5
being careful not to contaminate the
repair area. Always wipe from the
center of the repair area out towards
the edge. Follow immediately with
a clean, dry cloth before the solvent
can evaporate. Discard the wipes
after each use. Clean an area at least
6-11
TM 1-1500-204-23-11
2 to 4 inches larger than the proposed
repair area in all directions.
2 Continue wiping until the entire repair
area has been cleaned. The area is
clean when the dry wiping cloth con-
tains no visible residue after use.
3 Pay special attention to fasteners,
crevices, and seams where contam-
inants may be entrapped. These
areas may have to be flushed with
solvents. Solvent resistant brushes
may be used as an aid for crevice
and fastener cleaning.
6-6. DRYING PROCESS. This paragraph is used in
conjunction with paragraph 6-18, Vacuum Bagging,
and paragraph 6-19, Curing. For information on
the equipment cited in the following paragraphs, see
Chapter 3.
a. Composite Moisture Absorption. Composite
skins and sandwich structure inherently absorb water
and moisture when exposed to the environment for
extended periods of time (several months). This
water and moisture intrusion may not be obvious by
visual inspection of the structure. The structure may
look dry, but it is not. Some composite materials,
including resin, fiber, and core, have inherent water
absorption characteristics. This is reversible and
time/ temperature/humidity dependent. Painted lam-
inates have higher moisture content than unpainted
laminates as the paint tends to inhibit the moisture
egress from the laminate. Sandwich or honeycomb
panels are particularly prone to water absorption and
retention due to the increased air volume in these
panels. Water intrusion in honeycomb rotor blades
is one potential cause of not being able to track
and balance the blades. Cracked coatings, impact
damage, and loose fasteners all provide paths for
moisture intrusion. Moisture present in honeycomb
sandwich assemblies may not be detectable by x-ray.
b. Types of Moisture Damage. It is extremely
important to ensure water and moisture are removed
prior to performing any bonding, especially one incor-
porating a heated curing process. Standing water,
water vapor, and absorbed moisture in laminates
and honeycomb can produce the following damaging
effects:
(1) Moisture in laminate skins absorbs into the
adhesive bondline during the cure process
and results in bondline voids. This can be
alleviated when curing two part adhesive
systems by allowing the adhesive to gel
at room temperature prior to beginning the
6-12
heat cure (paragraph 6-19) or by drying the
part per paragraph 6-6e.
(2) Blistering of laminate plies can occur if the
vapor pressure of the moisture in the lam-
inate exceeds the strength of the matrix
material. The potential for blistering can
be reduced by drying the repair area as
described in paragraph 6-6e.
(3) Skin to core disbonds and honeycomb core
node bond failures can occur if the pres-
sure in the core (due to heating air and
trapped moisture in the core cells) exceeds
the strength of the skin to honeycomb core
bond and/or the strength of the core node
bond. The potential for node bond failure
and skin to core disbonds can be reduced
by reducing the repair cure temperature.
Laminate drying as described in paragraph
6-6e is still required prior to performing the
cure cycle to reduce bondline porosity and
the potential for laminate blistering. If liquid
water is present in the honeycomb sandwich
assembly (as detected by x-ray), use one of
the water removal procedures described in
paragraph 6-6e.
c. Field Concerns. In the field environment, repair
time and equipment may be limited. The parts must
be dried as much as possible, and this can be
a lengthy process. To mitigate the effects of any
moisture not removed during the drying process,
cure temperatures of 210 °F or below should be
used if authorized by the system specific technical
manual or engineering authority. Curing at less than
the optimum temperature, even when authorized,
will prevent adhesives from reaching their ultimate
properties; however, loss of adhesive strength is
more desirable than inducing damage from water
vapor pressure during the cure cycle.
d. Drying Verification. To ensure the repair area
is dry, a desiccant can be installed into the vacuum
bag to monitor the moisture removal. A moisture
indicator is used to determine if a part is dry following
a drying cycle; it uses a color changing desiccant to
indicate the presence of moisture. See paragraph 3-5j
for details on the moisture indicator. The verification
process involves inserting a tube, which will be used
to hold the color changing desiccant, in line between
the vacuum bag and the vacuum pump. The part is
heated in an oven (if possible) or in an envelope bag
with heat blankets. The temperature is held at the
drying temperature for several hours. At the end of
the drying cycle, a fresh supply of desiccant is placed
in the tube. If the desiccant picks up moisture over
the final hour (which will be indicated by a change in
color of the desiccant), the part is not dry; continue

drying and repeat the drying verification. Desiccant
can be reactivated by drying in an oven at 150 to
200 °F until the color change is reversed.
(1) Temperature and Altitude Considera-
tions. As discussed previously, absorbed moisture in
composite laminates can cause problems when heat
is applied during the curing process. It is, therefore,
necessary to dry the part prior to curing using drying
temperatures that do not allow the moisture vapor
pressure to exceed the matrix strength. Generally,
the part is not dried at a temperature higher than the
service temperature of the material used to manu-
facture the part and the phase shift (water to steam)
temperature of water (at sea level this would be 212
°F and decreases with increasing altitude, about 190
°F at 5,000 feet).
e. General Procedures. Always refer to the sys-
tem specific technical manual for any peculiar drying
Figure 6-9. Average Drying Time for Advanced Composite Laminates
Always dry an area larger than the repair
size. The heat blanket should extend at least
2 inches beyond the repair edges. DO NOT
use the following drying procedure if liquid
water has been detected in the honeycomb
sandwich assembly.
Take care not contaminate the repair surface
prior to bonding. Use only uncontaminated
TM 1-1500-204-23-11
procedures. When the service temperature of the part
is unknown or no system specific drying information
is given, a commonly used method is to heat the part
to 150 °F and hold it at that temperature until dry.
See figure 6-9 for typical drying times for different
laminate thicknesses. A vacuum chamber or a vac-
uum bag placed over the repair area will significantly
decrease drying time. The time required to completely
dry the skin varies with skin thickness, initial mois-
ture content, and drying temperature. Fortunately, it
is not necessary to completely dry the skin to pre-
vent laminate blistering and/or bondline porosity as
completely drying thin skins (4 to 10 plies) may take
more than 10 hours; completely drying thicker skins
(12 plies and up) can take more than 30 hours. It is
only necessary to reduce the near surface moisture
content by using the appropriate drying procedures.
fiberglass cloth as a breather material. Other
breather/bleeder materials may contaminate
the bonding surface. Heat-set and scoured
peel plies are appropriate breather material.
Direct contact between the heat blanket and
vacuum bag can burn the bagging material and
result in loss of vacuum. DO NOT exceed the
specified drying temperature or part damage
may result.
6-13
TM 1-1500-204-23-11
(1) Heat Blanket/Vacuum Technique.
Never use less than three thermocouples to
monitor a heating cycle. Support removed
core areas, exposed core and core edges to
prevent the vacuum bag from damaging or
crushing the core.
The following drying procedure is an effective
method for drying laminate parts with high moisture
content. This drying method works well on all com-
posites. See figure 6-9 for typical drying times for
composite laminates.
(a) Ensure damaged material and paint
have been removed in preparation for
the bonded repair. Support removed
core areas, exposed core and core
edges to prevent the vacuum bag from
damaging or crushing the core.
(b) Machine the repair joint as described in
the appropriate repair section. Never
use less than three thermocouples to
monitor a heating cycle.
(c) Attach thermocouples to the part at
least 2 inches in from the edge of the
heat blanket that will be used. Connect
the thermocouples to both a monitor
and recording device if required.
(d) Place two plies of fiberglass breather,
7500 if available over the area to be
dried to provide a moisture escape path,
other fiberglass weaves such as 181 or
120 are not as permeable. Use one of
the following guidelines when selecting
a breather:
1 Commercially manufactured
breather cloths have contaminates
and should not be placed directly
on the repair area.
2 Two plies of fiberglass cloth; 7500
weave is preferred because it
is more permeable than other
weaves; or,
3 Three plies of heat-set and scoured
peel ply; other peel plies may have
release agents and/or contami-
nates which will interfere with the
future bonding operation. Alternate
the weave orientation of the plies
by approximately 45 degrees to
6-14
give more permeability and allow
moisture to be drawn out; or see
step four.
4 One ply of heat-set and scoured
peel ply placed directly over the
damage removal area followed
by breather cloth. Heat-set and
scoured is a process performed by
manufacturers during the produc-
tion of certain peel plies.
(e) Prepare and apply a vacuum bag over
the breather material and the insulated
heat blanket. See paragraph 6-18 for
additional vacuum bagging information.
A minimum vacuum of 22 inches of
mercury is initially required. If available,
insert a moisture desiccant/moisture
indicator (shown in figure 3-26) between
the vacuum source and the vacuum
bag.
(f) After a good vacuum seal is made, at
the end of the bag and farthest away
from the vacuum source, induce a seal
leak. This seal leak provides air move-
ment through the bag, drawing the
moisture out. A vacuum level of 10 to
16 inch mercury should be utilized.
(g) Heat the part surface to 20 °F less
than the part service temperature or
180 (±10) °F, whichever is lower, at a
rate of approximately 5 to 10 °F per
minute. Hold at temperature until dry.
See drying chart in figure 6-9. Cool at a
maximum rate of 10 °F per minute down
to ambient temperature. Release the
vacuum and remove the entire vacuum
bag. If the moisture indicator still shows
moisture present, lengthen hold time
until no moisture is present.
(h) Sand the area lightly, as necessary as
allowed by the repair procedure.
(i) Proceed with the repair.
(2) Oven Technique. Use this procedure when
an oven is the heat source for performing bonded
repairs. This will ensure that any undetectable water
vapor in the core assemblies will not cause part
damage. It is also used for removal of water located
in a nonrepairable zone. The oven is used to heat the
water in the part and to drive it out the way it came
in. An envelope vacuum bag (a vacuum bag that
completely surrounds the part) is used to ensure a
path exists for moisture egress. A moisture indicator

is used to determine when drying is complete. This
procedure can only be used when the part can be
removed from the aircraft and an oven large enough
to hold the part is available. Perform the following
procedure for drying composite parts in an oven.
(a) Ensure damaged material and paint
has been removed in preparation for
the bonded repair. The paint should be
removed from an area larger than the
repair area.
(b) Machine and prepare the repair joint as
described in the appropriate repair sec-
tion.
(c) Attach thermocouples to the part in the
repair area.
(d) A vacuum bag may or may not be used.
If one is not utilized, proceed to step (g),
otherwise continue with step (e).
(e) Place two plies of fiberglass cloth
breather over the drying area to provide
a moisture escape path.
(f) Install a vacuum bag over the area to be
dried. See paragraph 6-18 for additional
vacuum bagging information. Apply 20
to 30 inches of mercury vacuum to the
vacuum bag. After a good vacuum seal
is made, at the far end of the bag and
farthest away from the vacuum source,
induce a seal leak. This seal leak pro-
vides air movement through the bag
drawing the moisture out. A vacuum
level of 10 to 16 inch mercury should be
utilized. If available, insert a moisture
indicator between the vacuum source
and the vacuum bag.
(g) Put the part in the oven and ramp the
heat to the specified drying tempera-
ture. Heat the part to 20 °F less than the
part service temperature or 180 (±10)
°F, whichever is lower. Upon reach-
ing the specified temperature, hold for
the minimum amount of time shown in
figure 6-9 or until the moisture indica-
tor shows no moisture present. The
TM 1-1500-204-23-11
drying temperature and time should be
recorded either using the thermocou-
ples applied to the part and a tempera-
ture recording device (preferred) or the
oven temperature recorder. If neither
of the recorders are available, temper-
ature recordings should be made man-
ually at 15 minute intervals.
(h) Cool to room temperature at a rate not
to exceed 10 °F per minute.
(i) Disassemble the vacuum bag and
remove the thermocouples.
(j) Inspect the part to determine the mois-
ture/water entry point. If the entry point
can be determined, seal the area with
liquid adhesive. Refer to the system
specific technical manual and cure as
specified in paragraph 6-19.
(3) Removal of Water From Honeycomb Core-
. Water present in the honeycomb core, either visually
apparent or detected by x-ray, must be removed to
prevent corrosion of metallic core or moisture related
degradation of nonmetallic core. Areas containing
water will appear lighter than adjacent areas in an x-ray
film. However, the presence of cured liquid adhesive
from a previous disbond or delamination repair can
give a similar appearance. If the water indication is in
proximity to a previous repair, obtain assistance from
an NDI technician to determine if water is present.
Water must be removed prior to using a cure temper-
ature of 200 °F or higher. Generally, water removal is
performed at a lower temperature than the laminate
drying temperature to prevent damage to the honey-
comb sandwich assemblies due to steam pressure.
Selection of the procedure to use is dependent upon
availability of equipment and materials, whether the
part can be removed from the aircraft and whether
the water is located in a repairable area.
(4) Heat Blanket, Oven or Hot Air Module
Method. This procedure uses any heat source to
locally heat the water in the assembly causing it to
egress out of the part. It is the easiest method to
use and is effective only when the moisture in the
area being heated has an open path to the vacuum
bag.
6-15
TM 1-1500-204-23-11
Support removed core areas, exposed core,
and core edges to prevent the vacuum bag
from damaging or crushing the core. DO
NOT exceed the specified drying temperature
or part damage may result.
(a) Perform NDI of part to determine loca-
tion of water in the core. If liquid water
has been detected in the honeycomb
sandwich assembly, proceed with step
(b). Otherwise proceed to step (e).
(b) Remove paint in the patch bond area as
described in paragraph 6-1. The paint
should be removed from an area larger
than the repair area.
(c) If the part has water in a nonrepara-
ble zone, as defined in the system spe-
cific technical manual, refer to the oven
method or use a heat module and tent
as described in paragraph 6-6.
(d) If the part has water in a reparable zone,
as defined in the system specific tech-
nical manual, drill holes through skin in
the area containing water. Use a 0.125
inch diameter carbide drill bit. For each
square inch of water accumulation drill
two holes.
(e) Machine and prepare the repair joint as
described in the appropriate repair sec-
tion.
(f) Layup heat blanket, thermocouples,
and vacuum bag as described in para-
graph 6-18 over the area containing
water.
(g) Apply 20 to 30 inches of mercury vac-
uum to the vacuum bag.
(h) After a good vacuum seal is made,
at the far end of the bag and farthest
away from the vacuum source, induce
a seal leak. This seal leak provides air
movement through the bag, drawing
the moisture out. A vacuum level of 10
to 16 inch mercury should be utilized.
If available, insert a moisture desiccant
indicator between the vacuum source
and the vacuum bag.
(i) Heat the part to 20 °F less than the
part service temperature or 180 (±10)
6-16
°F, whichever is lower. Do not exceed
10 °F per minute ramp rate.
(j) Upon reaching the specified temper-
ature, hold for the minimum time as
shown on figure 6-9. If a moisture
indicator has been utilized, hold at dry-
ing temperature until no moisture is
present.
(k) Cool to room temperature at a rate not
to exceed 10 °F per minute.
(l) Disassemble vacuum bag, heat blanket,
and thermocouples.
(m) Reinspect area using NDI to determine
if water has been removed or if it has
migrated to another location.
(n) If water has been removed from the
assembly, proceed to repair steps. Oth-
erwise, continue drying until all moisture
has been eliminated.
(o) If water has migrated as a result of the
drying process or if the previous proce-
dures prove unsuccessful and the water
is still in a repairable zone, remove the
skin from the area containing water.
Remove the skin cautiously to minimize
damage to the core underneath. After
skin removal, repeat the process start-
ing at step (d).
(p) If holes were drilled in skin, seal holes
with liquid adhesive and bond an exter-
nal patch over the drilled holes using
paragraph 7-6.
(q) If the skin was removed and/or the core
damaged, repair skin and core in accor-
dance with paragraph 7-5.
(5) Other Local Heat Sources. A quartz lamp
and hot-air module are two other heat sources. These
two sources are least effective in drying and must
be used in conjunction with a process controller to
control temperature.
(a) Quartz Lamps. Quartz lamps may be
used as a heat source, but the drying time must
be extended to ensure moisture removal. Follow the
procedures in paragraph 6-6e; however, do not use
the fiberglass breather and vacuum bag.
(b) Hot Air Module. A hot air module or heat
gun may also be used as a heat source for drying
composites. A vacuum bag and heat entrapment tent

will be required. The heat entrapment tent may be
fabricated from nylon vacuum bag material taped to the
part surface outside the repair area and insulated as
required with polyester or fiberglass breather material.
6-7. SURFACE PREPARATION FOR BONDING. T-
he simplicity and high degree of bond durability of this
process has contributed significantly to the repairability
of advanced composite parts. Unlike metallic parts,
the surface preparation does not require an elaborate
and process sensitive procedure using chemicals that
are difficult to work with and dispose of to obtain a
successful bond.
a. Surface Preparation For Resin Matrix. Surface
preparation for resin matrix composites consists of
sanding with fine grit abrasive paper. Clean according
to paragraph 6-5 until no further evidence of sanding
residue appears on the cloth.
(1) Use wiping cloth for wiping. This will reduce
the potential for contamination of surfaces to
be bonded.
NOTE
If the patch is precured and contains peel
ply material, the peel ply should be left on
the patch until the surface preparation step
to prevent contamination.
(2) Cover surfaces prepared for bonding with
clean barrier material taped in place to pre-
vent contamination while preparing for layup.
b. Surface Preparation For Pre-cured Composite
Patches. Perform the following steps to prepare a sur-
face for bonding using pre-cured composite patches.
(1) Cautiously remove the peel ply from both
surfaces of the patch to prevent pulling fibers
out of the patch material. If fiber removal
starts during peel ply removal, change the
peel ply removal direction so that peel ply
is being removed 90º to the patch outer ply
fibers.
(2) If the patch is cut from pre-cured square
sheet stock, the edge of the patch must
be tapered. Tapering is required to reduce
adhesive peel stresses at the edge of the
patch. First, cut the patch from pre-cured
square sheet stock to the dimensions
required for the repair patch. Then, taper
the patch edge as shown in figure 6-10. Use
a 90 degree router motor and an 80-100 grit
abrasive disk.
TM 1-1500-204-23-11
Figure 6-10. Patch Edge Taper Dimensions
(3) Sand (by hand or with an orbital sander)
both surfaces of the patch with an abrasive
paper according to the system specific tech-
nical manual. If no sandpaper is specified,
use 150-180 grit. Ensure that the majority of
any peel ply impressions on the patch sur-
face are removed as these impressions can
act as recesses that will trap air and other
vapors. Sand carefully to minimize removal
of load carrying fibers. Ensure 100% cover-
age of the patch surfaces during sanding.
(4) The patch still requires sanding even if peel
ply was not used during patch manufacture
(peel ply impression will not be present on
patch surface). This will remove any poten-
tial contamination from the patch manufac-
turing process and will roughen the surface
ensuring.
(5) Wipe the sanded surfaces with a clean, dry
cloth to remove sanding residue. Inspect
the cloth for evidence of sanding residue.
Repeat wiping process until no further evi-
dence of sanding residue exists on the cloth.
For each repeat wipe use a new, clean, dry
cloth.
(6) From this point forward, handle the patch
wearing powder free latex gloves. Cover the
patch with clean barrier material until ready
for layup.
c. Surface Preparation for a Part Surface. Per-
form the following steps to prepare the part surface
for bonding.
(1) Sand the part surface in the area where the
patch is to be applied with an abrasive paper
according to the system specific technical
manual. If no sandpaper is specified, use
150-180 grit. Ensure the majority of any
peel ply impressions on the part surface
are removed. Sand carefully to minimize
removal of load carrying fibers. Ensure
100% coverage of the patch bond area.
6-17
TM 1-1500-204-23-11

(2) Wipe the sanded surfaces with a clean, dry
cloth to remove sanding residue according
to paragraph 6-5. Inspect the cloth for evi-
dence of sanding residue. Repeat wiping
process until no further evidence of sanding
residue exists on the cloth. For each repeat
wipe use a new, clean, dry wiping cloth.
(3) Cut a clean piece of barrier material larger
than the area to be covered by the vacuum
bag/heat blanket. Tape the edges of the bar-
rier material to the paint system on the part
surface using preservation tape.
In general, temperatures due to drilling that exceed
the cure temperature of the matrix material being
drilled are cause for concern. The use of sharp cut-
ters, correct cutter material, control of feed rates and
use of coolant are all means used to control heat
buildup. In addition, matrix materials are compara-
tively weak in the out-of-plane direction and do not
provide adequate support for the fibers being cut to
prevent fiber breakout and splintering. Cutting tech-
niques which use out-of-plane cutting forces (band
sawing, table sawing and drilling, etc.) should use
backup material clamped on the exit side of the work
piece to reduce breakout whenever possible. Cutting
techniques which cut in-plane (router bits and sanding
drums) do not require backup material. (See figure
6-11).

Scuff sanding and solvent wipe is not an

acceptable surface preparation treatment for
metals.

d. Surface Preparation For Metal Bonding. Metal

treatment for bonding is also critical and care must be
taken to create an active surface for bonding in addition
to removing contaminates. Additional methods must
be used to prepare the surface for bonding. Some of
the methods include, but are not limited to, Alodine,
phosphoric acid anodizing, grit blast silane, sol gel
application or chemical conversion coatings. See the
system specific technical manual for metal surface
preparation techniques.

6-8. MACHINING, DRILLING, REAMING AND COU-

NTERSINKING ADVANCED COMPOSITES. Compo-
site materials may be sawn, cut, trimmed, and routed
using tools similar to those used on metals; however,
the tool’s cutting surfaces are made, preferably, from
diamond-coated materials when machining carbon or
boron fiber reinforced materials. The abrasiveness
of these materials degrades cutter performance and
drastically reduces cutter life. Using diamond-coated
tools ensures a quality cut and prolongs tool life.
Carbide tools can be utilized where a system spe-
cific technical manual directs such usage. Using
the correct tools and procedures to remove damage
from advanced composite aircraft structure provides
a satisfactory bonding surface for subsequent repair.
However, the use of improper tools and equipment
will further damage the repair area. This section does
not address how to cut, drill or trim panels made
with thermoplastic resins.
Figure 6-11. In-Plane Versus Out-Of-Plane Cutting
a. Matrix Materials. These materials although rel- Forces
atively easy to cut have an inability to dissipate heat
coupled with a low tolerance for heat buildup. Exces- b. Fibers. Fibers respond differently to machining,
sive heat buildup can result in resin damage and drilling, reaming and countersinking. The following
delaminations. Bismaleimide and polyimide resins paragraphs identify the characteristics of boron, car-
are more tolerant to heat buildup than epoxy resins. bon, and Kevlar®,

6-18

(1) Boron. Boron fibers are harder than most
conventional cutting materials (tungsten carbide, alu-
minum oxide, silicon carbide and tool steel) and
require the hardness of diamond for cutting. Vibra-
tory stress can be setup along the tungsten filament
during machining which may result in damage to the
boron fiber.
(2) Carbon. Carbon fibers are very abrasive
and rapidly dull high speed steel (HSS) cutters during
cutting operations. Either carbide or diamond is
acceptable materials to use for cutting carbon fibers.
Carbon fibers can be readily sanded and cut using
abrasive materials. Silicon carbide is the most effective
abrasive material for sanding carbon fibers. During
sanding the silicon carbide particles fracture exposing
a fresh cutting surface. By contrast, aluminum oxide
abrasive dulls during sanding reducing its material
removal capability. During cutting operations, carbon
fibers experience a brittle fracture of the fiber.
(3) Kevlar®. Kevlar® fibers are more ductile
and tougher than either boron or carbon. While
this has advantages in terms of impact resistance,
it provides problems during machining. Rather than
a brittle fracture occurring during cutting operations,
the Kevlar® fibers split along their length resulting
in fuzzing of fiber ends. In addition, Kevlar® fibers
have a relatively low compressive strength and tend
to recede into the matrix instead of being sheared off
during machining operations. To reduce fuzzing and
produce smooth edge cuts, cutter designs attempt to
keep the fiber preloaded in tension while shearing
the fiber. Sharp HSS or carbide cutters are adequate
for shearing Kevlar® fibers. Unlike dust generated
when machining carbon fibers, Kevlar® fibers tend
to generate clumps of subfibers (fibrils) which clog
cutters and reduce the quality of cut surfaces.
(4) Fiberglass. While not quite as abrasive as
carbon fibers, fiberglass is still capable of dulling high
speed steel (HSS) cutters during cutting, machining
and drilling operations. In general, the same tooling
used to machine and drill carbon fiber should be used
for fiberglass.
c. General Safety. These are general safety
instructions to know and follow prior to executing
machining, drilling, reaming, or countersinking proce-
dures.
(1) Select the tools based on the recommenda-
tions in the system specific technical manual
or Chapter 3 of this manual.
(2) Follow the general tool use guidelines in
Chapter 3 and the material specific guide-
lines in paragraph 6-8.
TM 1-1500-204-23-11
(3) When using diamond tools inspect cutting
surfaces before use and replace if diamond
plating appears worn or if bare metal areas
are evident. Remove resin or other contam-
ination from diamond tool cutting surfaces
before use.
(4) Carbide tools are significantly heavier than
HSS tools and can be distinguished from
them by their difference in weight. When
using carbide tools, inspect and replace if
nicks, chips or other defects are present on
the tool cutting surface. Keep cutting sur-
faces free of resin buildup. Carbide tools are
very brittle and cutting surfaces are easily
broken or chipped if dropped. Use care in
handling.
(5) Cutting forces increase considerably as tools
become dull. It is essential to use sharp
cutters to provide quality cuts and minimize
the potential for delaminations. Replace or
re-sharpen tools if excessive cutting force is
encountered during cutting operations.
(6) The use of bandsaws, table saws and radial
arm saws for cutting generate a consider-
able out-of-plane cutting force and should
not be used on advanced composites with-
out firmly clamped backup material. Their
use on actual aircraft parts is impractical
unless cutting up scrapped parts for dis-
posal.
(7) Prevent exit side breakout/ splintering dur-
ing drilling. As the drill bit breaks through
the exit side of the laminate when drilling,
there is a sudden decrease in resistance
to drilling and a rapid increase in feed rate.
The increased feed rate results in exit side
breakout and splintering of the laminate.
Reduced strength of bolted joints can result.
Use firmly clamped backup material on drill
exit sides. When drilling blind holes, use
cutters designed to reduce drilling forces.
(8) Machined holes and edges in composites
must be deburred. Tools and techniques
vary for composites; however, methods
include hand and power sanding. When
sanding, composite laminates should be
sanded parallel to the fiber direction. When
deburring a hole, sand toward the center of
the hole. All deburring should be done with
the abrasive or tool inclined 45 degrees to
the edge. Power tools should be worked in
the direction of tool rotation.
6-19
TM 1-1500-204-23-11
(9) Machined and drilled surfaces shall be visu-
ally inspected for indications of delamina-
tions, excessive fiber breakout or overheat-
ing. Surfaces exhibiting these indications
shall be further inspected ultrasonically to
determine the extent of damage. Surfaces
of machined and drilled parts shall have a
smooth, polished appearance as opposed to
a dull, rough surface as determined visually.
Do not use oil-based coolant. Do not use any
type of coolant when holes will penetrate into
bonded honeycomb or foam core structure.
(10) Coolant can be used in conjunction with the
cutting tool to ease the cutting process by
removing debris and reducing heat buildup.
It also extends cutter life and provides some
control of dust. A high pressure, light spray
mist of water or air can be used when drilling
and reaming laminates alone or in com-
bination with metallic substructure. Non
oil-based lubricants such as BOELUBE,
cetyl alcohol, and oil-free Freon may be
used when authorized by the system spe-
cific technical manual. Coolant becomes
more important as the thickness of the lam-
inate increases. The composite should not
exceed 140 °F during drilling or machining.
Often, holes can be drilled successfully on
thin carbon laminates without the use of
coolant. Coolant use is mandatory when
machining boron fiber-reinforced materials.
Do not use coolant when cutting or drilling
honeycomb structures.
d. General Air Tool Safety. Air tools operate at
high revolutions per minute (RPM) and can cause
injury if not used properly. These are general safety
instructions to know and follow when using air tools.
(1) Always disconnect air supply hose from tools
before changing cutters or making adjust-
ments to attachments.
(2) Chuck keys or collet wrenches must always
be removed from tools before reconnecting
air supply hose.
(3) Use only sanding disks and disk holders with
positive locking features incorporated.
(4) Observe the safe speed rating of cutters,
drums and sanding disk holders. The safe
speed must be equal to or greater than the
speed of the tool.
6-20
(5) Never attempt to make arbors from nuts and
bolts for any cutter.
(6) Make sure tools and cutters are in good
condition before installing and using in air
motors (no bent shanks or loose hardware).
(7) Never hold small parts in your hands for
machining or drilling. Always secure parts
properly before beginning work.
(8) Always secure loose clothing (sleeves, etc.)
when using rotating equipment.
(9) Always start router motors before applying to
work piece.
(10) Never attempt to hold a vacuum cleaner
hose with one hand while operating equip-
ment with the other hand.
(11) Always wear the personal protective equip-
ment specified in table 2-1 before beginning
work.
6-9. CARBON- EPOXY, CARBON-BISMALEIMIDE
AND CARBON-POLYIMIDE REPAIRS. Carbon fibers
are brittle and have a tendency to break and pull
out of the laminate if not machined properly. Care
must be exercised to not force the tool or exces-
sive material removal will result. Speeds and feed
rates are important. Because most composite parts
are fabricated in layers or plies, forcing cutters into
the material and not supporting the backside of the
area being machined can create ply separations or
delaminations.
a. Repair Tools. Different types of carbon-epoxies
require varying tools to achieve the best repair. The
following paragraphs identify the recommended tools
for the type of epoxy being repaired.
(1) Woven Carbon Laminates. Woven carbon
laminates can be machined with most conventional
tools. However, the abrasiveness of the carbon
degrades the quality of the cut and drastically reduces
cutter life. To overcome this disadvantage, machining
should be done with carbide or diamond-coated tools.
(2) Unidirectional Carbon Laminates. Unidire-
ctional carbon laminates are more susceptible than
woven laminates to delamination and splintering at
the entrance and exit of the cutting tool. Depending
on the orientation of the materials, delamination and
splintering can propagate extensively from improper
speeds, feeds, and use of the wrong cutters. Carbide
or diamond-coated tooling should always be used on
unidirectional carbon laminates.

b. Machining. Diamond plated tools have proven
to be superior to carbide tools when machining carbon
fiber composites. They not only provide longer tool
life, they are not prone to breaking and chipping
during handling or use.
(1) Penetration Damage Removal. Perform
the following steps to remove penetration damage.
(a) For thin laminates and substructure ele-
ments, use 40-80 grit diamond cutting
wheels, a 90 degree router motor and
the procedures specified in paragraph
6-4b. As an alternate, 40-80 grit dia-
mond coated router bits and a 0 degree
router motor may be used. Cut outs
may be finish sanded using a 90 degree
router motor and either the abrasive
sleeve and sanding drum or the 1.0 inch
diameter diamond coated router bit.
The 1.0 inch diameter carbide router bit
while not the preferred cutter is a suit-
able alternate. Do not exceed a feed
rate of 15 inches per minute.
(b) For thick laminates use either the
template method or the hand method
described in paragraph 6-4b1 or para-
graph 6-4b2. Use 40-80 grit diamond
coated router bits. If using the hand
method, finish sand to the damage out-
line using either the abrasive sleeve and
sanding drum or the 1.0 inch diameter
diamond coated router bit. The 1.0 inch
diameter carbide router bit while not the
preferred cutter is a suitable alternate.
Do not exceed a feed rate of 15 inches
per minute.
(2) Partial Thickness Damage Removal. Re-
move the damage using a 90 degree router motor,
a sanding disk holder and an 80 grit sanding disk.
Use the procedures specified in paragraph 6-4c.
(3) Edge Trimming. When trimming edges of
laminates, determine the trim line and mark on the
part using a suitable marking pen. Sand the edge
of the part to the trim line using either the abrasive
sleeve and sanding drum or the 1.0 inch diameter
diamond coated router bit. The 1.0 inch diameter
carbide router bit while not the preferred cutter is a
suitable alternate. Do not exceed a feed rate of 15
inches per minute. Break sharp edges after trimming
by hand sanding with 150-240 silicon carbide abrasive
paper.
(4) Repair Joint Machining. There are two
types of repair joints found in Army aviation, the blunt
cut repair joint and the scarf joint.
TM 1-1500-204-23-11
(a) Blunt Cut Repair Joint. Externally bond-
ed patches use a blunt cut repair joint. This is formed
during the penetration damage removal operation.
(b) Scarf Joint. Following damage removal,
the scarf joint is machined by hand using a 90 degree
router motor an 80 grit silicon carbide sanding disk and
a sanding disk holder. Use the procedures described
in paragraph g.
c. Drilling, Reaming and Countersinking. Use
carbide drill bits, reamers and countersink cutters
only. Carbide cutters are significantly heavier than
HSS cutters. Do not use HSS cutters for carbon fiber
composites as they dull rapidly and can cause lam-
inate damage. Flat flute carbide drills, drill reamers
and carbide twist drills are used for drilling operations.
The flat flute drill is designed to reduce the feed force
required to penetrate the laminate which reduces the
potential for exit side damage.
(1) Drilling. A drill bushing and drill guide are
required to stabilize drill bits to prevent wobble and
to provide moldline perpendicularity control. Carbide
drill bits are limited to no more than 30 holes per bit.
Bits which exceed this limit must either be sharpened
or discarded.
(a) Free Hand Drilling. Use a 2,000 RPM
drill motor. Carbide twist drills are acceptable for use
if backup material is used or if small diameter injection
holes are being drilled. The Align-A-Drill, drill bushing
and drill guide are required when using twist drills
(except when drilling injection holes). Use micarta,
wood or masonite as backup material firmly clamped
to the drill exit side of the surface being drilled.
(b) Drilling Blind Holes. Use a 2,000 RPM
drill motor, carbide flat flute drill bits, the Align-A-Drill,
a drill bushing and a drill guide to drill blind holes.
(c) Set up the Align-A-Drill. Adjust the
hydraulic check damper to obtain a maximum feed
rate of 10-15 seconds per inch.
(d) Drill Press. A drill press and backup
material may also be used in lieu of the Align-A-Drill
and drill bushing. Ensure drill bit is properly chucked
to prevent wobble. Do not operate the drill press at
speeds in excess of 2,000 RPM. Use a feed rate of
4-6 inches per minute.
(e) Hole Saw. Carbide or diamond abrasive-
coated hole saws are the best choice for cutting round
holes in carbon materials.
6-21
TM 1-1500-204-23-11
(2) Reaming. A reaming operation is used to
enlarge an undersized hole to very accurate dimen-
sions in laminates with metallic material in the stack
up. Fluted reamers cut primarily on the periphery of
the hole removing 0.004 to 0.008 inch on the bore.
The removal of a small amount of material reduces
the amount of metal chips pulled through laminate
holes as well as allowing high quality close toler-
ance hole patterns to be produced. During reaming
operations, holes are first drilled in the patch mate-
rial 1/64 inch undersized using a twist drill. These
holes are then transferred into the laminate using the
patch as a guide. The inner and outer patches are
installed and the patches and laminate holes reamed
simultaneously to final size. This allows both patch
and laminate holes to be line reamed ensuring hole
center alignment.
(a) Ensure pilot on reamer engages inner
patch hole before beginning reaming.
Use straight flute, piloted carbide ream-
ers only.
(b) Perform reaming operation by hand
using a drill motor operating at a maxi-
mum of 250 RPM and a feed rate of 4-6
inches per minute. Limit holes reamed
to no more than 10 per reamer. Ream-
ers which exceed this limit must be
sharpened or discarded.
(3) Countersinking. Following drilling, lami-
nate holes must be countersunk if flush head fasteners
are to be installed. To ensure countersinks are cut
to the proper depth and are correctly oriented with
the part surface, use a countersink micro stop cage.
(a) Select the carbide countersink cutter
(or HSS cutter body with carbide chips)
with the pilot diameter that corresponds
to the drilled hole being countersunk.
Insert the cutter in a micro stop cage
and adjust depth.
(b) Install the micro stop cage in a 2,000
RPM drill motor. Center cage over hole
to be countersunk and ensure piloted
cutter is aligned with hole.
(c) Cut the countersink to the depth set in
the micro stop cage. Use a feed rate of
4-6 inches per minute. Ensure counter-
sink cutter is rotating before contacting
laminate surface to prevent splintering.
6-10. KEVLAR®-EPOXY REPAIRS PROCESS. W-
oven aramid laminates are easier to drill or machine
than unidirectional laminates, and plain-weave lami-
nates are easier to drill or machine than satin weave
6-22
laminates. Dense fabrics tend to be easier to drill
or machine than loose fabrics. The unique physical
properties of aramid fibers call for different cutting
tools than those used to drill or machine carbon or
glass composites. Sawing, drilling or machining of
any kind generally cannot be accomplished using dia-
mond or carbide abrasive or resin coated abrasive
cutting tools. The relatively low compressive strength
of aramid allows deformation to occur at relatively
low machining loads. Consequently, the fibers have
a tendency to move away from the cutter within the
laminate.
a. Machining. Laminate structure, fiber orienta-
tion, fiber content, and material process can signifi-
cantly affect machining quality and tool life. To attain
high machining quality and avoid fuzzing, the aramid
material must be pulled taut and the fibers cut in a
shearing motion. For a rotating tool, this requires that
particular attention be given to the outermost layers
and that the outermost layers are restrained and the
shearing action is directed toward the center of the
laminate. Tools that have a radical C-shaped (positive)
cutting edge and a centering point to maintain con-
centricity perform best on most laminate thicknesses.
Use of water coolant when cutting aramids helps to
reduce cutter friction and adds resilience to the fiber,
permitting cleaner cuts while reducing resin buildup on
the cutter surfaces. In general, tool selection, feeds,
and speeds are more critical in cutting aramids than
in cutting carbon or fiberglass composites.
b. Penetration Damage Removal. Use the tem-
plate method described in paragraph 6-4b1 and an
split helix router. Routing with conventional aircraft
tool steel routers is very difficult and special routing
bits have been developed which use the principle of
shearing the outermost fibers towards the interior of
the laminate. The split helix cutter is especially useful
for severing laminates into sections, cutting slots and
notches, and trimming honeycomb panels. Inspect
the router bit after every few inches of cut for clog-
ging of the bit with Kevlar® fibrils. Keep bits clean
to improve quality of the cut. Some back sanding of
the damage cleanup hole per paragraph 6-10f below
may be required to remove fuzzing. Do not exceed
a feed rate of 15 inches per minute.
c. Partial Thickness Damage Removal. Remove
damage by sanding with an 80 grit silicon carbide
abrasive sanding disk and a 90 degree router motor.
Change the sanding disk frequently as it tends to load
up with Kevlar® sanding residue. Some fuzzing may
occur. Carefully remove damage to keep fuzzing to a
minimum. Fuzzing can be removed by back sanding
per paragraph 6-10f below.

d. Edge Trimming. Trim edges using the split helix
router bit and a template as described in paragraph
6-4b1 above except use backup material (micarta,
wood or masonite) firmly clamped to the edge being
trimmed. Do not exceed a feed rate of 15 inches
per minute. Back sand and seal the trimmed edge
to remove fuzzing per paragraph 6-10f below.
e. Repair Joint Machining. Externally bonded
patches use a blunt cut repair joint. This is formed
during the penetration damage removal operation.
The method described in paragraph 6-15h makes
use of X-acto knives or razor blades to cut through
individual woven plies of Kevlar®. Some care must
be used with this technique as a significant amount
of force is required to cut through the cured epoxy
matrix and the Kevlar® fibers. There is a tendency to
cut deeper than required. Be careful not to cut any
deeper than the ply being removed or a reduction in
joint strength will result. Use only sharp blades and
replace them frequently. Use a straight edge and/or
templates to assist in cutting.
f. Removal of Fuzzing by Back Sanding. Hand
sand fuzzed areas with 120-150 grit silicon carbide
abrasive paper. Sand away from the center of the
laminate in one direction only. After majority of fuzz
is removed, dress the edge by lightly sanding parallel
to the edge of the laminate. Vacuum clean sandpaper
frequently to remove Kevlar® sanding residue. Fol-
lowing removal of fuzz, coat back sanded areas with
epoxy resin and cure to prevent excessive moisture
intrusion.
g. Drilling and Countersinking Kevlar®-Epoxy
Composites. Use the spade bit, dagger bit, and the
brad point bit or carbide countersink cutters. Bits
and cutters should be inspected after each hole for
Kevlar® fibril clogging. Keep bits and cutter clean to
improve quality of the cut. The brad point drill is a
special drill bit designed to shear the outer surface
Kevlar® fibers as it enters the laminate and produce
fuzz free holes.
Do not use a normal twist fluted drill on aramid
laminates as unacceptable hole quality and
laminate damage will result.
(1) Drilling. A drill bushing, drill guide and
backup material are required for drilling. Only sharp
drill bits should be used. Replace at frequent intervals
(after 15-20 holes).
(a) Free Hand Drilling. Drill holes using the
Align-A-Drill, a 2,000 RPM drill motor, a
bushing and drill guide to stabilize the
TM 1-1500-204-23-11
drill bit. Use micarta, wood or masonite
as backup material firmly clamped to the
drill exit side.
(b) Set up the Align-A-Drill. Adjust the
hydraulic check damper to obtain a
maximum feed rate of 120 seconds per
inch.
(c) Drill Press. A drill press and backup
material may be used in lieu of the Align-
A-Drill and drill bushing. Ensure the drill
bit is properly chucked to prevent wob-
ble. Do not operate the drill press at
speeds in excess of 2,000 RPM. Use a
feed rate of 0.5 inch per minute.
(2) Countersinking. Following drilling, lami-
nate holes must be countersunk if flush head fasteners
are to be installed. To ensure countersinks are cut
to the proper depth and are correctly oriented with
the part surface, a countersink micro stop cage is
required.
(a) Select the countersink cutter with the
pilot diameter that corresponds to the
drilled hole being countersunk. Insert
the cutter in the micro stop cage and
adjust depth.
(b) Apply flash breaker tape to outside sur-
face of hole to be countersunk. Cut
through tape to expose fastener hole.
If flash breaker tape is not available,
fuzzing of outer surface plies will occur.
Remove fuzzing and reseal with resin
per paragraph 6-10f.
(c) Install the micro stop cage in a 2,000
RPM drill motor. Center cage over hole
to be countersunk and ensure piloted
cutter is aligned with hole.
(d) Cut the countersink to the depth set in
the micro stop cage. Use a feed rate
of 0.5 inches per minute. Ensure coun-
tersink cutter is rotating before contact-
ing laminate/flash breaker tape surface
to prevent splintering.
(3) Cutting. When using scissors to cut aramid
fabric or pre-preg, use ones which have a shearing
edge on one blade and a serrated or grooved surface
on the other. These serrations hold the material from
slipping. Sharp blades should always be used as
they minimize fiber damage. Always clean the scissor
serrations immediately after use so the uncured resin
doesn’t ruin the scissors.
6-23
TM 1-1500-204-23-11
(4) Sawing. Sawing with a band saw, saber
saw, radial arm saw, circular saw or table saw can
cut panels of either solid laminate or honeycomb
successfully. Water as a coolant has been found to
be useful to remove surf and cool the cutter and the
panel.
(a) A bandsaw blade with fine teeth that is
run backwards or has a raker set with
the teeth alternately reversed produces
the best quality (see figure 3-1). Some
fuzzing that remains on the edges after
a cut may be removed by light wet sand-
ing, with the sanding directed in towards
the laminate from the edge.
(b) A table saw, radial arm saw, circular
saw or cutoff saw with fine teeth run
backwards or alternately reversed teeth
produce good quality cuts. Carbide
tips are usually required. Some fuzzing
remains on the edges after a cut may
be removed by light wet sanding, with
the sanding directed in towards the
laminate from the edge.
(c) A traditional hole saw may provide sat-
isfactory results on aramid reinforced
composite materials only when used in
the reverse cutting direction. Hole saws
do not work well on aramid laminates.
Routers or fly cutters made from high
speed steel or carbide work well when
cutting aramid composite materials.
(5) Sanding & Grinding. Grinding wheels of
alumina composition run fast at about 6500 surface
feet per minute with a shallow depth cut of 0.0005 to
0.001 inch and water will produce a desirable finish
which has a glazed appearance. Sanding with silicon
oxide abrasive paper of 80 to 100 grit with water as
a lubricant and the sanding action directed towards
the interior of the material ensures cleaned, trimmed
edges.
6-11. BORON-EPOXY REPAIRS. Boron is much
more difficult to drill or machine than other compos-
ites. Diamond-cutting tools are used when drilling
boron laminates or hybrid laminates containing boron.
The same tools used to drill carbon generally work
well for boron.
a. Machining Boron-Epoxy Composites. Dia-
mond plated tools are the only tools acceptable for
machining boron fiber composites. Water must be
used to cool the boron during machining and drilling
operations to avoid heat damage. The part must be
6-24
dried after machining to remove moisture. See para-
graph 6-6 for information on drying. See paragraph
3-5l about coolant. Machining boron fiber composites
will damage fibers resulting in strength loss.
(1) Damage removal. Use 80 grit diamond
abrasive router bits and the template method described
in paragraph 6-4b1. Use a feed rate of 2 inches per
minute.
(2) Repair Joint Machining. There are two
methods of performing repairs to boron-epoxy bonded
patches, field repairs and depot repairs.
(a) Field Repairs. Field repairs to boron/ep-
oxy composites use externally bonded patches. The
blunt cut repair joint is formed during the damage
removal operation.
(b) Depot Repairs. Depot repairs to boron-
/epoxy composites use step joints. The step joint
uses a controlled depth router and 1.0 inch diameter
diamond plated router bits.
b. Drilling Boron-Epoxy Composites. Hand drill-
ing small diameter holes for performing resin injection
repairs is the only drilling allowed on boron/epoxy
surfaces. Carbide is the specified drill bit material.
Use a 2,000 RPM drill motor, a carbide twist drill and
a maximum feed rate of 0.5 inch per minute.
c. Routing. Boron requires diamond-coated router
bits and a supply of approved coolant, either water
or alcohol based.
d. Reaming. Reaming boron requires diamond-
coated reamers.
6-12. FIBERGLASS-THERMOSETTING RESIN RE-
PAIRS. Refer to system specific manual for fiber-
glass/thermosetting resin repairs.
6-13. HONEYCOMB CORE REPAIR PROCESS. M-
achining honeycomb core replacement sections can
be difficult due to the fragile nature of honeycomb
core. Core densities of 3.5 pounds per cubic foot
(PCF) or less provide little support for machining. The
thin foil used in the construction of aluminum core
easily “rolls over” when machining 90 degrees to the
cell axis. In addition, the core has little strength 90
degrees to the cell axis and is easily distorted if it is
not stabilized during machining. The core is strongest
along its cell axis. Sawing expanded honeycomb,
either aluminum or aramid, is usually done with a
special high speed bandsaw with a blade speed of
16,000 feet per minute.

a. Vertical Cuts. These cuts are used to cut
replacement core sections from honeycomb core stock
material. The cuts are made along the core cell axis
using a core slicer or an end sharpened core knife.
A Mylar template defining the damage cut out shape
and containing the part ribbon direction should be
used as a guide in cutting the core section. The core
slicer or knife tends to dull rapidly and should be reg-
ularly sharpened to facilitate cutting. Core densities
higher than 6.0 PCF require a significant application
of force for slicing.
b. Angle Cuts. These cuts are made at an angle
to the core cell axis and require core stabilization.
Core stabilization is provided by bonding or tacking
the replacement core in place on the part prior to
machining. The part surface is then used as a guide in
machining the core to the required shape. Machining
is performed using a 0 degree router motor, a router
holder and the burr special core cutter. After the core
is stabilized in place, use a hand held hacksaw blade
to perform an initial rough cut on core (to within 0.5
inch of the part surface) to remove excess material.
(1) Install the burr cutter in router motor. Adjust
router motor in router holder so that cutting
edge of burr cutter is flush with outer mold-
line (OML) surface of part.
(2) Using the part surface as a guide, carefully
machine core flush with OML surface of part.
Start by machining around the core periph-
ery. Use caution during machining not to cut
into the part skin or to undercut core.
(3) Use a straight edge which extends beyond
the machined core and onto the part sur-
face to check that the surface of the replace-
ment core is flush with the surrounding part
surface. If the core surface is higher than
the part surface, finish sand using 180-240
grit abrasive paper and a sanding block. If
the core surface is lower than the part sur-
face, bring it flush by surface filling with paste
TM 1-1500-204-23-11
adhesive (See the system specific technical
manual).
(4) Inspect the core cells for areas of rolled over
core cell walls. Finish sand any rolled over
areas using 180-240 grit abrasive paper and
a sanding block.
(5) Vacuum the machined core surface to
remove sanding residue.
c. Foam Core. Foam core can easily be removed
with a face sheet or by itself. Hole saws or routers
can be used. Replacement foam core can be shaped
with hand tools such as knives and scissors.
(1) Use hole saw pilot drill to make a hole in the
center of the damaged skin area. Set the
blunt pilot in the hole saw 1/8” beyond the
cutting edge of the hole saw or long enough
to engage the previously drilled pilot hole in
the damaged skin. Cut through damaged
skin and core close to the opposite skin but
not cutting into it. The blunt tip pilot will pre-
vent cutting into the undamaged back side
skin.
(2) Pry off damaged skin plug and remove core
material down to the opposite face skin.
(3) Remove any remaining X-Cor® pins
attached to the opposite face sheet using a
pair of pliers.
(4) Use carbide router bits because PMI foam
tends to be fairly abrasive.
(5) Use high RPM while machining, up to 15,000
rpm.
d. Spoiling Core. This procedure can be used
for spoiling honeycomb or foam core for fastener
installation, rapid densification, or to repair a small
skin to core disbond. See figure 6-12.
6-25
TM 1-1500-204-23-11
Figure 6-12. Spoiling and Potting Core
NOTE
Failing to use a guide plate will result in
elongating the hole in the laminate and result
in additional damage.
An internal cutter can be made from an Allen
wrench. Sharpen the short leg of the wrench
so that when rotated, it will cut and push
the core material 1/4 inch beyond the desired
size to leave a clean hole. Make sure the
Allen wrench is small enough to fit through
the drilled hole and the cutter is short enough
6-26
to be inserted through the drilled hole size
and the thickness of the core. Long cutters
may not be able to be inserted into small
diameter holes or thin core structure.
(1) Determine the hole location.
(2) Drill the appropriate size hole through one
skin. Consult with the system specific tech-
nical manual for the appropriate hole size.
(3) Drill the same size hole through an aluminum
or composite guide plate.
 TM 1-1500-204-23-11

(4) Double face tape the drilled plate over the
hole in the skin using the back of the drill bit
to align the holes.
(5) Insert the internal cutter or modified Allen
wrench through the hole and rotate from the
top skin down to the bottom skin to disrupt
the core material from the skin surfaces.
replacement ply materials without an autoclave. The
step joint is generally used to repair laminates made
from woven materials. It is limited to lightly loaded
parts due to the reduced strength of replacement
plies.

(6) Remove the guide plate using a putty knife

or similar tool.

(7) Remove the disrupted core material through

the drilled skin hole using a vacuum cleaner.

6-14. CARBON-METAL REPAIR PROCESS. Twist

drills made of cobalt or carbide are recommended
for drilling through a carbon laminate with either alu-
minum or titanium substructure. Eight Faceted bits
are also used for this application.

6-15. REPAIR JOINTS. Implementing structural

repairs to advanced composite structures involves
Figure 6-13. Basic Repair Joints
repair joint machining. One of the advantages in
repairing advanced composite parts over repairing
metallic parts is the ability to machine repair joints in b. Basic Repair Joints. Restoration of strength
the laminate. Perform joint machining prior to drying and/or stiffness to damaged parts requires damaged
to ensure that the surface dried is in fact the surface areas to be joined for load path continuity. This
upon which the repair is to be performed. restoration involves a repair joint and the joining of
the patch material to an undamaged area of the part
through this joint (see figure 6-14). Load travels along
a. Repair Joint Types. There are three types of
the undamaged skin’s neutral axis through a joining
repair joints used in repairing advanced composite
material (adhesive or mechanical fasteners) into the
materials are shown in figure 6-13. The most com-
patch. The patch provides a bridge for the load across
monly used repair joint and the easiest to machine
the damaged area. Load travels along the neutral
is the blunt cut joint. It is used for externally and
axis of the patch, through the joining material and
internally bonded and bolted repairs. The scarf joint
back into the part skin. As can be seen in Detail A of
is the next easiest to machine and is used to repair
figure 6-14, the load in the skin and the load in the
laminates made from either unidirectional or woven
patch are horizontally opposed to one another. This
materials. However, scarf joints have limited applica-
sets up a shear force in the joining material. Some
tion in a field environment. They are used in the field
basic joints used for repair and their load transfer
only when moldline protrusion requirements dictate a
mechanisms are described below.
flush repair and load conditions are low enough to
allow for the reduced strength that results when curing

6-27
TM 1-1500-204-23-11
Figure 6-14. Basic Repair Joints (General)
c. Bonded Joints. Bonded joints make use of a
repair patch to carry load across the damaged region.
A common misconception is that the adhesive is
applied to hold the patch in place on the part. While
that is one function of the adhesive, the primary
function is to transfer load from the undamaged part
to the patch. Load transfer is accomplished via
shearing action in the adhesive. Three commonly
used bonded repair joints are shown in figure 6-15.
Only those bonded repair joints and patch/adhesive
materials specified in either a system specific technical
manual or by engineering shall be used for repair.
6-28
Figure 6-15. Basic Repair Joints (Bonded)
(1) External Bonded Patch. The external
bonded patch is the easiest bonded repair joint to
fabricate. Adhesive bondline area for load transfer
is provided by overlapping the repair patch and the
part skin. One of the limiting factors for this type of
joint is the eccentric load path caused by the offset
of patch and part neutral axes due to the overlap.
This eccentricity can result in interlaminar failure of
the patch or part skin, or premature failure of the
adhesive. Another limiting factor in the use of an
external bonded patch is the stress concentration
that exists at the edge of the patch and the edge
of the damage cleanup hole in the part skin. This
stress concentration can be reduced at the edge of
the patch by gradually increasing the thickness at its
edge (by stepping or tapering the edge of the patch)
to “ease” the load into the repair joint, but the stress
concentration at the hole edge remains and limits the
load carrying capability of the external bonded patch.
(2) Internal Bonded Patch. The internal bond-
ed patch is similar to the external bonded patch and
has the same limiting factors. However, the internal
bonded patch is very difficult to incorporate without
backside access and virtually impossible on honey-
comb sandwich parts due to interference with the
 TM 1-1500-204-23-11

core. For these reasons, the use of internal bonded

patches has been limited.

(3) Scarf or Step Bonded Joints. A scarf joint,

(or step joint) machined in the part skin reduces the
stress concentration and the adhesive shear stress at
the edge of the damage cleanup hole. In addition, the
scarf or step joint almost eliminates joint eccentricity
as the patch and part skin neutral axes are nearly
coincident. Adhesive bondline area is provided along
the scarf or step surfaces within the thickness of the
part skin. A scarf or step joint can result in joints as
strong as the original part skin. The machining of the
scarf or step joint in the part skin is time consuming,
must be done with accuracy and removes a large
quantity of sound material. A major disadvantage to
using this type of joint is the need to very accurately
layup and position replacement ply material in the
repair joint. In addition, curing of replacement ply
material can result in significantly reduced strength if
not cured in an autoclave. The scarf joint is preferred
over the step joint as it is more efficient from a load
transfer standpoint, and is easier to fabricate. Step
joints have been used for repair of parts fabricated
from woven materials utilizing Kevlar® and glass fibers.

d. Bolted Joints. Bolted joints also make use of a

repair patch to carry loads across the damage region.
Fasteners attaching the repair patch to the damaged
structure complete the joint. Three commonly used
bolted repair joints are shown in figure 6-16. A
common misconception is that the purpose of the
fasteners is to hold the patch in place. The fasteners
do provide clamp-up between the plate and the part
surface, but their primary purpose is to allow the
load to be transferred from the original part surface
through the patch. This load is transferred through the
fasteners and patch by shear forces as the fasteners
contact the loaded structure and the plate at the edge
of the fastener hole. These forces are transferred
more efficiently with tighter fastener hole tolerances.
For fastener holes other than interference fit fasteners,
a deflection in the structure and plate is required for
the fasteners to contact the loaded structure and
the plate. However, interference fit fasteners should
not be used in composite structures. The composite
matrix may crack or delaminate resulting in strength Figure 6-16. Basic Repair Joints (Bolted)
degradation as the interference fit fastener is pressed
into place. A Class II fit (clearance of +0.0025/-0.000 (1) External Bolted Patch. The external bolted
inch) is normally specified for structural fasteners in patch is the easiest bolted repair joint to fabricate.
composite materials. The external patch overlaps the part skin to allow
sufficient fasteners to be installed for load transfer.
Like the external bonded patch, the external bolted
patch is also limited by the eccentricity due to the
offset of patch and part neutral axes. This eccentricity
results in fastener tipping, fastener failure, or bearing
failure in the composite skin/patch material.

6-29
TM 1-1500-204-23-11
(2) Internal Bolted Patch. The internal bolted
patch has the same eccentricity problems as the
external bolted patch. The internal bolted patch is
easier to fabricate than the internal bonded patch.
When backside access is not available, this patch is
split to allow installation through an elliptical or circular
cutout in the skin. Internal bolted patches may have
interference problems with substructure members.
(3) External/Internal Bolted Patch. The use of
external/internal bolted patches of the same material
and thickness eliminates eccentricity as the fasteners
are loaded in double shear. The eccentricity caused
by the offset of the external patch and part neutral
axes is balanced by the eccentricity caused by the
offset of the internal patch and part neutral axes.
The load is shared by both patches on either side
of the repaired skin. This patch configuration makes
use of split backing plates to facilitate installation,
but has the disadvantage of possibly interfering with
substructure members.
(4) Multiple Row Fastener Patterns. The rep-
air of composite structures requires careful attention
to design to prevent premature failure. Multiple row
fastener patterns are required to gradually introduce
load from the part being repaired into the repair patch.
It is virtually impossible to distribute the load evenly
between all the fasteners in a multiple row pattern.
In general, the load in the fasteners increases with
their distance from the center of the damage cleanup
hole, with the load being the highest in the outer-
most fasteners. The amount of load shared by the
fasteners in the pattern can be increased by using
close tolerance fasteners and close tolerance fastener
holes patterns. In addition, load sharing of fastener
can be increased by tapering or stepping the repair
patch. An improperly designed fastener pattern or
tapered/stepped patch can result in premature fail-
ure of the repair. Only those fastener patterns and
patches called out in either a system specific technical
manual or by engineering shall be used for repair.
e. Bonded Versus Bolted Repairs. These are the
advantages and disadvantages of bonded and bolted
repairs.
(1) Bonded Repairs. Bonded repair concepts
have found applicability in both types of manufacturing
assembly methods. They have the advantage of not
introducing stress concentrations by drilling fastener
holes for patch installation and can be stronger than
original part skin. They have the disadvantage of
using process sensitive materials that require special
storage, handling and curing procedures. In addition,
the presence of moisture can cause part damage
during elevated temperature cure cycles. To preclude
6-30
this damage, drying of the part is required prior to
heating.
(2) Bolted Repairs. Bolted repairs are quicker
and easier to fabricate than bonded repairs. They
are normally used on composite skins thicker than
0.125 inch to ensure sufficient fastener bearing area
is available for load transfer. They have the potential
for moisture intrusion from the fastener holes and the
resulting core degradation. Bolted repairs are heavier
than comparable bonded repairs limiting their use on
weight sensitive flight control surfaces.
f. Scarf Repairs. These are the two types of scarf
repairs. Scarf repairs are typically used to repair
laminates on highly-loaded structures. The size of
the repair area depends on the thickness of the skin
and the required scarf ratio.
(1) Partial Thickness Scarf Repair. Thicker
structures require larger patches relative to the orig-
inal damage area. Highly-loaded structures require
high scarf ratios (e.g., 80 to 1), therefore, large patch
areas in order to carry the necessary loads. As a
result, patch areas may be very large. Scarf ratios
are determined according to the loads that must be
transferred. The scarf ratio for any repair in a given
weapon system will be called out in the system spe-
cific technical manual or other authorizing document.
Scarf repairs can be used on all glass, carbon, and
aramid composite materials. Full thickness repairs
generally use scarf ratios of 20 to 1 while partial
depth scarf ratios are generally 30 to 1.
(2) Full Thickness Scarf Repair. Full thickness
scarf repairs are accomplished using the same pro-
cedures for a partial thickness repair per paragraph
6-15f with the exception that a taper ratio of 20 to 1
is typical. Full thickness repairs may require installa-
tion of a backside seal (see paragraph 6-18e). Full
thickness repair may also be repaired by means of
bonded or bolted on scab patches. See paragraphs
7-6 and 7-7.
(3) Determining Scarf Dimensions. The fol-
lowing steps are used to determine scarf dimensions.
Consult the system specific technical manual or engi-
neering for scarf preparation details.
(a) Clean out the damaged area as outlined
in paragraph 6-4b, Damage Removal.
(b) Determine the size of the scarf repair
using the following steps:
1 Measure the cleaned up damaged
area (e.g., 2 inches in diameter).

2 Count the number of damaged
plies (e.g., six plies).
3 Determine the repair ply thickness
and the scarf ratio (e.g., repair ply
thickness of 0.0055 inch and scarf
Figure 6-17. Ply Overlap Chart
TM 1-1500-204-23-11
ratio of 30 to 1). (See figure 6-17
and figure 6-18) The system spe-
cific technical manual will specify
the scarf ratio and will identify the
repair material.
6-31
TM 1-1500-204-23-11
Figure 6-18. Dimensions of a Scarf Repair
4 Multiply the repair ply thickness by
the scarf ratio (0.0055 x 30 = 0.165
inch).
5 The overlap for this scarf repair
would be 0.165 inch per ply.
Do not mark the composite with any method
that will indent or deform the surface.
(c) Apply masking tape, centered on the
repair area 1.0 inch beyond the mini-
mum finished repair size (determined in
Figure 6-19. Cross Section of Typical Scarf Repair
6-32
paragraph 6-15f3(b)). Locate the cen-
ter of the repair area and using an air-
craft marking pencil, mark perpendicu-
lar lines across the masking tape that
would extend through the repair center.
Orient the lines such that one of the lines
is parallel to a straight edge of the part.
Also, mark a circle on the part indicating
the minimum finished repair size.
(d) Determine the scarf outline perimeter.
(e) Measure the skin thickness (t). Multi-
ply the skin thickness by 20 to obtain
the scarf outline dimension (D). This will
provide a scarf slope of 20 to 1 (see fig-
ure 6-19).

(f) Measure outward from the damage
cleanup hole edge to the scarf outline
dimension (D) (see figure 6-18). The
scarf outline perimeter is defined by
this dimension. If variations in skin
thickness are encountered, the scarf
outline dimension (D) must be changed
accordingly.
(b) Machine the edge of the damage
Refer to paragraph 6-8 or machining proce-
dures for composite materials. If a monolithic
skin is being scarfed, seal the backside as
described in paragraph 6-18.e prior to begin-
ning the scarfing operation. This will prevent
the loss of ply material at the scarf tip during
machining.
(4) Scarf Joint Procedures. The following pro-
cedures are used to determine scarf joint.
(a) Using 80 to 180 grit sandpaper, sand
by hand (or if properly skilled, a power
Figure 6-20. Scarf Joint Outline Layout
TM 1-1500-204-23-11
sander such as a 3 inch dual-action
sander or a right angle die grinder may
be used) the scarf into the laminate.
Ensure even concentric circles (indi-
cating different plies) and the correct
ply overlaps are obtained. If the dam-
age is all the way through the laminate,
the inner edge of the cutout can be
knife edged 0 to 0.005 inch. A ragged
appearance is acceptable.
cleanup hole to a knife’s edge using a
90 degree router motor and an 80 grit
abrasive disk. Keep the knife’s edge
steeper than required for the finished
scarf joint (see figure 6-20 and figure
6-21). This allows the skin plies to be
readily identified and serves as a ref-
erence point for the remainder of the
scarfing operation.
6-33
TM 1-1500-204-23-11

Figure 6-21. Scarf Joint Machining

(c) Using the powered sander, continue
working the scarf joint back to the scarf
outline dimension determined to obtain
the proper scarf slope. Sand carefully
as the composite material is removed
quickly. As the scarf outline dimension
is approached, use a sanding block and
80 grit abrasive paper to finish the scarf
joint.
(d) Finish sanding the area inside the
masked area, including the border, with
150 to 180 grit abrasive (by hand or by
power sander).
(e) Record the orientation of each ply
removed with reference to a convenient
axis. See figure 5-12, Patch Drawing
Example. For most parts, this template
provides a reference that will allow all
plies to be oriented at 0, +45, and 90
degrees. Draw the coordinate axis
system on the part, outside the paint
removal line, as shown in figure 6-22.
Indicate the positive directions.

6-34
 TM 1-1500-204-23-11

Figure 6-22. Laminate Fiber Orientation (Sheet 1 of 2)

6-35
TM 1-1500-204-23-11

Figure 6-22. Laminate Fiber Orientation (Sheet 2 of 2)

6-36
 TM 1-1500-204-23-11

(f) Inspect the finished scarf joint for the scarf joint extends to the scarf out-
following: (See figure 6-23.) line dimension marked in 6-15.g.

Do not scribe directly onto composite or metal.

Loss of structural integrity may occur.

4 The scarf joint tip must be

machined to a knife’s edge to elim-
inate any stress concentrations at
the edge of the hole.

g. Step Joints. Generally, step joints are used in

field repairs only on laminates made from woven
materials. This is because woven material, unlike
plies of unidirectional material, has a greater tendency
to separate between plies than within a ply. The
advantage to this is that the ply can be separated
along ply boundaries. This minimizes damage to
subsurface plies and ensures that the correct step
depth is achieved. Machining step joints on laminates
made from unidirectional pre-preg materials requires
the use of controlled depth router equipment and
templates. These are necessary to ensure that the
proper step depth and length is achieved. This repair
is difficult to perform on complex contours and is
better suited to depot level repairs.
Figure 6-23. Scarf Joint Inspection Requirements
(1) Outline and remove damage as described in
1 Visually inspect the scarfed sur-
paragraph 6-4b, Damage Removal.
face for the presence of preexisting
delaminations. Open up the dam-
age cleanup hole to remove all the (2) Determine the step outline perimeter.
delaminated area (if present), and
redefine the perimeter of the scarf (a) Determine the number of steps. The
outline, as necessary. number of steps is equal to the number
of plies in the laminate minus one.
2 Inspect the scarf joint surface with
a straight edge. The scarf surface (b) Determine the step outline dimension
must be flat and free of any convex (D) by multiplying the step length by the
or concave surfaces to avoid locally number of steps. In general, use a min-
changing the required slope. imum step length of 0.5 inch. Refer to
the system specific technical manual for
3 The required scarf joint slope must further guidance.
be achieved. Too steep a slope
can result in premature joint failure. (c) Measure outward from the damage
Too shallow a slope can remove an cleanup hole edge the step outline
excessive amount of good mate- dimension (D). (See figure 6-24). The
rial and/or move the joint into an step outline perimeter is defined by this
area of higher loading. Ensure the dimension

6-37
TM 1-1500-204-23-11

edge and circular template to assist in cut-

ting.

(5) To remove the ply, work the edge of a razor

blade or x-acto knife under the ply at the
cut line. Peel the ply toward the damage
cleanup hole edge. Once the ply has been
lifted slightly, use a sharpened putty knife
or spatula to completely remove the ply.
Use care not to damage the ply immediately
below the ply being removed.

(6) Mark the next step outline perimeter by

measuring 0.5 inch in toward the damage
cleanup hole edge from the perimeter of the
previous step. All step perimeters should be
parallel. (See figure 6-24).

(7) Repeat step in paragraph 6-15g(2) and (4)

through (6) until all of the required plies have
been removed.

(8) Inspect the step joint for the following (see

figure 6-25):

(a) Measure the step length of each step

Figure 6-24. Step Joint Outline Layout
(3) If a rectangular repair is to be used, make
a 1 inch diameter circle template to facilitate
cutting the perimeter radii.
(4) Starting at the step outline perimeter, care-
fully cut through the first ply of woven mate-
rial using an x-acto knife or single edged
razor blade. Cut along the step outline
perimeter marked on the part. Use a straight
to ensure the required step length has
been achieved.
(b) Visually inspect the cut line at each step
to verify that the remaining ply at that
step has not been cut through.
(c) Visually inspect the ply surface of each
step to ensure that damage has not
occurred as a result of previous ply
removal.

Figure 6-25. Step Joint Inspection Requirements

6-38

h. Blunt Cut. The blunt cut joint is formed by
machining the damage cleanup hole edge as described
in paragraph 6-4. No other machining is required.
6-16. WET LAYUP METHOD. Wet layup is a process
in which dry woven cloth is impregnated with a liquid
adhesive and then cured to form a laminate. The wet
layup process is used to manufacture substructure
details, and to make repair patches for complex
contoured surfaces which cannot accept a flat precured
repair patch. There are several disadvantages to
this process; it is messy to perform, there is little
control over the resin content, and the laminates
exhibit reduced mechanical properties due to the large
degree of porosity present. Porosity is caused by air
entrapped in the laminating resin and by poor fiber
wetting during impregnation. This porosity cannot be
removed under the vacuum pressure that is normally
used for consolidation of the laminate.
a. Background. Following impregnation of dry
cloth with liquid resin and cutting of individual plies
by the dry cloth technique or the Vacuum Assisted
Impregnation technique, two methods for ply layup
are described: individual ply technique and the flat
ply collation. The individual ply technique applies to
the fabrication of patches or repair details where part
geometry (tight radii or complex contours) dictates that
each resin impregnated ply be applied individually to
the part or tool surface. The second technique, flat
ply collation, is the preferred method. This technique
allows all resin impregnated plies to be laid up on
a flat plate and then transferred to the part or tool
surface for forming and curing.
b. Process Control Sheet. Create a process con-
trol sheet for each repair which contains the following:
1. Repair conducted referencing the system
specific technical manual, including page
number, figure number and/or item number
2. Repair materials used, including expiration
dates and lots
3. Resin mix time
4. Hot bonder program
5. Cure start time
6. Hot bonder printout tape
c. Method 1, Dry Cloth Impregnation. The follow-
ing describes the tools, equipment, materials and pro-
cedures needed to perform dry cloth impregnation.
(1) Tools, Equipment and Materials Require-
d. These items are required to perform dry cloth
impregnation: Gloves (latex, nitrile, etc.), Eye pro-
tection, Cutting tools, Layup tool, Squeegee, Paint
brush, Templates, Smooth worktable or 1/4-inch caul
plate, Scale, Transparent non-porous film (vacuum
bag, release film, etc.), Repair fabric (See System
TM 1-1500-204-23-11
Specific Technical Manual), Laminating resin (See
System Specific Technical Manual), Mixing cups and
sticks, Wiping Cloth, Silicon Carbide Abrasive Paper.
(2) Procedure. Follow these steps to perform
Method 1 of dry cloth impregnation.
(a) Create a template of the repair plies
according to paragraph 5-6f.
(b) Have a the following available.
1. A layup tool. A layup tool is
a pre-manufactured tool. The
damaged part or another part
identical to the damaged one may
be used as a layup tool. Lightly
sand the surface of the layup tool
to remove any protrusions. Wipe
sanded area with a clean dry
wiping cloth to remove sanding
residue.
2. Flat Surface. This surface will be
used during impregnation of the
composite fabric. It can also be
used for ply layup when the flat
ply collation method is used. It
should be at least 12 inches larger
than the composite fabric cut in
step ((c)) below.
NOTE
Selvage edge is only included for maintaining
the correct warp direction during the layout
process, it should never be included in a
repair ply itself.
(c) Determine the required number of plies,
ply orientations, and fabric material from
the system specific technical manual.
Cut one ply of composite fabric large
enough so enough layers of material
can be cut out with the template cre-
ated in step ((a)). Including warp trac-
ers (if applicable) or leaving the selvage
edge on the fabric material cut for this
step will aid in aligning the templates
later in this procedure. If the repair
involves more than six plies of mate-
rial, you may divide the number of plies
into groups and repeat this procedure
for each group; this will minimize waste
and provide ease of handling.
(d) Cut a sheet of release or vacuum bag
film big enough to fold over and fully
cover the fabric. Ensure the film is at
least 2 inches larger than the dry fabric
on each side
6-39
TM 1-1500-204-23-11
(e) Tape the release film onto a flat surface.
(f) Measure and record the total square
footage of the dry fabric.
Resins, accelerators, and potting compounds
are toxic to the skin, eyes, and respiratory
tract. Prevent eye and skin contact by wearing
goggles and gloves. Perform all mixing in a
well ventilated area. If resin contacts the skin,
wash immediately with soap and water. Do
not use solvents to remove resin from skin.
Do not exceed the maximum amount of mixed
resin per the manufacturer’s instructions or a
hazardous exothermic reaction will result. If
multiple sheets are to be impregnated, the
resin will need to be mixed in a separate cup
for each sheet to ensure the correct amount
of resin is applied to each sheet.
Apply pressure to adhesive within the pot life
of the resin. For ambient temperatures in
excess of 90 °F, decrease this time by 50%.
An unsatisfactory repair will result if the resin
gels before adequate pressure is applied and
may result in loss of structural integrity. Select
and prepare a heat blanket (if required) and
all necessary vacuum bag materials prior to
mixing resin.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount of
air is introduced into the resin during mixing,
or if mixing is inadequate and may result in
loss of structural integrity.
NOTE
Mixing resin and fabric impregnation must be
done in a controlled environment.
Adhesive of combined parts A and B will be
uniform in color when properly mixed.
Part A of adhesive may require stirring after
prolonged storage as chemical agents of part
A may separate.
To ensure accurate mix ratio, a minimum of
25 grams of adhesive should be mixed.
(g) Determine the amount of laminating
resin that will be needed. Refer to the
6-40
system specific technical manual for
the amount and type of resin to use. If
no resin amount is specified, use the
amount specified in paragraph 6-17.
Use resin manufacturer’s recommen-
dations for mixing. Prepare the vacuum
bag according to paragraph 6-18 prior
to mixing resin.
(h) Use a clean wax-free cup to mix resin.
Cut the end of a tongue depressor
square to mix the resin so the stick can
reach the corners of the cup. If multiple
sheets are to be impregnated, the resin
will need to be mixed in a separate
cup for each sheet to ensure the cor-
rect amount of resin is applied to each
sheet.
(i) Impregnate the fabric following these
steps:
1 Using an adhesive spreader such
as a brush or spatula apply a thin
layer of resin, approximately the
same size as the dry fabric, onto
the release film taped to the flat sur-
face.
2 Place pre-cut dry fabric on the
resin. Maintain fiber alignment; i.e.
minimize wrinkling and waviness.
3 Apply resin to the dry side of the
woven fabric and work resin into
fabric using the adhesive spreader.
Pour the resin onto the center of
the fabric; pour it into a single
pool of resin (multiple pools, donut
shapes, and random patterns can
entrap air). Scrape the cup to
ensure the calculated amount of
resin is placed on the fabric.
4 Fold the release film cut over the
woven fabric. Using a clean roller,
spatula or straight edge, work resin
into the fabric and remove any air
bubbles. Keep all the resin in the
fabric and use care to minimize dis-
tortion of the woven material dur-
ing resin impregnation. Carefully
impregnate the fabric as evenly as
possible; work outwards from the
center of the resin pool adjusting as
necessary.
(j) Place the template on the release film.

(k) Align the orientation for the ply being cut
with the fibers (uni-tape) or warp direc-
tion of the repair material (woven fab-
rics).
(l) Trace around the periphery of the tem-
plate using a permanent ink marker.
Remove the template and mark
each ply tracing with its orientation
(0,90,+45,-45, etc.) and ply number.
(m) Look through the release film and find
a warp yarn traveling down the approx-
imate center of the ply and trace it onto
the release film to aid in proper ply ori-
entation during the lay-up process.
(n) Cut each individual ply using scissors.
Avoid distorting the repair plies during
cutting.
(o) Prepare the layup tool following these
steps. Follow step 1 for a cocured
wet layup and step 2 for pre-cured wet
layup.
1 If wet layup is to be cocured onto
part, clean and prepare the surface
TM 1-1500-204-23-11
of the part according to paragraph
6-5 and paragraph 6-7 prior to mix-
ing the resin. Using an adhesive
spreader such as a brush or spat-
ula, apply a thin layer of adhesive
onto layup area just prior to laying
up first ply.
2 If layup is to be pre-cured and sec-
ondarily bonded, tape a layer of
release film over the layup tool/part.
Release film should be at least 1
inch larger than the largest ply of
the repair patch/detail. Using an
adhesive spreader such as a brush
or spatula, apply a thin layer of
adhesive to the release film in the
layup area.
(p) Make a ply layup log similar to the one
shown in figure 6-26, View A prior to
beginning layup. Mark on the log as
each ply is laid up to prevent stacking
sequence errors.
6-41
TM 1-1500-204-23-11
Figure 6-26. Ply Layup Log
(q) Layup the composite plies. Plies may
be laid using either the flat ply collation
technique (plies laid up on a flat tool
plate) described in step 1 or the individ-
ual ply technique (plies laid up individu-
ally on a part surface or tool) described
in step 2 below:
6-42
1 Layup: Individual Ply Technique.
a Remove one of the pieces
of release film from the first
ply of the laminate and place
the resin impregnated surface
of the ply on the prepared

part. Ensure the proper ply
orientation is maintained.
Form the ply to the surface
contour of the part and
remove ply wrinkles using a
clean roller or spatula.
b Remove the second piece of
release film from the surface
of the installed ply.
c Repeat the steps above for the
remaining plies. Place plies in
the proper stacking sequence
over the part, maintaining the
specified ply orientation for
each ply in the lay-up. The
entire process, from mixing
the resin to completing the
patch application, should not
exceed the pot life of the resin.
2 Layup: Flat Ply Collation Tech-
nique.
a Cut a layer of release film at
least 1 inch larger than the
largest ply of the laminate.
Tape to the flat surface.
b Remove one of the pieces
of release film from the first
ply of the laminate and place
the resin impregnated surface
of the ply. Place the resin
impregnated surface of the
ply onto the release film taped
to the flat surface in step a
above. Ensure the proper ply
orientation is maintained. See
paragraph 5-6.
c Remove the second piece
of vacuum bag film from the
surface of the installed ply.
d Repeat steps (b) and (c)
above for the remaining
TM 1-1500-204-23-11
plies until all plies have been
placed in the proper stacking
sequence on the flat surface,
while maintaining the specified
ply orientation for each ply in
the layup. See paragraph 5-6.
e Transfer collated plies from
the flat tool plate to the layup
tool or part. Form the plies
to the surface contour of the
layup tool or part and remove
wrinkles using the adhesive
spreader.
d. Method 2, Vacuum Assisted Impregnation. T-
he vacuum assisted impregnation method is used to
impregnate repair fabric with a two-part resin while
enclosed inside a vacuum bag. This method is
preferred for tight-knit weaves and when near opti-
mum resin-to-fiber ratio is required. Compared to
squeegee impregnation, this process reduces the level
of entrapped air within the fabric and offers a more
controlled and contained configuration for completing
the impregnation process; however, at ambient tem-
peratures above 80 °F, or with epoxies that have a
pot life of less than 90 minutes, the resin will probably
cure before it is applied to the repair area.
(1) Tools, Equipment, and Materials Require-
d. The following items are required to perform Vacuum
Assisted Impregnation: Vacuum source, lines, and
ports, Gloves (latex, nitrile, etc., Eye protection, Cut-
ting tools (see paragraph 3-5), Squeegee, Templates,
Smooth worktable or 1/4 inch caul plate, Scale, Bag-
ging film, Breather material, Transparent non-porous
film (vacuum bag, release film, etc.), Vacuum Bag
Sealant Tape or Vacuum Bag Repair Materials Kit,
Repair fabric (See System Specific Technical Manual),
Laminating resin (See System Specific Technical Man-
ual), Mixing cups and sticks, Adhesive tape (masking
tape, flash breaker tape, etc.)
(2) Procedure. Follow these steps to perform
Method 2, Vacuum Assisted Impregnation. Refer to
figure 6-27 for the vacuum bag arrangement.
6-43
TM 1-1500-204-23-11

Figure 6-27. Vacuum Assist Impregnation Process (Sheet 1 of 2)

Figure 6-27. Vacuum Assist Impregnation Process (Sheet 2 of 2)

6-44

(a) Create a template of the repair plies
according to paragraph 5-6f.
NOTE
Selvage edge is only included for maintaining
the correct warp direction during the layout
process, it should never be included in a
repair ply itself.
(b) Determine the required number of plies,
ply orientations, and fabric material from
the system specific technical manual.
Cut one ply of composite fabric (car-
bon, glass), large enough so enough
layers of material can be cut out with
the template created in step (a). Includ-
ing warp tracers (if applicable) or leav-
ing the selvage edge on the fabric mate-
rial cut for this step will aid in aligning
the templates later in this procedure. If
the repair involves more than six plies of
material, you may divide the number of
plies into groups and repeat this proce-
dure for each group; this will minimize
waste and provide ease of handling.
(c) Measure and record the total square
footage of the dry fabric.
(d) Cut a sheet of release or vacuum bag
film big enough to fold over and fully
cover the fabric. It must be at least 6
inches larger than the dry fabric on each
side
(e) Fold the non-porous film in half and
crease the fold to locate a centerline.
Once the centerline is located unfold the
film to its full size.
(f) Place the fabric in the center of one half
of the non-porous film.
(g) Place a strip of 1 inch wide (minimum)
breather material around the perimeter
of and just touching the repair fabric.
Overlap the breather material at the cor-
ners to ensure a continuous air path to
the vacuum ports. Tape the corners of
the breather.
(h) Place an additional piece of breather
material for the vacuum port; this piece
should be at least 5 inches square and
must overlap the perimeter breather.
In the event that resin is drawn into
the breather, this extra large square of
material will help prevent the vacuum
port from becoming clogged.
TM 1-1500-204-23-11
(i) Apply sealant tape inside the perimeter
of the bagging film. Leave the backing
paper on the sealant tape.
(j) Place a vacuum port base on the 5 inch
square of breather material.
Resins, accelerators, and potting compounds
are toxic to the skin, eyes, and respiratory
tract. Prevent eye and skin contact by wearing
goggles and gloves. Perform all mixing in a
well-ventilated area. If resin contacts the skin,
wash immediately with soap and water. Do
not use solvents to remove resin from skin.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount of
air is introduced into the resin during mixing,
or if mixing is inadequate and may result in
loss of structural integrity.
Apply pressure to lay-up within the pot life
of the resin. For ambient temperatures in
excess of 90 °F, decrease this time by 50%.
An unsatisfactory repair will result if the resin
gels before adequate pressure is applied.
Select and prepare all necessary vacuum bag
materials prior to mixing resin. If multiple
sheets are to be impregnated, the resin will
need to be mixed in a separate cup for each
sheet to ensure the correct amount of resin
is applied to each sheet.
NOTE
Mixing resin and fabric impregnation must be
done in a controlled environment. Material
has a limited pot life. Mix only the amount
of material that can be used within the pot
life listed by the manufacturer.
(k) Determine the amount of laminating
resin that will be needed. Refer to the
system specific technical manual for
the amount and type of resin to use. If
no resin amount is specified, use the
amount specified in paragraph 6-17.
Use resin manufacturer’s recommen-
dations for mixing. Prepare the vacuum
bag according to paragraph 6-18 prior
to mixing resin.
(l) Pour the resin onto the center of the fab-
ric; pour it into a single pool of resin
6-45
TM 1-1500-204-23-11
(multiple pools, donut shapes, and ran-
dom patterns can entrap air). Scrape
the cup to ensure the calculated amount
of resin is placed on the fabric.
(m) Fold the non-porous film over along the
creased centerline so it covers the dry
fabric and resin pool. Remove the paper
backing from the sealant tape and seal
the vacuum bag. Pierce the film at the
vacuum port base, insert the vacuum
port pass-through, tighten, and apply
vacuum. Check sealant tape seal for
leaks.
(n) Using a squeegee or other nonabrasive
spreading tool, carefully impregnate the
fabric as evenly as possible; work out-
wards from the center of the resin pool
adjusting as necessary. Keep all the
resin in the fabric and maintain the fab-
ric alignment.
(o) Mark the fabric’s warp direction onto the
film.
(p) Place the template on the release film.
Align the orientation for the ply being cut
with the fibers or warp direction of the
ply material. Trace around the periph-
ery of the template using a permanent
ink marker. Mark each ply with its orien-
tation and ply number.
(q) Cut each individual ply using scissors.
Avoid distorting the repair plies during
cutting.
(r) Prepare the layup tool. Follow step 1
below for a cocured wet layup and step
2 below for pre-cured wet layup.
1 If wet layup is to be cocured onto
part, clean and prepare the surface
of the part according to paragraph
6-5 and paragraph 6-7 prior to mix-
ing the resin. Using an adhesive
spreader such as a brush or spat-
ula, apply a thin layer of adhesive
onto layup area just prior to laying
up first ply.
2 If layup is to be pre-cured and sec-
ondarily bonded, tape a layer of
release film over the layup tool/part.
Release film should be at least 1
inch larger than the largest ply of
6-46
the repair patch/detail. Using an
adhesive spreader such as a brush
or spatula, apply a thin layer of
adhesive to the release film in the
layup area.
(s) Make a ply layup log similar to the one
shown in figure 6-26, View A prior to
beginning layup. Mark on the log as
each ply is laid up to prevent stacking
sequence errors.
(t) Layup the composite plies. Plies may
be laid using either the flat plate col-
lation technique (plies laid up on a flat
tool plate) described in step 2 below or
the individual ply technique (plies laid
up individually on a part surface or tool)
described in step 1. below:
Failure to observe the correct number of repair
plies, the correct repair ply orientation, the
correct repair ply overlap and removal of all
pieces of vacuum bagging film will reduce the
strength of the repair and may result in the
loss of structural integrity.
1 Layup: Individual Ply Technique.
a Remove one of the pieces
of release film from the first
ply of the laminate and place
the resin impregnated surface
of the ply on the prepared
part. Ensure the proper ply
orientation is maintained.
Form the ply to the surface
contour of the part and
remove ply wrinkles using a
clean roller or spatula.
b Remove the second piece of
release film from the surface
of the installed ply.
c Repeat the steps above for the
remaining plies. Place plies in
the proper stacking sequence
over the part, maintaining the
specified ply orientation for
each ply in the layup. The
entire process, from mixing
the resin to completing the
patch application, should not
exceed the pot life of the resin.

Failure to observe the correct number of repair
plies, the correct repair ply orientation, the
correct repair ply overlap and removal of all
pieces of vacuum bagging film will reduce the
strength of the repair and may result in the
loss of structural integrity.
2 Layup: Flat Plate Collation Tech-
nique.
a Cut a layer of release film at
least 1 inch larger than the
largest ply of the laminate.
Tape to the flat surface.
b Remove one of the pieces
of release film from the first
ply of the laminate and place
the resin impregnated surface
of the ply. Place the resin
impregnated surface of the
ply onto the release film taped
to the flat surface in step (a)
above. Ensure the proper ply
orientation is maintained. See
paragraph 5-6.
c Remove the second piece
of vacuum bag film from the
surface of the installed ply.
d Repeat steps b and c above
for the remaining plies until
all plies have been placed in
the proper stacking sequence
on the flat surface, while
maintaining the specified ply
orientation for each ply in the
layup. See paragraph 5-6.
e Transfer collated plies from
the flat tool plate to the layup
tool or part. Form the plies
to the surface contour of the
layup tool or part and remove
wrinkles using the adhesive
spreader.
6-17. RESIN PREPARATION AND USE. This para-
graph describes the cure process of a resin and
identifies the limitations associated with the use of
resins. Follow the steps in subparagraph c for resin
preparation.
TM 1-1500-204-23-11
a. Cure Process. During the cure process, the
resin system progresses from a liquid to a weak
gel and then into a strong, highly structured solid.
Pressure (either positive or vacuum) is applied during
the cure to facilitate resin flow, degassing, compaction,
and to ensure bonded details remain in contact while
the chemical reaction is in progress. The resin system
can be sanded usually within 8 to 24 hours after the
start of the cure process once the adhesive hardens.
Full strength of the resin system is not achieved
until 5 to 7 days after the initial mixing of the base
resin and the curing agent (unless heat is applied).
See paragraph 6-19 for more information on curing
adhesives.
b. Limitations of Resins When in Use. When
working with resins, be aware of these limitations
which may affect the strength and life of the resin.
(1) Mixing Container. Use an approved type
container for mixing. Do not use wax-coated cups or
ones that can absorb liquids, or any container that
will react with the resin. When possible, use a flat
ended mixing stick to ensure that resin in the corners
of the container is adequately mixed.
(2) Storage. Do not allow pre-measured resin
to be stored in an open container for an extended
period of time as the resin will become contaminated
with moisture. This degrades the resin and it must
be disposed.
(3) Batch Limitation Size. Do not exceed the
batch limitation size (include the quantity of both
components) when mixing the material in a container
because the material may exotherm and create a
hazardous safety condition.
(4) Pot Life. Do not exceed the pot life (working
life) of the material. Know how much time is required
to properly mix the material, apply it to the repair, and
prepare the area for application of pressure and heat
application. Break up the batch into smaller quantities
and mix/apply them together to minimize exotherm
potential. Pot life is shortened when temperatures
exceed 77 °F.
(5) Disposal. Dispose of any excess uncured
resin in accordance with the local hazardous material
disposal procedures. Do not combine uncured materi-
als such that the accumulation will result in exceeding
the material batch size limitation. If this limitation is
exceeded, the materials may exotherm and present
a smoke and fire hazard.
6-47
TM 1-1500-204-23-11

result in high porosity and low strength. Excessive

NOTE
Ensure expiration of the shelf life marked
on paste adhesive containers has not been
exceeded.
Mixing or preparing adhesives and resins
should be done immediately prior to applica-
tion/use and according to the system specific
technical manual. If technical manual guid-
ance does not exist, consult the manufacture’s
technical data sheets or engineering.
c. Preparing Two-Part Repair Materials. Two-part
repair materials must be prepared properly before they
can be used in the repair. Wet layup resins, adhesives,
and sealants often come in two parts: Part A contains
the base resin and Part B contains the curing agent.
The overall amount of repair material must first be
determined, then the amount of Part A and Part B
can be calculated. Each part is then weighed out
in separate containers before thoroughly mixing. Too
little curing agent to base resin could result in low
mechanical properties as well as slow down the curing
cycle when curing at room temperature. Too much
curing agent to base resin can decrease the pot
life, result in excessive exothermic reaction, and/or
significantly degrade the structural properties of the
material.
(1) Facilities, Tools, Equipment, and Mate-
rials Required. The following items are required:
Repair material information sheet (system specific
technical manual, vendor data, etc.), Calculator, Pen-
cil, Notepad, Worktable or workbench, Weighing scale
(grams) or triple beam balance, Mixing cups (do not
use wax coated), Latex or nitrile gloves, Two-part
resin (Part A and Part B) (See System Specific Tech-
nical Manual), Stirring sticks, Non-porous release film
resin will add weight and may reduce strength slightly.
Optimum fiber volume content is 62% of the total
volume (fiber plus resin); however, this is often too
difficult to achieve in wet layups.
NOTE
Do not mix several batches at once, in order
to avoid an exotherm or exceeding pot life
conditions.
(a) Determine the amount of each part to
mix as follows. First, determine the
amount of material required to perform
the repair. Next, determine the mix
ratio from the adhesive container or
system specific technical manual. Filler
materials (such as chopped carbon
or glass fibers, milled glass fibers or
microspheres) may be added to the
adhesive to produce filler compounds.
The amount of material to be added is
specified in parts by weight. Determine
the amount of each part to be added
using the following formulas in figure
6-28. Figure 6-29 is an illustration of
how to calculate the required amounts
of components to mix to obtain a spe-
cific amount of material for repair.

(2) Calculate Resin Amounts. To accurately

determine the overall amount of resin required consult
the system specific technical manual or resin manu-
facturer’s recommendations for the amount required.
If no technical data is available, mix 25 grams of
resin according to the manufacturer’s instructions for Figure 6-28. Two Part Adhesives and Filler
each square foot of dry fabric. Typically, you should Compounds Formula
strive for the minimum amount of resin required to
completely wet out the fabric. Too little resin will

6-48
 TM 1-1500-204-23-11

Figure 6-29 is an illustration of how to calculate

NOTE the required amounts of components to mix
to obtain a specific amount of material for
repair.

Figure 6-29. Examples for Preparing Two Part Adhesives and Filler Compounds
6-49
TM 1-1500-204-23-11

(b) Filler materials (such as chopped car-
bon or glass fibers, milled glass fibers,
microballoons or glass beads) can be
added to the resin to produce pot-
ting compounds or paste adhesives if
required. If no system specific techni-
cal data is supplied, mix 50.0 g of total
resin and add filler until the desired
weight fraction is achieved. Continue to
make individual batches as needed to
complete the task. Table 6-2 provides
a general guideline for the amount of
filler to be used for the different filler
materials. Consult the weapon system
specific technical manual or engineer-
ing authority if a filler material is required
to determine the required amount.

Table 6-2. Filler Guidelines

Filler Material Typical Usage Range Notes

Microballoons 1 to 20% 20% for a 40 lb/ ft³ syntactic foam
Used to control viscosity, not
Fumed Silica (Cabosil) 1 to 5%
as a filler
Glass Beads 0.5 to 5% 0.5% used for bondline control
Powdered Aluminum 30 to 70%
Milled Fiber 1 to 10%
Chopped Fiber 10 to 25%

Do Not mix more Part B than is specified.
The result could be a hazardous exothermic
reaction and an improperly cured repair patch.
It will not decrease the time for cure. Structural
strength will be degraded if the proper resin
ratio is not used. Resin mixtures must be
accurate to within 1 percent for Parts A and
B.
Do not mix several batches at once, in order
to avoid an exothermic reaction or exceeding
pot life conditions.
NOTE
If containers are in refrigerated or freezer
storage, allow the material to reach room
temperature before opening.
(3) Measure and Mix Resin Parts. Resins,
accelerators, and potting compounds are toxic to the
skin, eyes, and respiratory tract. Prevent eye and
skin contact by wearing goggles and gloves. Perform
all mixing in a well-ventilated area. If resin contacts
the skin, wash immediately with soap and water. Do
not use solvents to remove resin from skin.

Do not open the resin containers until you

are ready to mix and use the resin. Minimize
exposure of the resin to the environment as
heat and moisture can degrade the compo-
nents over time.

Do not mix in one container more than that

specified by the resin manufacturer (usually
marked on the container). Exotherm or heat
buildup may result by mixing large amounts
of resin. If the amount of resin needed for
the fabric to be impregnated exceeds the
maximum allowed in one container, the batch
will have to be split up accordingly. If this is
required, mix the batches simultaneously.

6-50

Apply pressure to layup within the pot life
listed by the manufacturer. For ambient
temperatures in excess of 90 °F, decrease
this time by 50%. An unsatisfactory repair
will result if the resin gels before adequate
pressure is applied.
Select heat blanket (if required) and all nec-
essary vacuum bag materials prior to mixing
resin.
NOTE
Use clean wax free cups to mix resin. Cut
the end of a tongue depressor square to mix
the resin so the stick can reach the corners
of the cup.
(a) Remove the containers of resin from
storage. If containers are in refrigerated
storage, allow material to reach room
temperature before opening. Ensure
material has not exceeded its shelf life.
(b) Place a piece of release film down on a
workbench and position the scale.
(c) Ensure the cups used will be capable of
holding the total resin amount required.
Label each cup with the resin compo-
nent it will be filled with and batch num-
ber (e.g. Part A-1).
(d) Weigh the mixing cups for each compo-
nent. Record the weight of each cup.
(e) Place the proper amounts of base, cur-
ing agent, and filler, if required, in its cor-
responding mixing cup. Remember to
subtract the weight of the cup to deter-
mine the amount of material in the cup.
A stirring stick can be used to aid in
pouring very thin components.
(f) When ready to impregnate the fabric,
pour the curing agent (Part B) into the
corresponding base (Part A) container.
Also pour in the filler material if required.
Remove as much of the material, from
the cup as possible. Use separate flat
end stirring sticks for each application.
(g) Mix thoroughly using a new flat end stir-
ring stick being careful to minimize the
amount of air introduced into the mixture
TM 1-1500-204-23-11
during mixing. If flat end stick is unavail-
able, one can be created by cutting the
end off a rounded stirring stick.
Inadequate mixing will result in poor structural
performance. Do not whip resin when mixing
but gently fold over the material to minimize the
introduction of air into the mixture. Trapped
air causes excessive porosity and thereby
reduces the strength of the bonded repair.
Solvents shall not be used to aid in mixing
adhesives and sealants. Bonding is degraded
when solvents are used to thin adhesives.
(h) Mixing is complete when the resin
shows uniform color and viscosity
throughout its total volume.
(i) When mixing is complete, record the
time to indicate the start time of the
resin’s pot life as adhesives start to cure
when mixed.
d. Vacuum Degassing Vacuum degassing of
adhesives may be needed to remove or eliminate any
entrapped air that may cause voids in the product.
Follow these steps to perform vacuum degassing:
(1) Place the mixed material that is to be
degassed in a degassing chamber.
The material may foam and expand rapidly
and overflow the container. During this frothing
process, it may be necessary to disconnect
and then reconnect the vacuum as needed
to prevent the material from overflowing.
(2) Connect the vacuum source to the
degassing chamber.
(3) The entire degassing process usually can
be completed within 5 minutes from the time
this frothing process stops. The degas time
should not exceed one quarter of the pot life
of the material.
(4) When pouring the mixture into the mold, do
not stir or fold the material, which could lead
to air reentering the material.
e. Liquid Shimming. Fit up gaps and mismatches
between two adjoining parts can be sometimes met by
applying and curing a liquid shim between the parts.
Generally, liquid shim should not be any thicker than
6-51
TM 1-1500-204-23-11
0.090 inch. When authorized by the system specific
technical manual, use the following procedure for the
liquid shimming process:
(1) Prepare those surfaces to be shimmed by
thoroughly sanding and using a solvent
wipe. Refer to paragraph 6-5 and paragraph
6-7 for cleaning instructions..
(2) Apply a parting agent to any surfaces you
don’t want bonded; this allows for easy sep-
aration of parts.
(3) Mix and apply the required compound
according to system specific technical man-
ual.
(4) Assemble parts and clamp together. Install
fasteners if applicable. Bolts and screws
which may require removal after the shim-
ming operation is complete should be coated
with a suitable parting agent.
(5) Remove excess compound.
(6) Cure compound as required.
6-18. VACUUM BAGGING THEORY AND TECH-
NIQUES. Vacuum bag theory and techniques are
discussed in this paragraph. Techniques include
single side vacuum bag procedure, backside seal
6-52
procedure, testing for vacuum leaks, and conducting
a thermal survey. See Chapter 3 for identification and
selection of vacuum bagging materials. Vacuum bag
materials vary in quality and application. Ensure the
bagging materials, including the sealant or tacky tape,
being used are those specified in the system specific
technical manual or by engineering. Consideration
should be given to the bagging material capability,
at the cure temperatures required, and the time at
this temperature. Rehearse the repair procedures
to discover trouble before the actual process starts.
Rehearsal is important for placement of the bagging
materials and placement of the thermocouples in
close proximity to the patch.
a. Purpose. Vacuum bags serve a twofold pur-
poses. First, they assist in the removal of entrapped
air from wet layups and pre-preg materials. Remov-
ing air reduces porosity which makes the laminate
stronger. Second, they apply pressure. The pressure
is created because the atmospheric pressure outside
the bag is greater than the pressure inside the bag.
The greater the difference in pressures, the greater
the compacting force. When the layup is compacted,
the different layers of fiber are pushed closer together,
thus making a stronger laminate. The key to any suc-
cessful vacuum bag process is to ensure the proper
level of vacuum is maintained, ensure a tight vacuum
seal exists, and ensure a good air path exists from
the repair material to the vacuum source (see figure
6-30)

Figure 6-30. Vacuum Bagging Arrangement
b. Vacuum Bagging Theory. When vacuum is
applied to a vacuum bagged repair, air is removed
from inside the bag to create a vacuum. To provide
a path to draw off the air initially inside the bag,
layers of fiberglass cloth or similar non-contaminating
materials known as breather plies are placed inside
the bag. The following paragraphs discuss how it
works:
(1) Porosity is tiny air bubbles that are
entrapped in the repair. When vacuum is
applied, the air bubbles are drawn out of the
repair plies into the bleeder and/or breather.
Reducing the porosity increases the quality
of the repair. Air leaks in a vacuum bag of
greater than 1 in Hg/min introduce air and
negatively affect porosity.
(2) Compaction, or clamping pressure, is
applied by normal atmospheric pressure
when the vacuum is applied. At sea level
with maximum vacuum on a standard day
(ideal), you can apply 14.7 psi of pressure;
that would be the equivalent of stacking
1470 pounds of weights onto a 10 x 10 inch
repair. In reality, your pressures will vary
between 10 and 15 psi.
TM 1-1500-204-23-11
(3) Water is removed quicker from wet com-
ponents. When vacuum is applied, water
vaporizes at temperatures below 212 °F
and the vapor is drawn out. This offers a
great advantage over drying at tempera-
tures above 212 °F; since the water is only
vaporized (boiled) where the vacuum exists,
there is no chance of entrapped boiling
water blowing out the honeycomb core.
(4) Small parts may be envelope bagged (i.e.,
enclosing the entire part in the bag). Larger
parts with localized repairs can be bagged
by sealing the surface completely around
the repair areas with sealing tape and apply-
ing the bagging material to the sealing tape.
When using an oven to cure repairs, sand-
wich skin panels must be entirely vacuum
bagged to prevent delamination and con-
toured parts must be restrained with tooling
to prevent warpage. Delamination and
warpage occur when the cure temperature
nears the cure temperature of the original
manufactured part or the cure temperature
of previous repairs. Refer to paragraph
6-18d for envelope bagging procedures.
(5) Strive to maintain the maximum vacuum
possible. When a lack of system specific
6-53
TM 1-1500-204-23-11
technical data exists, use a minimum of 20
inches of mercury (Hg) vacuum. Leak rate
of less than 1 in Hg per minute should be
maintained; if not, air will be introduced to
Table 6-3. Vacuum Pressure Conversion Chart
Inches of Hg
10
12
14
16
18
20
22
Convert inches of Hg to psi by multiplying by 0.49116.
Convert psi to inches Hg by multiplying by 2.036.
c. Single Side Vacuum Bag Procedure. The fol-
lowing steps explain how to construct a vacuum bag
on the repair side of the part. This is the most com-
monly used vacuum-bagging procedure. The vacuum
bag should be prepared/set-up prior to mixing resin.
This procedure only addresses the bleed system. The
bleed system is used when excess resin is present
in the wet layup; the excess resin is bled off during
the repair resulting in the correct resin-to-fiber ratio
in the finished repair. Consult the system specific
technical manual for procedures for a no bleed or net
resin system when the pre-preg contains the correct
resin to fiber ration desired in the finished repair.
(1) Facilities, Equipment and Materials. The
following items are required to perform Single Side
Vacuum Bag procedures: Vacuum source (venturi
or vacuum pump), Vacuum hoses, Vacuum port,
Vacuum gage, Self-vacuum fittings, Caul plate (if
used), Temperature/Vacuum controller, Heat blanket
(if used), Thermocouples, Scissors, Utility Knife, Peel
ply, Non-porous release film, Porous release film,
Bleeder plies, Breather cloth, Bagging film, Vacuum
bag sealant tape, Flash breaker tape
(2) Procedures. After the repair plies are in
place, use the following procedures. Minor variations
to these procedures are acceptable as long as the
intent is met. To achieve the desired resin-to-fiber
ratio, you must use the type of porous release film (size
and spacing of perforations), type of bleeders, and
number of bleeders specified in the system specific
technical manual or repair disposition; these vary
depending on the repair fabric, resin, and number of
plies. Refer to figure 6-30.
6-54
the repair. When damage is through both
skins, a vacuum bag is required on both
sides of the part. Table 6-3 provides a con-
version chart between inches of Hg and psi.
PSI
4.9
5.9
6.9
7.9
8.8
9.8
10.8
(a) Before beginning a repair process, per-
form a heat survey according to para-
graph 6-18g if required.
To achieve the desired resin-to fiber ratio,
you must use the type of porous release film
(size and spacing of perforations), type of
bleeders, and number of bleeders specified
in the system specific technical manual or
repair disposition; these vary depending on
the repair fabric, resin, and number of plies.
(b) Connect thermocouples to the heat con-
troller and check for proper operation
before placing on the part. Thermo-
couple readings should approximate the
ambient air temperature. If the thermo-
couple reading does not, replace ther-
mocouple.
Failure to electrically insulate the thermocou-
ples by placing flash break tape under them
may result in a condition known as “cross-talk”
and prevent the hot bonder-controller from
functioning properly.
(c) Attach a minimum of three thermocou-
ples with flash breaker tape no further
than ½ inch from the patch border.
Leave some slack in the wires inside
the vacuum bag area as they have a

tendency to be pulled and stretched
when the vacuum is applied. Do not
place thermocouples directly on the
patch as they will leave a mark during
cure.
(d) Lay a piece of porous release film over
the patch. The porous release film
should extend 1-1/2 inch beyond the
edges of the patch area.
(e) Lay bleeder material over the porous
release film. This should be the same
size as the porous release film. Avoid
wrinkles. Place the number and type of
bleeder plies as specified by the system
specific technical manual. The number
of bleeder plies is determined by the
number of repair plies in the patch, type
of bleeder cloth used, and the desired
resin content.
(f) Lay a piece of non-porous release film
over the bleeder material. The release
film should not extend past the bleeder
edges. Avoid wrinkles.
NOTE
The area within the rubber adhesive tape
must be large enough to accommodate the
heat blanket, breather cloth and vacuum port
assembly according to the bleeder schedule
being performed.
If using a caul plate for the repair, it is
a requirement to evenly distribute the four
thermocouples on top of the caul plate.
The minimum permissible vacuum for com-
posite repairs is 20 inches Hg unless a lower
vacuum is specified.
(g) Place caul plate (if used). Ensure caul
plate matches the contour of the repair
and is slightly larger than the patch; fail-
ure to do so will result in inconsistent
pressure and poor structural properties
of the finished part. Caul plates may
be used to ensure a smooth patch sur-
face and facilitate even heat distribution
across the repair.
The area within 2 inches of the edge of
any heat blanket is known as the “cold zone”
and is unreliable for achieving and maintaining
the proper cure temperature. Exercise special
care when selecting a heat blanket so that
TM 1-1500-204-23-11
neither the repair nor the thermocouples are
within the cold zone. Failure to do so will
result in a repair that may be overcured.
(h) Select a heating blanket large enough to
extend a minimum of 2 inches beyond
the patch edge.
The dimensions of many of the materials cut
for use in this procedure are based on the
size of the heat blanket.
(i) Cut a piece of bleeder material or dry
satin cloth 1 inch beyond the edges
of the heating blanket. Lay piece of
bleeder material over the release film.
Contact between the edges of the
bleeder plies and the breather cloth
applied later must exist in order for an
adequate air path to exist.
(j) Lay heating blanket on top of bleeder
material.
(k) Solvent clean the area where the vac-
uum bag sealant will be placed step
6-18(l). After the dry wipe, allow 10 min-
utes for any residual solvent to evapo-
rate.
Failure to separate thermocouple wires where
they exit the vacuum bag will result in leaks
and failure to achieve minimum acceptable
vacuum.
NOTE
If thermocouple wires or heat blanket power
cables contain outside insulation in addition to
individual wire insulation, the outside insulation
must be removed to prevent vacuum leaks.
Remove 1 inch of outside insulation in the
area where wires interface with bag sealant.
The area within the rubber adhesive tape
must be large enough to accommodate the
heat blanket, breather cloth and vacuum port
assembly according to the bleeder schedule
being performed.
(l) Apply vacuum bag sealant tape com-
pletely around the repair area. Apply
extra sealant tape over the heat blan-
ket and thermocouple wires. Leave the
backing paper on the sealant. Press
sealant onto part surface. Inspect the
6-55
TM 1-1500-204-23-11
sealant overlap areas to ensure that no
gaps exist. Ensure there are 2 inches
between the heater blanket and sealant
tape. Ensure enough room for the vac-
uum port. If thermocouple wires or heat
blanket power cables contain outside
insulation in addition to individual wire
insulation, the outside insulation must
be removed to prevent vacuum leaks.
Remove 1 inch of outside insulation in
the area where wires interface with bag
sealant.
(m) Lay a piece of breather material over the
heater blanket. This should extend to
the sealant tape border and contact the
bleeder material.
Place vacuum port assembly at least 3 to 4
inches away from the repair area to prevent
wet epoxy resin from being drawn up into
the port. Failure to do this could destroy the
port, vacuum hose assembly, and possibly
the vacuum pump.
(n) Lay vacuum port base on breather
material. Ensure the vacuum port base
is not on top of the heat blanket. Use
one vacuum port for each 10 sq ft of
vacuum bag.
(o) Lay vacuum bag film over the repair
area. This material should be large
enough to overlap the sealant tape by at
least one to two inches around the bor-
der of the repair area. If pleats are to be
used, place sealant tape directly on the
bagging film at the location of the pleats.
(p) Remove the backing paper from the
sealant tape and press the vacuum bag
to the sealant tape. Start on one end
and carefully work your way around. Be
careful not to introduce wrinkles into the
vacuum bagging film where it meets the
sealant tape as this will likely cause an
air leak. To avoid wrinkles, sealant tape
may be applied around the perimeter of
the bagging film (in addition to the strip
on the component being repaired), the
backing tapes removed, and the sealant
tapes pressed against each other.
(q) Connect the vacuum port top by cutting
a small slit in the vacuum bag material
over the vacuum port base. Use a sharp
6-56
blade in the utility knife to prevent tear-
ing the bagging film.
(r) Connect the vacuum port to the vacuum
source using the vacuum hose.
NOTE
The minimum permissible vacuum for com-
posite repairs is 20 inches Hg unless a lower
vacuum is specified.
(s) Draw a full vacuum (>22 in Hg) on the
repair area. Smooth out wrinkles in the
vacuum bag as the vacuum is being
drawn down. If neither a caul plate nor
heat blanket is used, all wrinkles must
be outside the patch area; any wrinkles
left over the patch area will be trans-
ferred to the patch.
(t) Perform a vacuum integrity test per
paragraph 6-18f and the system specific
technical manual. Ensure the minimum
vacuum level is achieved.
(u) Program the hot bonder with the cure
profile from the system specific tech-
nical manual or recommended by the
resin manufacturer per engineering dis-
position.
(v) Operate the hot bonder following the
manufacture’s instruction manual.
(w) After the repair has cured, turn off the
power to the hot bonder and allow to
cool before releasing the vacuum and
debagging the patch. Verify the cure
temperature profile by reviewing the
printout from the hot bonder.
(x) Inspect the repair patch according to
Chapter 5 and the system specific tech-
nical manual.
d. Envelope Bagging Procedure. Envelope bag-
ging is a process in which the part to be repaired is
completely enclosed in a vacuum bag or the bag is
wrapped around the end of the component to obtain
an adequate seal. It is frequently used for removable
aircraft parts such as flight controls, access panels,
etc., and when a part’s geometry and/or the repair
location makes it very difficult to properly vacuum
bag and seal the area in a vacuum. In some cases,
a part may be too small to allow for the installation
of a single-side bag whereas other times, the repair
is located on the end of a large component that
must have a vacuum bag wrapped around the ends
and sealed all the way around. In addition, some

components require envelope bagging because they
can be very difficult to seal and insufficient vacuum
is achieved using a single-sided bag.
(1) Facilities, Equipment, and Materials. The
following items are required to perform envelope bag-
ging procedures: vacuum source (venturi or vacuum
pump), vacuum hoses, vacuum port, vacuum gage,
self-vacuum fittings, caul plate, temperature/vacuum
controller, heat blanket (as needed), thermocouples,
scissors, straightedge or tape measure, marking pen,
fairing bars, edge supports, caul plates, utility knife,
peel ply, non-porous release film, porous release film,
bleeder plies, breather cloth, bagging film, vacuum
bag sealant tape, and flash breaker tape.
Parts can be damaged from the application
of vacuum pressure when using the enve-
lope bagging process. Tooling aids must be
fabricated to prevent part damage. Refer to
system specific technical manual for tooling
and vacuum pressure requirements.
(2) Procedure. When envelope bagging, many
part configurations will require the bag be pleated when
Figure 6-31. Envelope Bagging a Part on a Worktable
TM 1-1500-204-23-11
installed. The pleats need to be placed in strategic
locations that ensure the vacuum bag material will
not be stretched too far and burst upon vacuum
application. In addition, great care must be taken
when using the envelope-bagging process to prevent
damaging the repair part. Vacuum pressure can easily
crush core and collapse edge structure if the part
is not bagged properly or is inadequately supported
in the vacuum bag. On thin skin components, it
may be necessary to locate the vacuum ports off
the structure to eliminate the possibility of damaging
the skin when vacuum is applied. This can be
accomplished by fabricating a vacuum bag extension
or flap. Tooling may also need to be fabricated to
protect the part before the envelope-bagging process
can begin. Parts can be damaged from the application
of vacuum pressure when using the envelope bagging
process. Tooling aids must be fabricated to prevent
part damage. Refer to system specific technical
manual for tooling and vacuum pressure requirements.
Figure 6-31 illustrates the procedure for envelope
bagging a component that can be placed onto a
worktable.
6-57
TM 1-1500-204-23-11
(a) Fabricate tooling, such as fairing bars,
edge supports, and caul plates as
required to prevent damage to the repair
part from vacuum pressure. The tooling
must be fabricated from materials that
can survive the repair processing envi-
ronment in regards to temperature and
pressure. In addition, the tooling must
closely match the repair part contour to
be effective.
Improper bagging can result in part damage
or in failed vacuum bag. Care must be taken
to ensure enough bagging material is used
to follow the part contour and not bridge any
openings (figure 6-32).
(b) Before beginning a repair process, per-
form a heat survey in paragraph 6-18g.
if required.
Failure to electrically insulate the thermocou-
ples by placing flash break tape under them
may result in a condition known as “cross-talk”
and prevent the hot bonder-controller from
functioning properly.
(c) Connect thermocouples to the heat con-
troller and check for proper operation
before placing on the part. Thermo-
couple readings should approximate the
ambient air temperature. If the thermo-
couple reading does not, replace ther-
mocouple.
(d) Cut a sufficient amount of bagging film
to completely surround the part with a
minimum 4-inch margin around the part
once vacuum pressure is applied. If the
bagging film width is less than the part to
be repaired, two pieces of bagging film
may be joined with vacuum bag sealant.
If the part has been removed from the
aircraft and can be placed on a table,
place the cut bagging film on the work-
table.
(e) Cut a piece of breather cloth 2 inches
smaller than the bagging film. Center
6-58
the breather material on top of the bag-
ging film.
(f) Cut a piece of porous release film iden-
tical in size to the breather material.
Place release film on top of the breather
cloth.
(g) Place the part to be repaired on top of
the stacked bagging materials damaged
side up.
(h) Position the repair part so that when
the bagging materials are folded over
the repair part, there is sufficient room
for the vacuum ports and sealant tape.
Install the repair patch, thermocouples,
heat blankets, breathers, bleeders,
release film, etc., on the part as directed
by the system specific technical manual
for the part/material being repaired.
(i) Install any required fairing bars, edge
supports, caul plates, etc., to prevent
the bagging film from excessively bridg-
ing the part and possibly damaging it by
the vacuum pressure.
(j) Fold and/or roll the breather mate-
rial around the repair part and tooling,
ensuring no bridging exists across the
part contours.
(k) Run vacuum bag sealant tape around
the three sides of the bagging material
that will be the bottom of the vacuum
bag.
Failure to separate thermocouple wires where
they exit the vacuum bag will result in leaks
and failure to achieve minimum acceptable
vacuum.
(l) Route thermocouple wires, heat blan-
ket power cords, etc., to the edge of
the vacuum bag and over the vacuum
sealant tape.
(m) Fold the release film and breather over
the repair part.

Place vacuum port assembly at least 3 to 4
inches away from the repair area to prevent
wet epoxy resin from being drawn up into
the port. Failure to do this could destroy the
port, vacuum hose assembly, and possibly
the vacuum pump.
(n) Place a 4-inch square pad of loose
weave breather material at each of the
vacuum port locations and place vac-
uum port bases on these pads.
(o) Fold bagging film over the repair part
and seal. Ensure the bagging film is
supported all the way around before
applying vacuum as unsupported bag-
ging film can fail and result in loss of
vacuum and possibly damage the part.
If space is not available on the part,
place the vacuum port on a tuck of bag
material. Create a large pleat of vacuum
bag material with sealant tape on both
sides. Place breather in the pleat so
it contacts the breather over the repair
patch. Install the vacuum port on the
pleat.
(p) Cut a small slit in the bagging film over
each vacuum port base and install vac-
uum line and vacuum gauge. Use a
sharp blade in the utility knife to pre-
vent tearing the bagging film. Vacuum
can now be applied and the cure can be
started.
Figure 6-32. Vacuum Bag the Part Contour
e. Backside Seal Procedure. If damage com-
pletely penetrates the thickness of the skin, a backside
TM 1-1500-204-23-11
seal will have to be installed prior to vacuum integrity
testing. The backside seal is not a structural repair.
It merely ensures a vacuum seal can be obtained
in the repair area when a vacuum is drawn on the
front side. This paragraph explains how to perform
a two-side and one-side seal access repair when
performing a backside seal procedure. Repair of an
area that allows access to only one side requires a
much more involved process for backside sealing.
(1) Two-Side Access Seal Technique. Repair
areas that allow access to the backside of the repair
require only a simple two-side access procedure to
install the backside seal.
(a) Facilities, Equipment and Material. The
following items are required: Scissors, Aluminum plate
for backup plate (Local Procurement), Non-porous
release film, Vacuum bag sealant tape, Bagging film,
Flashbreaker tape, Breather material, Solvent, Wiping
cloth.
(b) Two Side Access Backside Seal Proce-
dure. Follow these steps to perform the two side
access technique for a backside seal procedure.
1 Clean the backside of the repair area
with solvent.
2 Cut a backing plate from aluminum
sheet stock at least 1 inch larger than
the actual damage size. Use mate-
rial thick enough to cover the damage
and not flex when a vacuum is drawn
over the repair area.
3 Cut a piece of release film slightly
larger than the backing plate. Place
it centered over the backside of the
damage and tape into place.
4 Center the backing plate over the
separator film and tape into place.
5 Cut a piece of breather material 1 inch
larger than the backup plate. Center
the breather material over the backup
plate and tape into place.
6 Run a bead of vacuum sealant tape
around the perimeter of the breather
material.
7 Cut a piece of vacuum bagging film 1
inch larger than the vacuum sealant
tape. Install bag film over the back-
side seal.
6-59
TM 1-1500-204-23-11
8 Vacuum bag the front side of the
repair area and perform a vacuum
integrity test in accordance with
paragraph 6-18f if vacuum integrity
does not meet requirements, reinstall
the backside seal with new vac-
uum sealant tape and bag film and
repeat the test until vacuum integrity
is achieved.
(2) One-Side Access Backside Seal Tech-
nique. This procedure is applicable for repair of skin
damage in thin skinned stiffened composite structures
for which there is no backside access. It applies only
to damages between substructure members. It uses
a nonstructural internally bonded patch to seal the
backside and allow for the installation of a bonded
load carrying structural patch. The applicability of
this repair depends upon additional factors such as
loading conditions and laminate thickness. Consult
the system specific technical manual or engineering
for further guidance. The one side access seal
requires a high quality bond be obtained between the
seal plates and the inner side of the skin to prevent
the seal from popping off inadvertently during the
structural patch repair preparation and vacuum seal
process for subsequent repair activity. Consequently,
a Phosphoric Acid Anodized (PAA) primed aluminum
material or Grit Blast Siline (GBS) is specified for
use in the following procedures. Alternate materials
can also be used for the slotted discs, such as
locally manufactured pre-cured composite (fiberglass
or carbon/epoxy) panels. It is important to ensure the
discs/patches fit up tightly to the inner skin surface
to obtain an adequate seal. The following single-side
access procedure can be used for skin thicknesses
of 0.30 inch or less.
(a) Method 1, One-Side Access Backside
Seal Procedure. The following tools and materials
are required to perform method 1, one sided access
backside seal repair when performing the steps out-
lined.
1 Facilities, Equipment and Materi-
als. The following items are required: Tempera-
ture/Vacuum controller, Heat blanket, Thermocouples,
Hacksaw/hacksaw blades, Drill motor/drill bits, Die
grinder, Files, Inspection mirror, Flashlights, Tape
measure, Machinist rule, Hand shears, Calipers,
Compass, Anodized and primed aluminum sheet
stock or 16 to 24 ply precured composite sheet (for
disc fabrication) (Local Procurement), Aluminum plate
for backup plate (Local Procurement), Silicone rubber
6-60
sheet stock (plug material), Non-porous release film,
Nylon rod threaded (0.25 inch diameter x 12 inches
long), Wingnut (to fit threaded rod), Nylon nuts x 4
(to fit threaded rod), Solvent, Adhesive comb, Adhe-
sive, Paste (See System Specific Technical Manual),
Safety equipment as required, Wiping cloth, Abrasive
sheets, Carbide cutoff wheels, Marker.
2 Procedure. Follow these steps to per-
form the method 1, one side access technique for a
backside seal procedure.
Care must be taken to ensure a high-quality
bond is achieved. Failure to achieve a quality
bond could result in loose backside seal
components inside the aircraft and possible
aircraft damage due to Foreign Object Damage
(FOD).
The single-side access limitation causes the
backside seal to be a permanent part of the
completed repair. It is recommended that
if aluminum plates are used for the slotted
discs, they should be PAA or GBS and primed.
This will ensure maximum bond strength and
reduce the potential from FOD.
a Remove paint from the skin in
the repair area by sanding as
described in paragraph 6-1. Clean
the area per paragraph 6-5 and
inspect according to Chapter 5.
b The laminate penetration should be
machined according to paragraph
6-8 to a circular shape according
to the system specific technical
manual. Ensure sufficient space
is available between substructure
members to allow installation of
backside patch.
c Cut a slotted disc, figure 6-33,
using PAA and primed aluminum
sheet stock or pre-cured composite
sheet stock, to the size indicated
in the table. Damage penetrations
greater than 6 inches in diame-
ter will require two slotted discs to
achieve adequate stiffness when
vacuum is applied to the repair.

Figure 6-33. Component Sizes and Slotted Disc Geometry for Single-Side Access Seal
d Drill a 0.25 inch hole through the
center of the disc.
e Make a radial cut to the 0.25 inch
hole at the center of the disc.
Thicker laminates may require the
slot to be cut slightly past the cen-
ter hole to ease insertion through
the damage hole.
f If a second slotted disc is required
for stiffness, cut to size in accor-
dance with the table in figure 6-33.
Figure 6-34. Single-Sided Access Backside Seal
i Drill a 0.25 inch hole through the
center of the stiffener plate and
deburr all edges.
j Cut filler plugs from silicone rub-
ber sheet stock the same size as
the aluminum stiffener plate. Cut a
TM 1-1500-204-23-11
g Using a file or abrasive paper,
deburr all rough edges on the slot-
ted disc.
h Cut a stiffener plate from the PAA
and primed aluminum sheet stock.
The stiffener plate is sized to just
fit through the damaged opening.
See figure 6-34.
sufficient number of filler plug lay-
ers to equal the laminate thickness.
The filler plugs are temporary and
will be removed after the slotted
discs are bonded into place. Any
material may be used for the filler
6-61
TM 1-1500-204-23-11
plugs, but silicone sheet stock is
recommended. If alternate materi-
als are used, they must be wrapped
in non-porous release film before
insertion into the repair stack up to
be able to remove them later.
k Drill or punch a 0.25 inch hole
through the center of each filler
plug.
l Cut a backup plate from any alu-
minum sheet stock at least 2 inches
larger than the damage size in all
directions. The aluminum sheet
shall be of sufficient thickness to
prevent bending when clamping
pressure is applied.
m Drill a 0.25 inch hole through the
center of the backup plate.
n Thread two 0.25 inch nylon nuts
onto one end of the 0.25 inch
threaded nylon rod. Torque the
nuts against one another thereby
forming a bolt head. To facilitate
installation of the slotted disc com-
ponents, remove the threads using
abrasive cloth from the end of the
threaded rod opposite the nuts,
leaving 3 inches of thread at the
nut end.
o Test fit the backside seal compo-
nents to the damage area. Slide
the stiffener plate onto the nylon
rod. Holding the nylon rod by the
threadless end, pass the stiffener
plate through the damage opening.
Next, slide the slotted disc onto the
rod. If more than one disc is used,
slide the smaller of the two discs on
the rod first. Flex the slotted disc
so the slot opens. Slide the slot
over the edge of the damage open-
ing. Next, feed the disc through
the opening by pushing and rotat-
ing the rod and disc in a circular
motion around the hole. Insert the
larger slotted disc in the same fash-
ion. Check for any interference and
modify slotted discs as necessary
to achieve a good fit. Center the
6-62
slotted discs over the damage and
mark the perimeter of the damage
on the outer disc as an installation
aid.
p Clean the backside of the repair
area with the appropriate solvent.
q Using 150 to 180 grit abrasive
paper, as described in paragraph
6-7, abrade the backside of the
repair area. Hold the abrasive
paper under the forefingers and
reach through the damaged open-
ing. Using a side-to-side motion,
work around the circumference of
the opening until the surface is
roughened. Inspect the sanded
area using an inspection mirror and
a flashlight. Repeat the sanding
until there are no missed areas.
r Clean the abraded area using the
appropriate solvent and purified,
lint-free wiping cloth per paragraph
6-5. Continue cleaning until no
residue is seen on the cloths.
s Clean each of the backside seal
components with solvent. Place
each part on a clean piece of bag-
ging film. Take care to not remove
the perimeter mark on the outer-
most slotted disc.
NOTE
Adhesive of combined parts A and B will
be uniform in color when properly mixed.
Part A of adhesive may require stirring after
prolonged storage as chemical agents of part
A may separate. To ensure accurate mix
ratio, a minimum of 25 grams of adhesive
should be mixed.
t Mix the paste adhesive per para-
graph 6-17. Handle prepared sur-
faces wearing powder free latex
gloves until patch bonding is com-
plete. If patch or spacer is not to
be bonded immediately, cover with
clean barrier material and secure
with preservation tape to prevent
contamination.

Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
u Apply paste adhesive to the for-
ward side of the stiffener plate and
slotted disc(s). All internal com-
ponents of the backside seal must
be coated in adhesive to minimize
FOD potential.
v Using a gloved hand, apply a light
coat of adhesive to the backside of
the repair area. Use the inspec-
tion mirrors and flashlight to ensure
even coverage.
w Coat the nylon rod, nuts, and
threads with the adhesive to ensure
a good seal.
x Slide the stiffener plate onto the
threaded rod with the adhesive
side facing front. Feed the stiffener
plate through the damage hole.
y Slide the slotted disc(s) onto the
nylon rod with the adhesive side
facing front. Feed the slotted disc
through the damage opening. If
more than one slotted disc is used,
be sure to insert the smallest disc
first. Take care if more than one
slotted disc is used, ensure the
slots are not aligned with one
another.
z Using the alignment circle drawn in
step o, line up the front slotted disc
with the damage perimeter.
aa Next, slide the precut filler plugs
onto the nylon rod. Stack a suffi-
cient quantity to equal the laminate
thickness in the damage opening.
TM 1-1500-204-23-11
ab Place the backup plate over the
repair area by sliding it onto the rod.
Install the nylon nut on the threaded
rod and tighten to apply clamping
pressure to the backside seal. The
final installation is shown in figure
6-34. Take care not to over torque
the nut on the nylon rod. Over tight-
ening may cause the rod to break.
ac Allow the paste adhesive to cure
per the system specific technical
manual or manufacturer’s guide-
lines per engineering disposition.
Heat may be applied, using a heat
lamp, according to engineering
authority to speed up the curing
process and strengthen the bond.
Ensure the structural materials
exposed to the heat area are not
exposed to excessive tempera-
tures.
ad After the adhesive is cured, remove
the nut from the threaded rod and
remove the backup plate, filler
plugs, and separator film from the
nylon rod. Carefully, cut the nylon
rod flush with the surface of the
slotted disc.
ae Install outer moldline patch and
filler plies according to the system
specific technical manual.
(b) Method 2, One Side Access Backside
Seal Procedure.
1 Facilities, Equipment and Materi-
als. The following items are required to perform
these steps: Temperature/Vacuum controller, Heat
blanket, Thermocouples, Anodized and primed alu-
minum sheet stock or 3 ply pre-cured composite sheet
(Local Procurement), Inspection Mirror, Flashlight,
Non-porous release film, Solvent, Dry Fabric (See
System Specific Technical Manual), Adhesive, Paste
(See System Specific Technical Manual), Laminating
Resin, Acid Brush, Wiping cloth, Abrasive sheets,
Flashbreaker tape, Double Side tape, Wire, Safety
Equipment as required
2 The following tools and materials are
required to perform method 2, one sided access back-
side seal repair when performing the steps outlined.
6-63
TM 1-1500-204-23-11
Care must be taken to ensure a high-quality
bond is achieved. Failure to achieve a quality
bond could result in loose backside seal
components inside the aircraft and possible
aircraft damage due to Foreign Object Damage
(FOD).
The single-side access limitation causes the
backside seal to be a permanent part of the
completed repair. It is recommended that
if aluminum plates are used for the slotted
discs, they should be PAA or GBS and primed.
This will ensure maximum bond strength and
reduce the potential from FOD.
a Remove paint from the skin in
the repair area by sanding as
described in paragraph 6-1. Clean
the area per paragraph 6-5 and
inspect according to Chapter 5.
b The laminate penetration should be
machined according to paragraph
6-8 to an oval shape according
to the system specific technical
manual. Ensure sufficient space
is available between substructure
members to allow installation of
backside patch.
c Fabricate a support patch that will
overlap the hole opening on the
inside by 1/2 inch. Use an anodized
and primed aluminum patch or fab-
ricate a pre-cured composite patch.
Cut the number of plies of dry fabric
listed in the system specific tech-
nical manual (oversize initially and
then trim back after cure accord-
ing to paragraph 6-8). Wet out
with laminating resin per paragraph
6-16 and cure under vacuum and
heat blanket per paragraph 6-18
using the cure cycle noted in the
system specific technical manual or
recommended by the resin man-
ufacturer per engineering disposi-
tion.
d Prepare the underside of the repair
cavity and both sides of patch for
bonding by lightly hand sanding
with 150-180 grit abrasive paper as
described in paragraph 6-7. Sol-
vent wipe with clean lint-free wiping
6-64
cloth per paragraph 6-5. Hold the
abrasive paper under the forefin-
gers and reach through the dam-
aged opening. Using a side-to-side
motion, work around the circum-
ference of the opening until the
surface is roughened. Inspect the
sanded area using an inspection
mirror and a flashlight. Repeat the
sanding until there are no missed
areas.
e Attach a 1/4 inch wide strip of 2
sided tape around the perimeter
of the patch. This will hold the
patch in place while the adhesive
is curing. Wear powder free latex
gloves until patch bonding is com-
plete. If patch or spacer is not to
be bonded immediately, cover with
clean barrier material and secure
with preservation tape to prevent
contamination
f Place a piece of two-sided tape
on the center of the cured sup-
port patch. Attach a coil of wire to
this tape with the end of the wire
extending at least 3 inches away
from the patch. Attach another
piece of tape over the coil and two
sided tape, firmly clamping the coil
in place. The wire is used to pull
the support patch up against the
inside of the part to hold the patch
in place while the bond adhesive
cures.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
g Mix the adhesive per paragraph
6-17. Apply pressure to adhesive
within the pot life of the resin.

h Using an acid brush, brush on a
bead of adhesive around the sup-
port patch, inside the perimeter
of the 2 sided tape. Use enough
resin so that visible squeeze out
will occur when the patch is pulled
into place. All internal compo-
nents of the backside seal must
be coated in adhesive to minimize
FOD potential.
i Insert the patch through the hole,
and pull it up against the under-
side of the repair area skin, apply-
ing as much pressure as possible
without pulling the wire off. Look
for squeeze out around the cutout
edge. Tape the wire to the base
laminate.
j Place a piece of release film over
the repair area
k Attach a minimum of three thermo-
couples with flash breaker tape no
further than ½ inch from the patch
border. Do not place thermocou-
ples directly on the patch as they
will leave a mark during cure.
l Place a heat blanket 2 inches larger
than the patch on top and heat
the base laminate/support patch
area according to paragraph 6-19
using the cure cycle noted system
specific technical manual or recom-
mended by the resin manufacturer
per engineering disposition..
m Remove the tape and wire coil.
Sand the support patch lightly with
abrasive paper or cloth and clean
thoroughly with solvent. Allow to
air dry.
n Apply vacuum bag and perform
leak check per paragraph 6-18e.
o Install outer moldline patch and
filler plies according to the system
specific technical manual.
f. Vacuum Integrity Test. Vacuum leaks are
checked for after all paint and other coatings have
been removed and a backside seal has been installed,
if needed. Before the final repair is attempted, a
TM 1-1500-204-23-11
vacuum integrity test should be performed to ensure
there are no vacuum leaks in the part that would
degrade the repair. The vacuum integrity check is
sometimes performed in conjunction with a thermal
survey. Follow these steps to perform a vacuum
integrity test:
(1) Facilities, Equipment and Materials. the
following items are required to perform the vac-
uum integrity test: Solvent, Wiping cloths, Abrasive
mats, distilled water, breather material, adhesive tape,
breather material, vacuum bag material, vacuum, vac-
uum port bases, vacuum fittings, thermocouples and
heat blanket (as needed for thermal survey).
(2) Vacuum Integrity Test Procedure. Follow
these steps to perform a vacuum integrity test.
(a) Solvent clean the surface area to be
tested for vacuum integrity with an
approved solvent.
(b) If the surface is metallic, obtain water,
break-free surface by scrubbing the
repair area with abrasive mats to
remove any oxides and contaminants.
Using distilled water, check for water,
break-free condition. Repeat scrub-
bing process as needed to reach water,
break-free condition.
(c) If there are no obvious leak paths, such
as loose fasteners, rivets or open joints,
continue with this procedure.
(d) Place breather material over the repair
area and tape into place. Place two
vacuum port bases in opposite corners
and run vacuum sealant tape around
the repair area perimeter. Cut a piece
of vacuum bagging film to fit the repair
area and install the film. If a thermal sur-
vey is to be performed concurrently, the
thermocouples and heat blanket would
be installed at this stage.
(e) Install self-sealing vacuum fittings to the
vacuum port bases. Attach a vacuum
gauge to one vacuum port and a vac-
uum source to the other and draw a vac-
uum in the bag.
(f) Listen for any obvious leaks in the vac-
uum arrangement and seal.
6-65
TM 1-1500-204-23-11
NOTE
The minimum permissible vacuum for com-
posite repairs is 20 inches Hg unless a lower
vacuum is specified.
Refer to the system specific technical manual
for vacuum criteria for your repair procedure
to ensure no restrictions exist in performing
this test at full vacuum. Delicate compo-
nents, honeycomb core, and certain enve-
lope-bagged parts could be damaged from
excessive vacuum pressure if the proper pro-
cedures are not followed.
(g) When full or the maximum allowed vac-
uum level is reached, disconnect the
vacuum source fitting from the bag.
Observe the vacuum gauge for any
signs of leakage. Consult the aircraft
technical manual for the acceptance
criteria for the vacuum bag leak test.
In the absence of specified criteria,
ensure the vacuum bag does not lose
more than 1 in Hg over a 1-minute
period. Refer to the system specific
technical manual for vacuum criteria
for your repair procedure to ensure no
restrictions exist in performing this test
at full vacuum. Delicate components,
honeycomb core, and certain enve-
lope-bagged parts could be damaged
from excessive vacuum pressure if the
proper procedures are not followed.
(h) If unable to reach the required vacuum
level or the bag fails to maintain the vac-
uum level after the vacuum source is
disconnected, the repair area must be
sealed before continuing with the repair.
(3) Solving for Vacuum Leaks. Vacuum leaks
within the repair area are known to cause porous
bondlines and weak repairs. Therefore, all cracks,
fastener holes, and joints in the structure must be
sealed to prevent vacuum leaks and entrapment of
processing chemicals. Extreme care should be given
to all bagging film; simply throwing the thermocouple
wires onto the bagging film can cause a leak that
may be very difficult to find. Keep all sharp edges
away from the bagging film and protect the bagging
film from creases and folds. Several methods can
be used to solve vacuum leaks. One method is with
the use of leak detectors. These instruments can be
very expensive and elaborate and come in all shapes
and sizes. Most of the time the vacuum leaks can be
detected using your ear. Another method is to drag
a thin film of non-porous release film across the bag
and look for dimples in the film. This method works
6-66
well on flat surfaces where there are no creases in
the bagging film and the leak is suspected to be the
bag and not in the seams. Care should be taken to
watch the edges of the parts where the release ply
cannot make full contact with a corner.
(a) Vacuum Bag Sealant Tape Technique. If
thermocouple wires or heat blanket power cables
contain an outside sheath or insulation in addition to
individual wire insulation, the gap between the outer
insulation and wire insulation may allow air to leak.
Remove 1 inch of the outside insulation in the area
where the wires interface with the vacuum bag sealant
tape.
(b) Frontside Seal Technique. The frontside
seal technique is used when leak paths are suspected
around fasteners, joints or substructure. It consists
of coating the suspected leak areas, fasteners, etc.,
with an epoxy adhesive or sealant. Any material used
in the sealing process must be able to survive the
maximum temperatures used in the repair process.
Follow these steps to perform this technique:
1 Solvent clean the repair area. Pay
special attention to any cracks or
crevices around fasteners and joints.
2 If removable fasteners are present
in the repair area, remove them
and reinstall wet with an approved
sealant. Refer to the system specific
technical manual for your applica-
tion. If blind side fasteners or rivets
are present and backside access is
possible, sealant or adhesive may be
applied at the fastener to skin junc-
tion. If a gap or joint is in the repair
area and is a suspected leak path,
apply sealant or adhesive to the sus-
pect area.
3 If the previous steps do not solve the
leak problem and there is no back-
side access to the blind fasteners or
no obvious leak paths are visible, per-
form the following procedure:
a Using an appropriate spreader
or applicator, apply a thin coat
of epoxy adhesive or sealant
over the entire repair area; place
an approved peel ply over the
resin and cure it per the manu-
facturer’s directions.
b Once the sealant has cured,
carefully remove the peel ply
and sand the repair area until all

the sealant has been removed,
except for the sealant in the
crevices and fastener recesses.
All sealant remaining should be
flush with the repair surface. Be
careful not to remove too much
sealant, as this would allow the
leaks to continue. The appli-
cation of heat can significantly
shortened the amount of time
required to cure the sealant.
c Perform the vacuum integrity
testing process in paragraph
6-18f.
4 If a leak path exists which cannot
be isolated using a backside vacuum
bag and a minimum vacuum of 20
inches of mercury cannot be main-
tained, use an envelope vacuum bag.
g. Thermal Survey Procedure. A heat survey is
performed on parts requiring an elevated temperature
heat cycle during the repair process. In order to
achieve maximum structural properties in a bonded
composite repair, it is essential to cure these materials
within the recommended temperature range. Failure
to cure at the correct temperatures can produce weak
patches and/or bonding surfaces and can result in
a repair failure during service. A thermal survey
should be performed prior to installing the repair
to ensure proper and uniform temperatures can be
achieved. The thermal survey determines the heating
and insulation requirements as well as thermocouple
(TC) locations for the repair area. The thermal survey
is especially useful for determining the heating method
and monitoring requirements in cases where heat sinks
(substructure for instance) exist in the repair area. It
should be performed for all types of heating methods
to preclude insufficient, excessive or uneven heating
(e.g., repair near the edge of a part, low ambient
temperature, etc.). It is required when specified by a
system specific technical manual, engineering direction
or when the ability to obtain the proper cure cycle
parameters is in question.
(1) Thermal Survey Considerations. When
performing a thermal survey, considerations must be
taken for estimating bondline temperatures, thermal
variations and temperature controls.
(a) Bondline Temperature Estimation. Du-
ring a cure, no TCs may be placed in the bondline;
consequently, the only source of information during a
cure is the TCs placed around the repair’s perimeter.
Because these TCs are not in the actual bond area,
they may not accurately reflect the temperatures within
the repair zone. Thermal survey data will allow repair
TM 1-1500-204-23-11
technicians to accurately estimate internal patch and
bondline temperatures by observing the perimeter TC
readings.
(b) Thermal Variations. Thermal variations
in the repair area occur for many reasons. Primary
among these are material type, material thickness,
and underlying structure in the repair zone. For
these reasons, it is important to know the structural
composition of the area to be repaired. Substructure
existing in the repair zone will conduct heat away
from the repair area resulting in a cold spot directly
above the structure. Thin skins heat quickly and can
easily be overheated. Thick skin sections absorb heat
slowly and take longer to reach soak temperature.
The thermal survey will identify these problem areas
and allow the repair technician to develop the heat
and insulation setup required.
(c) Maximum Temperature Control. The
heat generated by the heating source must be con-
trolled so that it will not damage aircraft systems and
degrade surrounding coatings, sealant, and wiring.
A thermal survey will help determine the maximum
temperature required for a cure in order to overcome
heat sinks in the structure.
(2) Facilities, Tools and Materials. Before per-
forming the thermal survey, the aircraft or part should
be positioned in the same location the actual repair
will be performed; usually an area that is thermally
stable and wind free. If this is not possible, a tem-
porary shelter should be erected to protect the area
from the elements. The repair location should be
convenient to electrical power, vacuum source, and
compressed air. If the repair location is not within
easy reach of shop air and electricity, a generator
and air compressor will be needed. Collect all equip-
ment, tools, and consumable materials before starting
the thermal survey procedure. Ensure all methods of
heating (hot air modules, heat lamps, heat blankets,
etc.) that will be used for the repair are tested during
the thermal survey. If heat lamps are to be used
for the repair, baffles may have to be constructed
to ensure adequate heating of the repair area. If a
heating blanket is to be used, ensure the repair area
has been vacuum sealed so vacuum bag integrity can
be maintained for the thermal survey. Refer to earlier
in this chapter for procedures on vacuum sealing the
repair area.
(a) General Rules. These rules apply to the
use of tools used during thermal survey.
1 Use one TC for approximately each
10 square inches of patch area. Use
a minimum of three control TCs per
patch.
6-67
TM 1-1500-204-23-11

2 Place additional TCs near potential
hot or cold spots.
3 Use welded TC wire if available. If
only twisted wire TCs are available,
inspect the twisted ends to ensure
they are firmly connected.
(3) Thermal Survey Procedure. Follow these
steps to perform a thermal survey.
NOTE
Before beginning the thermal survey proce-
dure, all coatings will have to be removed in
accordance with the system specific techni-
cal manual. If vacuum-bag processing will be
used in the repair process, a vacuum integrity
test should be performed in accordance with
paragraph 6-18f. before this process is con-
ducted.
(a) Place TCs and connect to temperature
measuring device. Ensure proper oper-
ation of all thermocouples. Refer to
paragraph 3-3i and figure 6-35.

Figure 6-35. Heat Blanket Placement and Temperature Variations in Repair Area

6-68

Failure to electrically insulate the thermocou-
ples by placing flash break tape under them
may result in a condition known as “cross-talk”
and prevent the hot bonder-controller from
functioning properly.
(b) Place TCs in the bondline area on a
3 to 4 inch grid or strategically place
the TCs over suspected heat sinks
(i.e., stringers, spars, ribs, bulkheads,
longerons) and hot spots. Place flash-
breaker tape below and above the TC
tips to protect the control unit from elec-
trical shorts.
(c) Place additional TCs in the locations
that would be used during an actual
Figure 6-36. Typical Thermal Survey Setup
(e) Create a simulated patch made of
appropriate material and temporarily
attach it to the repair area. Ensure the
simulated patch is in contact with the
underlying structure.
(f) All TCs directly exposed to a heat lamp
(infrared, quartz, and other) must have
a small piece of metallic foil tape placed
over the flash breaker tape on the bare
ends. The metallic foil tape prevents
direct heating and erroneous readings
of the TCs.
TM 1-1500-204-23-11
cure to control the heat. These must be
placed around the patch perimeter (out-
side the bondline). Use these as con-
trol TCs on the hot bonder or tempera-
ture control equipment. Be sure to place
the control TCs in the exact same loca-
tion when performing the cure. Ensure
TCs are installed away from the vacuum
port. See paragraph 3-3.i for TC infor-
mation.
(d) Using clear Mylar film or other template
material, create a map of the part, heat-
ing device, exact TC locations and pro-
posed patch perimeter as shown in fig-
ure 6-36.
(g) Position the heat source in the same
position and orientation as it will be used
during the actual repair.
(h) If the repair process requires a vacuum
bag heat blanket cure, set up the vac-
uum bag (with breather, bleeder, peel
ply, caul plates, etc.) exactly as it would
be done during the repair. Apply vac-
uum.
6-69
TM 1-1500-204-23-11
Do not overheat any part. Elevated temper-
atures can damage aluminum, sealant, paint
and other composites. Ensure all materials
in the heat-affected zone can withstand the
temperatures used for the curing process.
Do not exceed a temperature of 300 °F on
any aluminum part. If the aluminum is shot
peened, do not exceed 200 °F.
(i) Heat the repair area to the cure tem-
perature using the recommended ramp
rate; see paragraph 6-19, Curing
Advanced Composites. Once the repair
area has stabilized at the cure temper-
ature, record the TC temperatures. The
repair temperature has stabilized when
there is no rise in the bondline temper-
ature over 10 minutes. See figure 6-35.
If drafts are present, temporary screens
may have to be erected to prevent
cooling to the repair area. The same
screens will need to be used during the
cure.
(j) Examine the temperature readings in
the bondline. If they are within the limits
specified in the system specific techni-
cal manual, the thermal survey is com-
plete. If the system specific techni-
cal data does not specify an acceptable
range, ensure the bondline TCs are ±20
°F; if not, do the following:
(k) If the temperature readings within the
bondline vary more than ±20 °F from the
average, add insulation or heat in accor-
dance with paragraph 6-18g. Repeat
the thermal survey.
(l) If the temperature readings within the
bondline are within ±2 °F from the bond-
line average but they are lower than
the acceptable cure temperature, raise
the cure temperature setting on the hot
bonder. Continue or repeat the thermal
survey until satisfactory temperatures in
the bondline are obtained in the thermal
survey.
(m) Record the exact setup to include the
position and intensity of heat sources,
insulation, and hot bonder cure settings.
In general, only the hottest and cold-
est thermocouples will be required for
the required for the subsequent cure
6-70
cycle. Use the hottest thermocouple as
the control and the coldest thermocou-
ple(s) for monitoring purposes.
(4) Solutions to Heat Sink Problems. Several
methods to minimize heat being conducted away from
the repair area have been found to be effective to
include insulation, heat blanket selection, and applying
backside heat.
(a) Insulation. Additional insulation can be
placed over the repair area. This insulation can
also be extended beyond the repair area to minimize
heat being conducted away. Breather materials and
fiberglass cloths work well, either on top of the vacuum
bag or within the vacuum bag or on the accessible
backside of the structure. Place more insulation over
cool spots, and less insulation over hot spots.
To prevent heat damage to part, 100 percent
contact must be maintained between heat
blanket and part contour.
(b) Heat Blanket Selection. Heat blankets
can aid fabricating with varying watt densities and mul-
tiple zones (must be run with multiple-zone hot bonder
controllers) to accommodate heat sinking underlying
structures. See Chapter 3 and paragraph 6-19.
(c) Backside Heat. If the backside of the
structure is available, additional heat blankets, heat
lamps, hot air modules and such may be used. Heat
pucks may also be used to heat surrounding structure
discreetly.
6-19. CURING ADVANCED COMPOSITES. This
paragraph provides fundamental information in regards
to the heating process which is used for moisture
removal and resin cure. Primary focus is on resin
curing; however, the heating principals also apply
to paragraph 6-6, Drying; paragraph 6-18g, Thermal
Survey; and paragraph 6-18f, Vacuum Bagging. This
paragraph is used to accomplish the repairs in the
following sections or in the system specific technical
manual. For more information on the equipment cited
here, see Chapter 3, Tools, Equipment, and Supplies.
Adhesives and resins can be cured in many ways.
The traditional approach used by the aircraft industry
is to accelerate the curing process by applying heat
while applying pressure. Typical aircraft adhesives
and resins are cured at temperatures above 150º
F. Heat accelerates the reaction for most two part
adhesive systems. Heat can be applied by means
of heat blankets, heat guns or heat lamps. In most
repairs in the field, heat is provided by a heat blanket.
Proper application of pressure and heat is essential

in ensuring the strength of the repair is achieved,
in preventing damage to parts and obtaining a good
fit of repair details. Rehearse the repair procedures
to discover trouble before starting the heating/curing
cycle. Rehearsal is important for placement of the
bagging materials and placement of the thermocou-
ples in close proximity to the patch.
Failure to follow the system specific technical
manual or the manufacturer’s recommenda-
tions for cure cycle will result in a loss of struc-
tural strength which may not be detectable
by visual or nondestructive inspection.
Care should be taken to not overheat any
of the materials being used, as they will be
damaged. Thermosetting resins can easily
be overheated and care should be taken to
not induce an uncontrolled exothermic reac-
tion. Uncontrolled exothermic reactions can
produce toxic fumes that may be hazardous.
a. Curing Cycle. Cure cycles are directly related
to the adhesive used. Failure to follow the prescribed
cure cycle will result in a loss/lack of structural strength
Figure 6-37. Typical Cure Cycle
b. Mechanics of Curing. The curing process is
accomplished by the application of heat and pressure
to the laminate. The resin will begin to soften
and flow as the temperature is increased. At lower
temperatures, very little reaction occurs. Any volatiles
TM 1-1500-204-23-11
of the repair material as well as a loss of strength of
the parent material. Heat is never arbitrarily applied
to a repair; it must be applied in a controlled manner
to achieve the desired results without further damag-
ing the part. See system specific technical manual
for the prescribed cure cycle; if not listed, follow the
adhesive manufacturer’s recommended cure cycle per
engineering direction. Adhesives and resins can be
cured in many ways. Some adhesives and resins
can be cured at ambient temperatures with the sim-
ple addition of the curing agent; however, the cure
time to achieve structural properties is typically days
and the cured material typically will not stand up
to environments that are hot, cold, and/or involve
moisture or harsh fluids. Most aerospace applications
requiring bonded structural repairs involve processing
of the repair using heat while under pressure, typi-
cally vacuum pressure. In most cases, the repair is
vacuum-bagged and uses a heat source and a hot
bonder for control and monitoring of the tempera-
tures and pressure within the vacuum bag. In some
cases, two to three temperature holds during ramp-up
are required. The additional holds are for properly
debulking, bleeding, and/or consolidating the repair
material. The final temperature hold is to complete
the cure state of the adhesive or resin that provides
the material with its structural properties. A typical
cure cycle is shown in figure 6-37.
contaminants such as air and/or water are drawn
out of the laminate with vacuum during this time.
The laminate is compacted by applying pressure,
usually vacuum (atmospheric pressure); autoclaves
(historically used by original equipment manufacturers
6-71
TM 1-1500-204-23-11
and depots) apply additional pressure, typically 50
to 100 psi. As the temperature approaches the final
cure temperature, the rate of reaction greatly increases
and the resin begins to gel and harden. The hold
at the final cure temperature lets the resin finish
curing and attain the desired structural properties. It
is important to understand these concepts as applied
to cure cycles.
(1) Debulking. Debulking is a process used
with some resins and pre-pregs to remove entrapped
Figure 6-38. Typical Vacuum-Bagged Cure Cycle
(a) Cold Debulking . Cold debulking is
accomplished at the ambient temperature. Pre-pregs
are often cold debulked every five plies during the
layup procedure, but may be debulked more often if
necessary. The debulk process is ineffective if the
layup contains too many plies between debulking
cycles.
(b) Hot debulking. Hot debulking is similar
to cold debulking; however, heat is used to change
the adhesive to a less viscous state, thus allowing
more entrapped volatiles to escape. The hot debulk
temperature is always lower than the cure temperature
of the adhesive. Hot debulking is often accomplished
just prior to the final cure for thin parts; for parts greater
than 1/8 inch thick, hot debulking is accomplished
periodically during the layup process. When multiple
hot debulks are required due to the thickness of the
laminate, the pressure specified for the cure must
be used during each hot debulk cycle to maintain a
void-free laminate as the resin from the first set of
plies may be passed their gel point before the final
plies are added to the laminate. Resin bleed also
6-72
air and to compact the repair stack-up before starting
the adhesive cure. A vacuum bag is used to draw
the air out and to apply the pressure for compaction.
Quite often, a single vacuum bag is built and the
debulk/cure cycle is run sequentially. Debulking times
and temperatures depend on both the resin and fabric
used. Debulking is usually necessary when more than
five or six repair plies are necessary or when directed
by the system specific technical manual. A cure cycle
with cold and hot debulk holds is shown in figure
6-38.
begins to occur; therefore, the specified hot debulk
cycle must be followed to allow, if necessary, the
precise amount of resin to be removed. All of this
occurs just before the adhesive and resin begins to
gel or harden. A cure cycle with cold and hot debulk
holds is shown in figure 6-38.
(2) Ramp Rates. Generally, parts and repairs
must be heated and cooled slowly. If heated or
cooled too fast, previously cured laminates and some
types of adhesives can be thermally shocked and lose
structural integrity. The ramp up rate refers to how
fast the repair is heated and is usually expressed in
degrees per minute. The ramp-down rate refers to
how fast an area is cooled. Part temperature ramp
rates are typically 3 to 10 ºF per minute. If temperature
ramp-up and ramp-down rates are not specified, do
not exceed 10 ºF per minute. An exception to this
would be for hot debulking; in this case the intent
is to compact the laminate and remove volatiles.
This generally is accomplished using the fastest rates
possible for both heat up and cool down.

(3) Pressure Ramp Rates. Ramp up and ramp-
down may also apply to pressure increases and
decreases; however, they are seldom called out in field
repairs. If a pressure ramp rate is not specified, full
pressure is applied prior to the temperature ramp-up
and then released after temperature ramp-down.
(4) Control Thermocouples. When the control
thermocouples are not able to be placed over the
center of the repair area but must be placed around
the perimeter of the repair, the temperature holds
may need to be adjusted to compensate for the
temperature difference at the patch center. This
adjustment and correlation of the outer thermocouple
readings to the actual temperature at the center of
the repair depends greatly upon a thermal survey and
the type of heat blanket used, constant watt-density
or variable watt-density. See paragraph 6-18g. for
directions on conducting a thermal survey.
(5) Cure Temperature. Some adhesives have
multiple cure cycles to choose from. For instance,
some resins, according to the manufacturer’s data
sheet, can be cured at 200º F for 220 minutes or
250º F for 150 minutes or 300º F for 130 minutes.
The properties of the resin are dependent on the final
cure temperature; therefore, when a particular cure
temperature is called for in a system specific tech-
nical manual, it must be followed. When you have
the prerogative to choose between cure temperatures,
you should use the highest cure temperature at which
you can maintain a uniform temperature across the
repair. If a temperature range is given such as 240 to
260º F, ensure all areas of the repair are maintained
between those temperatures. When no temperature
range is given, ensure the lagging thermocouple (low-
est temperature) reaches the given cure temperature
and the leading thermocouple (highest temperature)
is within 20º F. If the difference between the leading
and lagging thermocouples exceeds 20º F, seek engi-
neering assistance. For complex structures or where
substructure exists in the repair area, a thermal survey
shall be performed prior to the bonding operation and
corrective actions taken in accordance with paragraph
6-18g to ensure a uniform cure temperature can be
maintained.
(6) Cure Time. Cure time is not the same as
cure cycle. Cure cycle is the total times of the curing
process, including cold debulk, ramp up, hot debulk,
cure time, and ramp-down. When a programmable
heat source is used, the cure cycle must be determined
in order to program the control unit. The cure cycle can
be determined using the specified cure temperature
and the desired ramp rate. Unless otherwise specified
in the repair, the cure time starts when the lagging
thermocouple reaches the cure temperature.
TM 1-1500-204-23-11
c. Heat Transfer Theory. Heat is transferred to the
surrounding parts and air by conduction, convection,
radiation, and induction as detailed in the following
paragraphs. Heat is also lost from parts in the same
ways. Heat transfer during repairs often uses a
combination of the types. For example, when a heat
lamp is used to repair a part, it warms the surface
of the part and/or patch by radiation. The fibers in
the surface of the patch are heated and conduct the
heat to other layers of the patch. Likewise, heat is
conducted away from the skins to any substructure
which is touching the heated skin. Air in contact
with the warm surface area of the patch or vacuum
bag warms up and rises, thus taking heat away from
the repair by convection. When in a liquid state,
the resin matrix transfers heat throughout the resin
by convection. Knowledge of heat transfer principals
may aid the mechanic in selecting a heat source
and/or mitigating heat sink problems. It is important
to know the following concepts as they apply to the
heat transfer theory.
(1) Conduction. Conduction takes place when
a hot surface meets a cold surface, such as when
a heat blanket touches the part to be repaired.
Technically, conduction is heat transfer by means
of molecular agitation within a material without any
motion of the material as a whole. If one end of
a metal rod is at a higher temperature, energy will
be transferred down the rod toward the colder end
because the higher speed particles will collide with
the slower ones with a net transfer of energy to the
slower ones.
(2) Convection. Convection takes place within
a fluid, such as within an adhesive. Convection is
heat transfer by mass motion of a fluid such as air
or water when the heated fluid is caused to move
away from the source of heat, carrying energy with
it. Convection above a hot surface occurs because
hot air expands, becomes less dense, and rises. Hot
water is likewise less dense than cold water and rises,
causing convection currents which transport energy.
Heat guns use convection to heat a repair.
(3) Radiation. Heat from the sun is the classic
example of radiation. When a heat lamp is used in a
repair, heat is radiated from the lamp to the part or
patch surface, then conduction and convection take
place. The amount of heat transferred depends on
the amount of radiation absorbed by the object; dark
colors absorb and heat quicker than light colors. The
heat source does not touch the object being heated.
Technically, radiation is heat transfer by the emission
of electromagnetic waves which carry energy away
from the emitting object. For ordinary temperatures
(less than red hot), the radiation is in the infrared
region of the electromagnetic spectrum.
6-73
TM 1-1500-204-23-11
(4) Induction. Similar in concept to radiation,
the heat source does not touch the object being
heated. Electricity is used to produce a magnetic
field which, when placed near a certain type of mate-
rial called a receptor (usually magnetic) causes it to
heat up. This type of heating is not currently used for
composite repairs; however, research is underway to
add receptors to adhesives with the goal of develop-
ing a fool-proof way to cure composites. Technically,
induction heating relies on induced electrical currents
within the material to produce heat. The basic com-
ponents of an induction heating system are an AC
power supply, induction coil, and work piece (material
to be heated or treated). The power supply sends
alternating current through the coil, generating a mag-
netic field. When the work piece is placed in the coil,
the magnetic field induces eddy currents in the work
piece, generating localized heat without any physical
contact between the coil and the work piece.
d. Staging of Parts and Equipment. The aircraft
or part to be repaired should be placed in an area that
is thermally stable and wind free. If this is not possible,
a temporary shelter should be erected to protect the
area from the elements. The repair location should be
convenient to electrical power, vacuum source, and
compressed air. If the repair location is not within
easy reach of shop air and electricity, a generator
and air compressor will be needed.
e. Safety Issues. Failure to follow the general
safety requirements in the following paragraphs may
result in damage to the part or injury to personnel.
Table 6-4. Maximum Cure Temperatures on Aircraft
Fuel Grade Fuel
JP-8
JP-8+100
JP-6
Kerosene
JP-5
Jet A
Jet A-1
Blend of Kerosene and JP-4
Gasoline Jet B
Gasoline AVGAS
(3) Hazardous Fumes. During material cure,
hazardous fumes may be emitted. Ensure proper
ventilation exists and Personal Protective Equipment
(PPE) is worn as directed by the local safety office.
(4) Thermocouples. Proper thermocouple
selection, inspection prior to use, and correct place-
ment is necessary to ensure a properly cured repair.
6-74
(1) Thermocouple Placement. Control thermo-
couples must be placed properly to measure and
control the amount of heat applied. Placing the ther-
mocouples outside the area to be dried and/or cured
will affect the quality of the repair and may cause
under heating, overheating, damage the part, and/or
create a fire hazard. See paragraph 6-19.e.4 for
thermocouple placement. See paragraph 6-18g for
thermal survey. If a thermal survey was conducted,
the control thermocouples must be placed the same
during the cure as they were during the survey.
(2) On Aircraft Repairs. Aircraft and hangars
are often classified as class 1, division 1, (open
fuel tanks) or class 1, division 2, (closed fuel tanks)
hazardous areas because fuel and/or fuel vapors
may escape and be ignited by unprotected electrical
devices. Hot bonders, portable heat sources, and
other electrical equipment used on aircraft should
be designed for use in these areas. Contact your
local safety office for guidance. Cure temperatures
shall not exceed 80 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.
The auto-ignition temperature is the temperature at
which fuel can spontaneously ignite without a flame or
spark. The auto-ignition temperatures listed on MSDSs
can vary depending on test method, fuel formulation,
and fuel batch. The maximum cure temperatures
listed in table 6-4 were developed from guidance in
the National Fire Protection Handbook.
Auto-Ignition Temp (º F) Max.Cure Temp (º F)
440 to 475 365
470 to 480 390
825 to 960 660
Thermocouples may be reused. Welded thermocou-
ples shall be used when available. See Chapter 3
for thermocouple descriptions and local manufacture
information.
(a) Inspection Prior to Use. Perform the fol-
lowing inspection steps prior to each use:

1 Ensure the thermocouple wire used
is compatible with the temperature
monitoring device and the positive
and negative leads are not attached
to the wrong terminals.
2 Inspect and test all thermocouples for
continuity. If a thermocouple tester
is not available, use a multimeter to
measure the resistance between the
two ends on the connector plug; if the
resistance is greater than 1 ohm (Ω),
repair or replace as necessary.
3 Inspect the junction for breaks and
remove resin buildup before each
use.
4 Ensure the thermocouples are com-
patible with the units reading them
(e.g., a type-J thermocouple should
be attached to a type-J monitoring
unit). The monitor should be as close
as practical to the thermocouple. For
standard 24 gauge wire, the distance
shall not exceed 100 feet. Distances
greater than 100 feet can produce
incorrect thermocouple readings.
The higher the wire gauge the shorter
the allowed distance.
5 Plug the thermocouples into the
monitor and ensure they read ambi-
ent temperature. If your hands are
TM 1-1500-204-23-11
warmer than the ambient temper-
ature, place each thermocouple
between your fingers and observe
the temperature rise. If it does not
respond properly, replace the ther-
mocouple.
(b) Placement. Thermocouple placement is
the key in obtaining proper cure temperatures through-
out the repair. A thermal survey, discussed in para-
graph 6-18g, can aid in determining the exact location
for the thermocouples. In general, the thermocouples
used for temperature control (control thermocouples)
should be placed as close as possible to the repair
material without causing it to become embedded in the
repair or producing indentations in the repair. They
should also be placed in strategic hot or cold spot loca-
tions to ensure the materials will be adequately cured
but not exposed to excessively high temperatures
that could degrade the material structural properties.
Additional thermocouples that monitor temperatures in
noncritical areas can be placed throughout the repair
locations; these thermocouples are merely recorded
by the temperature control unit but do not drive the
application of power to the heat source. See figure
6-39 for typical thermocouple placement. The ther-
mocouples should be placed as close as possible to
the area that needs to be monitored. The following
steps should be taken when using thermocouples:
6-75
TM 1-1500-204-23-11
Figure 6-39. Typical Thermocouple Placement
Never use less than three thermocouples to
monitor a heating cycle.
To allow for heat blanket cold edge effects,
place the heat blanket control thermocouple
near the center of the heat blanket. Place
a minimum of two monitoring thermocouples
near the edge of the patch. Figure 6-39.
Failure to place the control thermocouple near
the center of the heat blanket may result in
an over temperature condition at the center
of the repair area.
6-76
1 If bonding a pre-cured patch, place
the control thermocouple near the
center of the patch.
2 A control thermocouple may be cen-
tered over a low temperature (200 ºF
or lower) cocured patch as long as it is
placed on top of a thin metallic sheet
thick enough to prevent a thermocou-
ple indentation onto the patch. This
may allow for a more accurate control
of the patch temperature.
3 When curing wet layup patches at
cure temperatures of 200 ºF and

above, place the control thermocou-
ple on top of the heat blanket to pre-
vent thermocouple mark off. When
the control thermocouple is placed on
top of the heat blanket, the materials
beneath the thermocouple (copper
sheet, bleeder material, release film)
act as insulators. A heat survey must
first be performed IAW paragraph
6-18g. to ensure the required cure
cycle parameters can be met.
4 The thermocouples installed around
the perimeter of the repair patch
should be placed approximately 0.5
inch away from the edge of the adhe-
sive line.
5 Place flash tape below and above
the thermocouple tips to protect them
from resin flash and to protect the
control unit from electrical shorts.
6 Do not place the thermocouple under
the vacuum port as the pressure may
damage the lead and cause erro-
neous readings to occur.
7 Do not place thermocouple wires
adjacent to or crossing the heat blan-
ket power cord to prevent erroneous
temperature readings caused by
magnetic flux lines.
NOTE
It is considered good practice to place the
control thermocouple at least 90 degrees from
the heat blanket power cord and ensure the
thermocouple and power cords don’t cross
between the vacuum bag and the hot bonder.
An additional thermocouple can be placed
inside the bag that could be used in the
event of a thermocouple failure.
8 Do not place any control thermocou-
ple beyond the heat blanket’s 2 inch
overlap of the repair to prevent the
controller from trying to compensate
for the lower temperature. If a vari-
able watt-density blanket is used, this
may be permitted as long as a ther-
mal survey has been performed.
9 Always leave slack in the thermocou-
ple wire under the vacuum bag to
prevent the thermocouple from being
pulled away from the area to be mon-
itored as vacuum is applied.
TM 1-1500-204-23-11
(c) Monitor. During the cure, monitor as
many thermocouples as practical.
f. Hot Bonders. A hot bonder is a temperature
control unit which is most often used with heat blan-
kets, but may be used with other heating devices.
A thorough understanding of your hot bonder’s pro-
gramming features will allow you to effectively cure a
repair. See Chapter 3, Tools, Equipment, and Sup-
plies for more information on hot bonder construction,
selection, and troubleshooting.
(1) Program. Program the cure in accordance
with the hot bonder manufacturer’s directions. To
ensure the proper cure is obtained, you must know
how the hot bonder selects the control thermocouples
and how the alarms are triggered.
To prevent damage to part, equipment, aircraft,
and/or repair facilities, hot bonders shall be
monitored.
(2) Monitor. Anytime a vacuum bag is used to
hold a heat blanket in place, the low-pressure alarm
shall be used. If the hot bonder is not equipped with a
low-pressure alarm, personnel shall visually verify the
integrity of the vacuum bag every 2 minutes. Monitor
the hot bonder during all heating cycles. Personnel
may move away from the hot bonder provided the
controller has an audible alarm, the alarm is tested
prior to the heating cycle and is serviceable, qualified
personnel remain within hearing distance of the alarm,
and qualified personnel periodically perform a visual
check of the hot bonder and repair.
To prevent heat damage to part, 100 percent
contact must be maintained between the
thermocouple and the part.
(3) Temperature Control. Temperature control
is accomplished by comparing the programmed tem-
perature ramps and holds (the set point) to the tem-
peratures measured by control thermocouples at the
repair location. Typically, three options for control are
available:
(a) A thermocouple may be assigned as a
single control thermocouple (not recom-
mended).
(b) An average of a specified set of thermo-
couples may be assigned to control the
heat cycle.
6-77
TM 1-1500-204-23-11
(c) Control may be established by either the
leading (hottest) thermocouple or lag-
ging (coldest) thermocouple automat-
ically. It is typically used when one
does not want to either exceed a tem-
perature value (leading) or when one
wants to ensure a minimum temper-
ature is obtained in the entire repair
area (lagging). This method is highly
dependent upon thermocouple place-
ment which should be determined by a
thermal survey of the repair area.
(4) Alarm. A hot bonder provides the operator
with the capability to set an alarm condition in which
the actual measured temperature or vacuum varies
from that specified in the programmed cure cycle. In
most cases, this alarm will put the controller into a
HOLD situation until the alarm condition is corrected.
g. Heat Blanket. Heat blankets are a common
method used to apply heat for repairs in the field.
See Chapter 3, Tools, Equipment, and Supplies for
information on heat blanket construction, selection, and
storage. Heat blankets are usually used in conjunction
with a hot bonder. Heat is transferred from the blanket
6-78
via conduction. Consequently, the heat blanket must
conform to and be in 100 percent contact with the
part. This is usually accomplished using vacuum bag
pressure. Lack of contact between the heat blanket
and the area to be cured will result in inadequate
heating of the repair area and an over-heating of
the heat blanket. For example, excessive height in a
core plug being bonded into place causes an air gap
at the edges of the core plug and correspondingly
inadequate heating at the plug’s edge. In addition,
heat loss occurs around the outer perimeter of the
heat blanket causing the temperatures on the outer
portion of the repair area to be less than the center.
See figure 6-40 and figure 6-35 for proper placement
of a standard heat blanket over the repair as well
as temperature variations that may exist in the repair
area due to edge effects, heat sinks, insulated areas,
and variations in part thickness. Refer to paragraph
6-19.e.4 and paragraph 6-18g, Thermal Survey, for
ways to identify and mitigate uneven heating and for
the proper number and placement of thermocouples.
Heat/vacuum blankets allow application of the heat
blanket without a vacuum bag. They are much less
flexible than standard heat blankets and are usable
only on relatively flat surfaces.

Figure 6-40. Thermocouple Placement in Repair Area
(1) Inspection. Prior to heat blanket use, per-
form the following inspections:
(a) Inspect the wires, connectors, and heat-
ing pad for loose or frayed wires or sili-
con cracking.
(b) Energize the heating pad and ensure all
areas of the heating pad are working.
It’s possible for a defective heating pad
to heat one side or area and be cool on
another.
(2) Use. Follow the manufacturer’s guidelines
and the following:
TM 1-1500-204-23-11
(a) Ensure the heat blanket overlaps the
repair by a minimum of 2 inches on
each side to ensure even heating of the
repair. This is necessary as tempera-
tures on the edges of the heat blanket,
especially constant watt density blan-
kets, can be as much as 50 ºF cooler
than the rest of the heat blanket. A
smaller overlap may only be used if a
thermal survey has been performed and
actions taken to ensure even heating of
the repair. For structures thicker than
0.100 inch, an overlap greater than 2
inches may be required.
6-79
TM 1-1500-204-23-11
(b) Hot or cold spots caused by uneven
heating within the heat blanket can be
mitigated by placing a thin copper or
aluminum sheet under the heat blan-
ket. The sheet metal may conduct the
heat more evenly. Ensure the sheet
metal matches the contour of the part
being repaired to eliminate air pockets
and ensure even distribution of pres-
sure. Annealed metal is preferred.
(c) When using heat blankets in a haz-
ardous environment such as class
1, division 1 or division 2, personnel
shall, when available, use heat blankets
designed for such areas. Heat blankets
designed for these areas often have a
secondary safety device which ensures
the heat blanket does not reach the
auto-ignition temperature of aviation
fuel.
(d) Do not use heat blankets on compo-
nents that have a radius smaller than
0.5 inch; too tight a radius will damage
the heat blanket.
(e) Handle heat blankets delicately; do not
fold, crush or pinch them. Store flat or
6-80
loosely rolled when not in use. Rough
handling will lead to broken heating ele-
ments resulting in cold spots in the blan-
ket.
h. Heat Lamp. Infrared heat lamps can also be
used for elevated temperature curing of composites if
a vacuum bag is not utilized. However, they are gen-
erally not effective for producing curing temperatures
above 150 ºF or for areas larger than 2 square feet.
It is also difficult to control the heat applied with a
lamp, and lamps tend to generate high-surface tem-
peratures quickly. If controlled by thermostats, heat
lamps can be useful in applying curing heat to large
or irregular surfaces. Heat lamps are used to heat
components to assist in flow of injection adhesives
as well as to reduce the gel time of paste adhesives
and wet layup patches. See table 6-5 for average
temperatures when using one of two heat lamps at
varying distances from the surface. Heat lamps from
different manufacturers produce different temperature
profiles. Each heat lamp configuration must be evalu-
ated to determine their heating characteristics; this is
usually done by conducting a thermal survey. Insulate
thermocouples with aluminum tape.
 TM 1-1500-204-23-11

Table 6-5. Typical Heat Lamp Performance Chart

Single Lamp Two Lamps

Surface
Temperature Effective Area
(ºF) Height (Diameter) Height Distance Apart Effective Area
(Inch) (Inch) (Inch) (Inch) (Inch)
115 to 135 22 11
135 to 155 19 8
155 to 175 16 8
155 to 185 16 14 8 x 22
175 to 195 16 11 8 x 13
195 to 215 13 5 to 6
200 to 220 16 9 8 x 9
195 to 225 13 11 5 to 6 x 17
200 to 250 16 5 5 x 9
220 to 250 11 5 to 6 13 8 5 x 9
230 to 250 11 4 x 5
230 to 280 11 9 5 x 15
250 to 300 9 5 to 6
275 to 325 8 5
290 to 340 8 8 4 x 12

NOTE

These temperatures can be obtained in still air only.

Thermocouples must be used to verify temperature due to the variations in heat lamps, reflectors,
materials, etc.

(1) Heat Lamp Temperature Effects. Variables
that effect part temperature when using heat lamps
are discussed in paragraph 3-3.k.
(2) Using Heat Lamps. Before using heat
lamps for a repair process, a heat survey shall be
performed on component(s) as described in paragraph
6-18.g.
(a) Place heat lamp(s) in the same posi-
tion as determined by the heat survey in
paragraph 6-18g to obtain the required
temperature.
(b) Using high temperature tape, tape ther-
mocouple sensors or thermocouples
in the repair area at the minimum and
maximum temperature, as determined
by the heat survey in paragraph 6-18g.
To ensure the thermocouple accurately
measures the surface temperature of
the part, use tape approximately the
same color as the part surface over the
aluminum tape to secure the thermo-
couples.
(c) Connect the thermocouple to a tem-
perature measuring device. (The hot
bonder, paragraph 6-19.f can be used
for temperature measuring). Check to
ensure proper operation.
(d) Turn on heat lamp(s) and continually
monitor the temperature to ensure the
required temperature is achieved.
i. Hot Air. When using hot air for curing of com-
posite laminates, care should be taken to not insulate
the repair by using excessive breather materials.

6-81
TM 1-1500-204-23-11
(1) Hot Air Module (HAM) Units. HAM units
are generally controlled either manually or in con-
junction with a hot bonder controller. They can be
used to heat large areas of any contour or material.
HAMs supply controlled heat to over 900 ºF. HAMs
lend themselves very well to heating and curing of
materials that require no contact such as paints and
coatings.
(2) Heat Guns.
j. Pressurization. Advanced composite structures
and repairs are fabricated from materials that are
processed using various temperature and pressure
profiles. Pressure is required to shape repair patches
to a part contour, to remove volatiles and entrapped
air from the repair patch and bondline, and also holds
the repair in place while it is being cured. The type
Figure 6-41. Pressure Levels Produced Using Various Pressure Methods (Sheet 1 of 4)
6-82
and level of pressure used can significantly alter the
quality and resulting strength of a repair. There are
two general types of pressure: positive and negative.
Positive pressure is produced by physically exerting
an external force onto an object (repair) such that
it is compacted as it reacts against another object
(tooling or the component being repaired) to resist
the pressure. Negative or vacuum pressure is a
term used when an object (the repair) is exposed
to a confined vacuum environment (supported by
a tool or component) while allowing the surrounding
atmospheric pressure to exert a compaction force onto
the object (repair). Most field level bonded repairs
involve the use of vacuum pressure to compact as
well as to remove volatiles and air from the repair.
Refer to figure 6-41 for a comparison of the pressure
levels produced using an autoclave, shot bags, and
negative vacuum pressure.
 TM 1-1500-204-23-11

Figure 6-41. Pressure Levels Produced Using Various Pressure Methods (Sheet 2 of 4)

6-83
TM 1-1500-204-23-11

Figure 6-41. Pressure Levels Produced Using Various Pressure Methods (Sheet 3 of 4)

6-84
 TM 1-1500-204-23-11

Figure 6-41. Pressure Levels Produced Using Various Pressure Methods (Sheet 4 of 4)

6-85
TM 1-1500-204-23-11
(1) Positive Pressure Methods. There are
many methods used to expose a component to
positive pressure. For a repair, positive pressure is
primarily used for expanding foam adhesive, clamping
edge members, and holding repair details in place
during the curing process. Figure 6-42 shows typical
tools for applying positive pressure in the field.
Figure 6-42. Methods for Applying Positive
Pressure
(a) Shot Bag. A shot bag is a typical method
used to contain expanding foam adhesives and for
keeping repair details together. Shot bags can be
applied to horizontal surfaces that are flat or contoured.
The amount of pressure a shot bag can exert is limited,
however, a 25 pound shot bag that is 5 x 5 inches
in size can only exert 1 psi. See figure 6-42. To
prevent the bag from bonding to the repair, release
film should be placed between the bag and the repair
details.
(b) Clamps. Clamps, such as C-clamps and
spring clamps, are tools used for pressing together the
edges of components and/or repair details. C-clamps
are commonly used items but require careful use
to prevent laminate damage due to over tightening.
Clamps should always be used with pressure distri-
bution pads as damage to the part may occur if the
6-86
clamping force is too high. Spring clamps can be
used in applications wherein resin squeeze-out during
cure would require C-clamps to be retightened peri-
odically. A wooden tongue depressor or 1⁄8 inch thick
silicone rubber pads may be used for pad material.
Release film should be used between the part surface
and these pads. Use care as heat absorption by the
clamps can effect a heat loss to the system during
the elevated temperature curing of repairs. Positive
pressure methods using clamps and shot bags have
very limited use due to the low level of pressure
imposed. They are considered nonstructural pres-
sure methods. Clamps should only be used where a
structural edge is available for clamping.
NOTE
When using clamps, excess pressure may
squeeze out too much resin in the repair
area. Refer to the system specific technical
manual or engineering for authorized method.
1 To distribute pressure evenly, clamps
should be placed approximately
every 1.5 to 2 inches on the parts
being bonded.
2 Determine the number of clamps
needed and the approximate place-
ment. Clamping sequence (and
adhesive and scrim cloth application)
is important in controlling bondline
thickness and providing void free
bondlines. (See paragraph 7-6 for a
discussion on controlling the amount
of paste adhesive applied to repair
details using an adhesive comb and
for scrim cloth application). A typi-
cal clamping sequence is shown in
figure 6-43. The clamps are applied
first at the center of the parts being
bonded and then placed alterna-
tively on each side. When applying
a C-clamp, tighten until it feels snug
and the body of the clamp does not
rotate when pulled from side to side.
Take care not to over tighten as dam-
age to the laminate will result. During
the cure process, the clamps must
be retightened every 5 minutes until
resin gelation.

Figure 6-43. C-Clamp Sequence and Placement
(2) Negative Pressure. Negative pressure is
produced using a vacuum bag. When a component
or repair area is sealed in a vacuum bag, the vacuum
source removes air from the sealed area. This creates
a vacuum in the bag and allows atmospheric pressure
to be exerted on the bag and repair area. The amount
of pressure obtained depends upon the vacuum seal
integrity, the vacuum source, and the altitude (the
higher the elevation, the lower the compaction level)
at which the repair is being performed. A vacuum
gauge is required to be installed in the vacuum
bag to monitor the vacuum level achieved at the
repair. Typically, a minimum of 22 in Hg (mercury),
equivalent to approximately 10.8 psi, is used to cure
most composite materials.
(a) Disadvantages of Negative Pressure.
Although vacuum pressure is the most feasible type
pressure that can be applied to field level repairs,
due to the level of pressure it can exert compared
to weights or clamps, it has several disadvantages
when compared to positive pressure.
1 The first disadvantage is that vac-
uum or negative pressure inside the
vacuum bag adversely affects many
types of materials during processing,
such that the size of any voids and
TM 1-1500-204-23-11
porosity present is increased. Posi-
tive pressure, on the other hand, sup-
presses their size. Also, many mate-
rials actually foam up when exposed
to a vacuum, some more than others.
The presence of voids and porosity is
detrimental to the resulting strength
of the repair. Consequently, some
materials require partial vacuum lev-
els to be used when curing them to
minimize this foaming effect.
2 The second disadvantage is that the
atmospheric pressure exerted on a
standard single vacuum bag tends to
pinch off the edges around the repair
patch, thereby, trapping air and other
volatiles from escaping. Alternate
cure cycles that incorporate a debulk
cycle, discussed in paragraph 6-19.b,
and alternate vacuum bag methods,
such as the double bag method dis-
cussed in paragraph 7-11, have been
developed to compensate for this
effect.
3 Third, obtaining a sealed vacuum bag
can be quite a challenge on aircraft
as very small leaks can occur that
are difficult to correct. Any leak that
is present allows air to flow through
6-87
TM 1-1500-204-23-11

the repair area, thereby increasing
the porosity level and possibly alter-
ing the quality of the resulting repair
patch. See figure 6-41 for pressure
levels verses barometric pressures
and altitudes.
(3) Double Vacuum Debulk (DVD) Wet Layup
Process The DVD procedure removes the entrapped
air that causes porosity in wet layup laminates. The
finished structural properties of a DVD produced repair
patch are better than a wet layup patch but less than
that of a pre-preg patch. See paragraph 7-11 for
details on DVD process.
k. Adhesive Cure Processes. Epoxy resins are
used for adhesives and pre-pregs for both the man-
ufacture and repair of advanced composite struc-
tures. They consist essentially of a base resin and
a curing agent. The cure process involves an irre-
versible chemical reaction between these two main
constituents. This reaction is typified by the poly-
merization of epoxy molecules into large molecular
chains and a joining or cross-linking of these chains
into a strong three dimensional network. The process
is exothermic, i.e. heat liberating. The inadequate
curing of a patch or adhesive material will result in
insufficient cross-linking of molecular chains and low
strength repairs.
initial mixing of the base resin and the curing agent
(unless heat is applied).
(b) The cure process can be shortened by
applying heat to accelerate the reaction. To prevent a
runaway reaction, allow the exotherm to be exhausted
at room temperature before any heat is applied. In
some cases, the cure strength can be increased by
raising the cure temperature. For example, wet layup
patches manufactured from EA956 laminating resin
and cured at 250 ºF are 25% stronger than those
cured at 190 ºF. Some two part resin systems require
heat to be applied for the cure to take place.
(c) Cure cycle requirements are provided in
the system specific technical manual. If no cure cycle
is provided in the system specific technical manual,
use the adhesive manufacturer’s recommended cure
cycle per engineering disposition. A typical two part
adhesive heat cure cycle is shown in figure 6-44.

(1) Two Part Adhesive Cure Process. For

most two part adhesives, the cure is initiated by
mixing, in prescribed amounts, the base resin (part
A) and the curing agent (part B). See paragraph
Figure 6-44. Typical Two Part Adhesive Heat Cure
6-17 on mixing two part adhesives. Both parts are
Cycle
initially a liquid. Most two part adhesive systems
can be cured at either room temperature or by heat
application.

(a) The chemical reaction between the base
resin and the curing agent occurs at room temperature
and is exothermic. Once these resin systems have
been mixed, they have a limited pot life (usable
working life). During the cure process, the resin
system progresses from a liquid to a weak gel and
then into a strong, highly structured solid. Pressure
(either positive or vacuum) is applied during the cure
to facilitate resin flow, degassing, compaction and to
ensure bonded details remain in contact while the
chemical reaction is in progress. The resin system
can be sanded after 8 hours. Full strength of the
resin system is not achieved until 5-7 days after the
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket

6-88

(if required) and all necessary vacuum bag
materials prior to mixing resin.
NOTE
(Heat Blanket Method).
Adhesive of combined parts A and B will
be uniform in color when properly mixed.
Part A of adhesive may require stirring after
prolonged storage as chemical agents of part
A may separate. To ensure accurate mix
ratio, a minimum of 25 grams of adhesive
should be mixed.
(d) Two Part Adhesive Room Temperature
Cure Cycle Method.
1 Weigh and mix part A and part B in the
correct amount as described in para-
graph 6-17. Ensure that both parts
are thoroughly mixed.
2 Apply the adhesive to the repair area.
Ensure that pressure is applied to the
repair before the adhesive pot life is
exceeded. Use one of the methods
specified in paragraph 7-6 for appli-
cation of the adhesive.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
3 Allow the material to set at room tem-
perature under pressure for a mini-
mum of 8 hours.
4 After 8 hours at room temperature,
pressure may be removed even
TM 1-1500-204-23-11
though the full cure strength will not
achieved for another 5 days.
(e) Two Part Adhesive Heat Cure Cycle
1 Weigh and mix part A and part B in the
correct amount as described in para-
graph 6-17. Ensure that both parts
are thoroughly mixed.
2 Apply the adhesive to repair area.
Install a heat blanket and vacuum bag
or heat/vacuum blanket as described
in paragraph 6-18 before the adhe-
sive pot life is exceeded.
3 If required by the system specific
technical manual, allow the material
to set at room temperature under 20
inches of mercury vacuum minimum
for the time specified.
4 Heat the repair area to the tempera-
ture specified in the system specific
technical manual for the type of mate-
rial being cured, at a rate of 2-6 ºF per
minute. Maintain the vacuum pres-
sure specified in the system specific
technical manual during the entire
cure cycle.
To prevent blistering, delaminations or dis-
bonds from occurring DO NOT set or adjust
temperature controller higher than the upper
limit for the cure temperature range specified
in the system specific technical manual.
6-89
TM 1-1500-204-23-11

(a) The cure process is verified by reviewing

NOTE the cure cycle data. If the temperature controller printer
is inoperative or a printer is not available, manually
Apply additional insulation (vacuum bag
record the temperature at 2 minute intervals during
breather material) over heat blanket as
rise to temperature and during cool down. Record
required to assist in obtaining the desired
the temperature at 15 minute intervals during the
cure temperature.
soak. Ensure the rise rate is between 2 to 6 ºF
per minute. Soak time and temperature requirements
5 Adjust the temperature controller to shall meet the system specific technical manual or
bring all thermocouples (control and resin manufacturer’s recommended cure cycle. The
monitoring) within the cure temper- cool rate shall not exceed 5 º F per minute.
ature range specified in the system
specific technical manual.
(b) For patch bonds, inspect the adhesive
squeeze out at the patch periphery. Adhesive squeeze
6 Upon the coldest thermocouple out should be hard with a smooth fillet (see figure
reaching the cure temperature range, 6-45).
begin a timed soak at temperature
as specified in the system specific
technical manual. Continuously mon-
itor and record all thermocouples to
ensure the cure temperature range is
maintained during the soak period.

7 After the soak at temperature is com-

plete, cool to 150 ºF at a rate not to
exceed 5 ºF per minute.

8 Upon reaching 150 ºF , the heat blan-

ket and vacuum bag materials may be
removed. Figure 6-45. Inspection of Adhesive Squeeze Out
Following Cure
(2) Cure Process Verification. Some common
handling and processing errors are shown in table
6-6.

Table 6-6. Common Bonded Repair Errors

Common Errors Results

• Incomplete mixing/incorrect mix ratio of two-part - Weak repair
adhesives
• Failure to apply pressure before two-part adhesive - Inadequate bond pressure
gels - Poor fit of repair details
- Weak/porous repair
• Cool down from cure temperature too fast (exceeds - Micro cracking of laminate
5 °F/minute) - Weak repair
• Poor fitup of repair details- or - - Inadequate bond pressure
• Loss of pressure during cure - Weak/porous repair
- Migration of repair details
• Rise to temperature too slow - Early gelation
- Inadequate flow
- Weak/porous repair
• Rise to temperature too fast - Excess heat liberated during cure
- Possible thermal damage to part
- Weak repair

6-90
 TM 1-1500-204-23-11

Table 6-6. Common Bonded Repair Errors — Continued

Common Errors Results

• Cure temperature too low- or - - Undercured material
• Cure time too short - Weak repair
• Cure temperature too high - or - - Thermal damage to part
• Failure to exhaust exotherm (two-part adhesive) - Thermal degradation of repair materials
before applying heat - Weak repair
• Storing film adhesive/pre-preg at ambient temperature - Excess resin advancement
- or - - Poor flow characteristics
• Using expired shelf life materials - Weak bond
• Failure to thaw film adhesive/pre-preg before opening - Condensation of moisture on material
sealed bag - or - - Weak porous repair
• Storing film adhesive/ pre-preg in unsealed bags
• Inadequate drying - or - - Skin to core unbond/laminate blistering
• Failure to dry part before repair - Weak/porous repair
• Improper surface preparation - or - - Contaminated bond surface
• Bond surface contaminated after surface preparation - Poor bond durability
- Weak bond

6-20. GALVANIC CORROSION OF CARBON COM-
POSITES Aluminum parts will extensively corrode if
they are used with carbon fiber composites and a
protective layer is not included.
a. A glass barrier ply must be used any time an
aluminum part is mated to a carbon fiber struc-
ture and should be included in the lay-up. Inti-
mate contact is not required, just an electrical
path so even if steel or titanium separates the alu-
minum and carbon composite, the isolation is still
required.
b. Titanium is the preferred metal to use with carbon
fiber composites. CRES fasteners are accept-
able if authorized in the system specific technical
manual. Use titanium fasteners if the type of fas-
tener is not specified in the system specific tech-
nical manual.
c. Fasteners used in carbon fiber composites must
also be protected to prevent galvanic corrosion.
Titanium fasteners are preferred and must be wet
installed with MIL-PRF-81733 sealant.

6-91/(6-92 blank)

CHAPTER 7
REPAIR PROCEDURES
7-1. GENERAL. This chapter provides detailed pro-
cedures for repairing damaged advanced composite
parts. Each repair includes an equipment list, mate-
rials list and process flow diagram for accomplishing
the repair. The processes in the flow diagram are
listed in the order in which they are to be performed
Table 7-1. General Description of Different Repair Types
Type of Repair Description
Resin Injection Holes drilled partially into
laminate area of void or
delamination. Liquid resin
injected with a syringe
through a vacuum duct
into one of the holes.
Vacuum applied to draw
the resin outward from the
point of insertion through
the delamination region.
Pressure and heat applied
to restore the bond.
Wet Layup (Simple Patch) Concentric circular or
rectangular patches cut
from woven aramid,
fiberglass, and/or carbon
fabric. Patches laid up
over damaged area and
impregnated with two-part
epoxy/resin mixed at the
repair site and applied by
hand. Patches stacked
for multiple ply repairs.
Pressure applied with
weight or vacuum device.
Repair is then cured at
room temperature or
elevated temperature,
depending on the curing
agent or resin system.
Wet Layup (External Same as the simple wet
Stepped Patch) layup repair described
above except the repair
plies are stepped (made
successively smaller in
diameter for smoother
load transition).
to ensure that the repair is performed correctly. Each
process should be reviewed and understood prior
to beginning the repair. A description of generally
applicable repair techniques for advanced composites
structures is listed in 7-1.
Application
Most types of thick
laminates.
All types of laminated and
sandwich panel facings.
All laminates and
sandwich panel facings.
Usually confined to thicker
laminates with directional
layups requiring a more
structural repair than a
simple patch.
TM 1-1500-204-23-11
Constraints and
Limitations
Broken fibers or remnants
of cured resin in the
void area may affect
the quality of the bond.
Difficult to ascertain if the
delamination has been
corrected. If vacuum is
used, surface laminate
must be relatively flat and
accessible.
Limited structural
capability. Used primarily
for thin laminates with
non-directional layups.
Not usable where close
tolerance control of
surface or mold line is
required. Usually no
requirement to orient
fiber direction relative to
the parent structure. If
hybrid patch, stacking
sequence generally not
critical. One-sided access
generally adequate.
Good structural capability.
May not be usable where
close tolerance control
of surface or mold line is
required. Prescribed
ply orientation and
stacking sequence usually
required.
7-1
TM 1-1500-204-23-11

Table 7-1. General Description of Different Repair Types — Continued

Type of Repair Description
Wet Layup (External Same as external stepped Same as above.
Overlapped Patch) patch described above
except the repair plies
are overlapped (made
successively larger in
diameter).
Wet Layup (Flush Scarfed Circular or rectangular Thick carbon laminates
Patch) patches cut from woven with highly directional
and/or unidirectional layups..
carbon. Patches are
custom tapered, i.e., each
ply made successively
smaller or larger in
diameter. Damage
area in parent structure
scarfed to match taper
of stepped repair plies.
Patches laid up over
prepared damage area
in prescribed sequence
and fiber orientation and
impregnated with two-part
epoxy/resin mixed at the
repair site and applied
by hand. For large-area
damage, restoration of the
structural shape of the part
using foam or templates
may be necessary before
installing the repair.
Pressure applied and
repair cured at room
temperature or elevated
temperature depending
on the curing agent.
Wet Layup (Flush Same as a flush scarfed Thick carbon laminates.
Double-scarfed Patch) patch except that the
damaged structure is
scarfed inward from both
sides.
Constraints and
Application
Limitations
Same as above.
Overlapped patch involves
larger fiber eccentricities
than a stepped patch, but
may be less susceptible to
edge peeling.
Quality of the repair
is sensitive to ply
pattern uniformity,
taper, concentricity,
fiber orientation,
stacking sequence, and
impregnation quality.
Layup will generally
duplicate the parent
structure. Woven
materials will generally be
oriented ±45 degrees
relative to the axis
at adjacent structural
members; unidirectional
materials in the direction
of the principal load.
For flush repairs, the
damaged part must
be carefully scarfed to
match the taper of the
patch. Uniform pressure,
temperature, and cure
cycle are important. If
the laminate thickness
permits, anti-peel rivets
may be installed around
the edges of the cured
repair. Rivets may
be mandatory when
the damage involves
substructure. For
through-damage, access
to both sides is required to
clean up back surface and
provide support for layup.
Same as above.
Two-sided access
required.

7-2

Table 7-1. General Description of Different Repair Types — Continued
Type of Repair Description
Bonded Pre-cured Structural repair.
Composite (Simple Pre-cured fiber/epoxy
External Patch) laminated patch made
from woven and/or
unidirectional aramid,
fiberglass, and/or carbon.
Geometry and size
tailored to a specific
structural configuration,
stiffness, and loading
condition. Circular or
rectangular patch. Patch
applied to structure with
film or paste adhesive. A
relatively thick and elastic
bond-line is desirable.
Similar to flat pattern
pre-preg with respect to
preparing the damaged
part and curing the repair.
Bonded Pre-cured Same as the simple
Composite (External external bonded patch
Stepped Patch) except the patch is tapered
by stepping the plies to
successively smaller or
larger diameters. May be
installed as a flush repair
by scarfing the parent
material to match the
taper of the patch.
TM 1-1500-204-23-11
Constraints and
Application
Limitations
Flat or gently contoured Patch usually must be
laminates. oriented with respect
to the parent structure.
Care needed to avoid
preloading during
installation. Uniform
pressure, temperature,
and cure cycle are
important. Adhesive
bond may have poorer
strength properties than
a wet layup or pre-preg
repair. Adhesive should
not be overly sensitive to
contamination and should
possess elastic properties
similar to an elastomer,
especially in areas which
experience high strain
rates or interlaminar
shears. If the laminate
thickness permits, rivets
may be installed prior to
adhesive cure to ensure
good surface contact
and to provide fail-safe
strength in case of bond
deterioration. Provides
no opportunity to form
repair parts to fit structural
contours as with metals.
Flat, gently contoured, Same as simple bonded
thick laminates requiring patch except for the added
greater structural complications associated
capability than a simple with scarfing the damaged
patch provides. structure to match the
taper of the patch.
7-3
TM 1-1500-204-23-11

Table 7-1. General Description of Different Repair Types — Continued

Constraints and
Type of Repair Description Application
Limitations
Bonded Reinforced Sheet of thermoplastic Various types of laminates Limited structural
Thermoplastic material reinforced subject to the limitations capability compared
with carbon, aramid cited in the adjacent with a fiber-reinforced
or fiberglass fibers. column. thermosetting repair
Thermoplastic fused to material. The high
surface of damaged part temperature required
under heat and pressure. to reflow the thermoplastic
May be used alone for a may limit its application
semi structural repair or to high-temperature
to create a bond between bismaleimide structures.
the damaged part and a
repair patch of metal or
composite material.
Bonded Metal Repair Repair formed by Thick carbon laminates. Metal repair parts must
(Stepped Laminated Foil) laminating titanium foil be compatible with the
patches with a film or parent structure (stiffness,
paste adhesive. Foil expansion coefficient,
patches may be stepped chemical interaction, etc.).
to create a tapered patch. Bonded foil may have
Repair may be external or poorer properties than
flush. a wet layup or pre-preg
repair.
Bonded Metal Repair Semi structural repair. Laminates and sandwich Metal repair parts must
(Sheet Metal) Repair patch cut from panel face sheets. be compatible with the
a single thickness of parent structure (stiffness
aluminum, titanium or expansion coefficient,
stainless steel sheet chemical interaction, etc.).
stock and bonded to the Limited to structural
damaged part with a paste shapes to which a
or film adhesive. Bond metal patch can be
cured under heat and formed. Elastic bondline
pressure. required. Properties
poorer than a wet layup
or pre-preg composite
repair. Primarily restricted
to low-risk emergency
repairs.

7-4
 TM 1-1500-204-23-11

Table 7-1. General Description of Different Repair Types — Continued

Constraints and
Type of Repair Description Application
Limitations
Riveted/Bolted Sheet Structural repair; external. Moderately thick to heavy Repair parts must be
Metal Used primarily when carbon laminates. compatible with parent
conditions prohibit structure (stiffness,
bonding. Circular or expansion coefficient,
rectangular patch and/or etc.). Fastener size
reinforcing angles cut and pitch are important
from metal sheet stock considerations. Drilled
or standard structural holes in structure may
shapes (aluminum or create unacceptable
titanium). Parts may be stress concentrations.
formed to fit contours of Riveting not feasible for
parent structure. Repair thin laminates.
installed with mechanical
fasteners. A sealant
which is not sensitive to
contamination is desirable
between the patch surface
to provide additional shear
strength and to reduce
bearing loads at the rivets.
Bolted Metal Plate Thick metal patch Heavy carbon structures. Very limited application
(titanium or stainless to helicopter structures.
steel) cut from plate Restricted to heavy carbon
stock and joined to the structures capable of
damaged structure with accepting drilled holes and
bolts. Sealant applied high-stress concentrations
between repair plates and created by the installation
surface of the part. of mechanical fasteners.
Two-sided access is
usually required.
Sandwich Core Repair Damaged core material Honeycomb sandwich Limited to no larger than
(Foam Plug) removed. Plug cut from panels using aluminum or 6 inches in diameter.
structural foam or a Nomex honeycomb. Two-sided access
foam-in-place liquid required for through
polyurethane foam. damage.
Foam cured and face
sheet repaired with one
of the laminate repair
procedures.

7-5
TM 1-1500-204-23-11

Table 7-1. General Description of Different Repair Types — Continued

Constraints and
Type of Repair Description Application
Limitations
Sandwich Core Repair Damaged core material Honeycomb sandwich Greater structural
(Honeycomb Plug) removed. Plug cut from panels using aluminum or capability than foam
honeycomb and fitted Nomex honeycomb. repair. Core plug repair
to cavity. Plug bonded may be difficult if panel
in place with film or varies in thickness.
paste adhesive. Face Two-sided access
sheet repaired using one required for through
of the laminate repair damage.
procedures.
Module Repair Section of the airframe Large area damage to Metal parts must be
(module) containing the structures designed for structurally and chemically
damage is removed modular repair. compatible with the
by cutting through parent structure. Module
the structure (skin and replacement may require
interior members) along substantial disassembly
designated splice lines. of system hardware in
A replacement module the affected area of the
is drawn from supply airframe. Maintenance
or cannibalized from an time may be extensive.
irreparable aircraft and
rivet holes are drilled
along the edges of the
module and the cutout
in the fuselage. Splice
straps and gussets are
formed from standard
sheet metal stock and the
replacement module is
installed with the metal
splices and mechanical
fasteners.

7-2. SURFACE DAMAGE REPAIR PROCEDURE-
. The following paragraphs provide generic procedures
for performing cosmetic repair to a surface dent or
scratch with no broken fibers or delamination present.
This repair procedure is not necessarily applicable
to a particular weapon system. The applicability of
this repair depends upon additional factors such as
loading conditions and laminate thickness. Refer to
the system specific technical manual for applicable
damage limits. 7-1 is a flow diagram that depicts
process repairing surface damage.

7-6

Figure 7-1. Process Flow Diagram for Surface
Damage
a. Facilities, Equipment and Materials. These
include a vacuum cleaner, dual-action sander, and/or
90 degree die-grinder and sanding mandrel, flash
breaker tape, silicon carbide abrasive paper, wiping
cloth, a spatula, adhesive liquid, and release film.
b. Removal Procedures.
DO NOT sand into laminate when removing
paint. When working on a carbon fiber lami-
nate, a black colored dust on the sandpaper
indicates that sanding into the laminate has
occurred and carbon fiber is being removed.
If this occurs, the sanding process should
be stopped immediately. A loss of structural
integrity may occur if fibers are exposed or
damaged.
NOTE
Fibrous mixtures are optional and need not
be used for scratches or dents.
(1) Remove dirt, grease and aircraft fluids from
repair area as described in paragraph 6-5.
(2) Remove paint from skin in the repair area by
sanding as described in paragraph 6-1.
(3) Clean the scratch and/or dent in accordance
with paragraph 6-7 with wiping cloth and
TM 1-1500-204-23-11
an approved solvent. Thoroughly clean the
area with repeated wiping until no residue is
left on the cloth.
(4) Measure the depth, length and width of the
surface damage to ensure compliance with
the limitations in the system specific techni-
cal manual.
(5) Dry the repair area per paragraph 6-6 for a
minimum of 1 hour or as directed by the sys-
tem specific technical manual, at 150 (+10)
ºF using a heat source per Chapter 3. Han-
dle the prepared surface of the part wear-
ing powder free latex gloves until after filler
application is complete. If filler is not to be
applied immediately, cover with clean barrier
material and secure with preservation tape
to prevent contamination.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
(6) Prepare the adhesive by mixing a suitable
resin and fiber mixture following the system
specific technical manual. In the absence
of specific instructions, use this mixing ratio:
1.5 grams chopped fiber to 48 grams resin.
Paragraph 6-17 describes resin mixing pro-
cedures.
(7) Fill the scratch or dent with the mixed resin
and fiber mixture. Apply the adhesive in
layered amounts to avoid air entrapment.
Bring flush with outer moldline surface of
part. Add additional filler as required to allow
for shrinkage.
(8) Place release film over repair. Smooth the
adhesive with a spatula and wipe off the
excess with a clean, dry cloth.
7-7
TM 1-1500-204-23-11

Failure to properly cure adhesive in accor-

dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.

(9) Cure the adhesive with a heat lamp or heat

blanket according to paragraph 6-19, the
system specific technical manual or the
resin manufacturer’s specifications per engi-
neering disposition.

(10) Prepare the surface for coatings by sanding

the repaired area smooth with 240 grit abra-
sive paper being careful not to sand into the
laminate.

(11) Remove all dust by vacuuming or wiping with

a clean dry cloth.

(12) Paint according to paragraph 7-13b or the Figure 7-2. Process Flow Diagram For Partial
system specific technical manual. Thickness Damage

7-3. PARTIAL THICKNESS DAMAGE. This repair is
applicable to surface damage that exceeds the lim-
its that can be repaired in paragraph 6-8 without
penetrating the composite skin, and to the repair of
unsuccessful adhesive injection delamination repairs.
This includes gouges, cracks and other damage that
results in broken fibers. This repair procedure is not
necessarily applicable to a particular weapon system.
The applicability of this repair depends upon additional
factors such as loading conditions and laminate thick-
ness. Consult the system specific technical manual
or engineering for further guidance.
a. Bonded Repair. Refer to figure 7-2 for the
Process Flow Diagram for Partial Thickness Damage
Bonded Repair.
(1) Facilities, Equipment and Materials. The
following equipment and materials are required for
repair: Vacuum Cleaner, HEPA Filter, Dual Action
Sander or 90 degree die-grinder, 90 Degree Router
Motor, 20,000 RPM , Overhose Assembly, Sanding
Disk Holder, Sanding Disks, 80 Grit, 1.0 Inch Diam-
eter, Cutting Wheel, Diamond Coated, 80 Grit, 1.0
Inch Diameter, Temperature/Vacuum Controller, Heat
Blanket, Adhesive Comb, Flash breaker Tape, Silicon
Carbide Abrasive Paper, Wiping Cloth, Release Film,
1 Mil, Spatula, Fiber (See System Specific Techni-
cal Manual), Cut 0.1 Inch Long, Adhesive, Liquid
(See System Specific Technical Manual), Adhesive,
Paste (See System Specific Technical Manual), Light-
ning Mesh (See System Specific Technical Manual),
Scrim Cloth, Vacuum Bag Repair Materials Kit, Copper
Sheet, Patch (See System Specific Technical Manual).

(2) Bonded Repair Procedure.

(a) Remove dirt, grease and aircraft fluids

from repair area as described in para-
graph 6-5.

7-8

DO NOT use oil or oil based materials
as NDI couplants on advanced composite
components. Use only water or water based
materials. Disbonds may result and loss of
structural integrity may occur.
(b) Define both the depth and extent of the
damage using NDI according to para-
graph 5-2 and the system specific tech-
nical manual. Lay out the damage as
described in paragraph 6-9.
(c) Remove NDI couplant by wiping with
clean, water moistened cloth.
(d) Remove paint from skin in the repair
area by sanding as described in para-
graph 6-1.
(e) Remove partial thickness damage as
described in paragraph 6-4 and as
shown in figure 6-4.
(f) Reinspect the damage removal area
using NDI to ensure no skin delamina-
tions remain below the damage area.
DO NOT sand into laminate when removing
paint. When working on a carbon fiber lami-
nate, a black colored dust on the sandpaper
indicates that sanding into the laminate has
occurred and carbon fiber is being removed.
If this occurs, the sanding process should
be stopped immediately. A loss of structural
integrity may occur if fibers are exposed or
damaged.
(g) Dry repair area as described in para-
graph 6-6 using a heat blanket to
remove subsurface moisture.
(h) Prepare area for filler application by
lightly hand sanding with 150-180 grit
abrasive paper as described in para-
graph 6-7.
(i) Clean per paragraph 6-5. Handle the
prepared surface of the part wearing
powder free latex gloves until after filler
application is complete. If filler is not
to be applied immediately, cover with
clean barrier material and secure with
preservation tape to prevent contamina-
tion.
TM 1-1500-204-23-11
(j) Prepare and apply filler.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount of
air is introduced into the resin during mixing,
or if mixing is inadequate and may result in
loss of structural integrity.
1 Estimate the amount of fiber floc
filled adhesive filler is required in
grams by multiplying the approxi-
mate area in inches of the dam-
age by thirty. Area is determined by
multiplying the depth by the length
by the width of the area (D x L x W).
2 Prepare the estimated amount of
fiber filled adhesive filler required
as described in paragraph 6-17. If
the system specific technical man-
ual does not specify the filler mix
ratio, use a filler mix ratio (mrF) =
14.
3 Apply filler in the damaged area
using a spatula. Bring flush with
outer moldline surface of part.
Remove air bubbles as required.
NOTE
Cure of filler will be achieved during patch
bond step.
4 Add additional filler as required to
allow for shrinkage.
(k) Tape release film over filler with high
temperature tape. Allow to set at room
temperature until it can be sanded
(approximately 8 hours). As an alterna-
tive, the adhesive/filler may be set using
a heat lamp. Use the cure cycle iden-
tified in the system specific technical
manual to set the adhesive/filler. Oper-
ate heat lamps per paragraph 6-19h.
(l) Refer to the system specific techni-
cal for patch selection. Composite
pre-cured patches may come in two
forms: large sheets from which the cor-
rect size patch is machined and circular
patches in assorted diameters which
are to be used without further machin-
ing.
1 If using a large sheet, cut patch
to the required dimensions from
7-9
TM 1-1500-204-23-11
the carbon/epoxy pre-cured sheet
using a 90 degree router motor and
a diamond coated cutting wheel.
Patch periphery shall extend a con-
stant 1.5 inches (minimum) beyond
the damage cleanup periphery.
See figure 7-3.
Figure 7-3. Partial Thickness Bonded Repair
2 If using a circular patch, select a
patch size which will allow a 1.5
inch (minimum) overlap between
the patch edge and damage
cleanup hole perimeter.
3 Remove peel ply from both sides
of patch. Use care not to inadver-
tently remove fibers from patch dur-
ing peel ply removal.
4 If required, taper edges of patch to
the dimensions shown in figure 7-4
using a 90 degree router motor and
a 1 inch diameter, 80 grit abrasive
sanding disk. Two ply patches and
pre-cured circular patches do not
require tapering.
Figure 7-4. Patch Edge Taper Dimensions
7-10
Ensure a minimum of 1.5 inch overlap is
achieved during the layup of a bonded external
patch. Insufficient overlap will result in reduced
strength. Load levels in the repair area may
dictate a longer overlap. Refer to the system
specific technical manual for further guidance.
(m) Prepare Surfaces For Bonding.
1 Sand filler flush with outer moldline
surface using an orbital sander and
180-240 grit abrasive paper.
2 Vacuum the repair area to remove
sanding dust.
3 Wipe area with clean, dry cloth to
remove sanding residue.
4 Prepare repair area and both sur-
faces of patch for bonding by lightly
hand sanding with 150-180 grit
abrasive paper as described in
figure paragraph 6-7. Handle pre-
pared surfaces wearing powder
free latex gloves until patch bond-
ing is complete. If patch is not to
be bonded immediately, cover with
clean barrier material and secure
with preservation tape to prevent
contamination.
(n) Select a 2 part paste adhesive. Refer to
the system specific technical manual for
the appropriate adhesive selection and
paragraph 7-6 for additional patch bond
procedures.

Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 ºF, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select a heat blanket (if required)
and all necessary vacuum bag materials prior
to mixing resin.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount of
air is introduced into the resin during mixing,
or if mixing is inadequate and may result in
loss of structural integrity.
1 Cut a piece of scrim cloth 1/4 inch
larger than the patch if required.
2 Prepare approximately 50 grams
of adhesive for patch bond as
described in paragraph 6-17.
3 Apply a thin layer of adhesive on
the part surface using a spatula and
adhesive comb per paragraph 7-6.
Adhesive shall extend a minimum
of 1/4 inch beyond patch periphery.
4 Apply the scrim cloth to adhesive
on the part surface if required.
NOTE
The bond surface of the patch is the flat
surface not containing the taper.
5 Apply a thin layer of adhesive on
the bond surface of the patch using
a spatula and adhesive comb per
paragraph 7-6.
Part to patch alignment must be main-
tained within ±2 degrees. Fabricated com-
posite patches are orientation sensitive from
a strength standpoint. Incorrect alignment
of part and patch during layup will result in
reduced strength and loss of structural integrity
may occur.
6 Apply bond side of patch containing
adhesive on part surface contain-
ing scrim cloth/adhesive. Ensure
patch is aligned on part to maintain
minimum patch overlap.
TM 1-1500-204-23-11
7 If multiple stacked patches are
required, stack the largest patch
on the part surface followed by
increasingly smaller size patches.
See paragraph 7-5. Repeat scrim
cloth and adhesive application for
each stacked patch applied. Tape
in place with flash breaker tape.
Figure 7-5. Layup of Stacked Patches and
Adhesive
(o) Bond patch.
1 Layup the vacuum bag and heat
blanket as described in paragraph
6-18, Vacuum Bagging. If a heat
blanket is not used to cure the
adhesive, omit heat blanket, cop-
per sheet and heat blanket control
thermocouple from layup.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
2 Cure adhesive as described in
paragraph 6-19, using the cure
cycle from the system specific tech-
nical manual.
3 Disassemble the vacuum bag (and
heat blanket if used).
(p) NDI Patch Bond(s).
1 Visually inspect adhesive squeeze
out at patch edge as described in
paragraph 5-2. See figure 6-45.
2 Perform NDI of patch to skin and
patch to filler bond areas to verify
bondline integrity.
7-11
TM 1-1500-204-23-11
DO NOT sand into laminate near patch edge
when sanding adhesive squeeze out.
(q) Repair the outer lightning mesh accord-
ing to paragraph 7-12 and the system
specific technical manual if applicable.
(r) Refinish.
1 Sand the area smooth with 180 grit
abrasive paper. Vacuum the sand-
ing dust from the repair area. Wipe
with clean, dry cloth to remove
sanding residue.
2 Apply finish system in accordance
with paragraph 7-13b or the system
specific technical manual.
b. Partial Thickness Scarf Repair. Scarf repairs
are typically used to repair laminates on highly-loaded
structures. The size of the repair area depends on
the thickness of the skin and the required scarf ratio.
Thicker structures require larger patches relative to the
original damage area. Highly-loaded structures require
high scarf ratios (e.g., 80 to 1), therefore, large-patch
areas in order to carry the necessary loads. As a
result, patch areas may be very large. Scarf ratios
are determined according to the loads that must be
transferred. The scarf ratio for any repair in a given
weapon system will be called out in the system specific
technical manual or other authorizing document. Scarf
repairs can be used on all glass, carbon, and aramid
composite materials. Full thickness repairs generally
use scarf ratios of 20 to 1 while partial depth scarf
ratios are generally 30 to 1. Refer to figure 7-6 for
the Process Flow Diagram for Partial Thickness Scarf
Repair.
Figure 7-6. Process Flow Diagram for Partial
Thickness Scarf Repair
7-12
(1) Facilities, Equipment and Materials. The
following equipment and materials are required: Vac-
uum Cleaner, HEPA Filter, Dual Action Sander or 90
degree die-grinder, 90 Degree Router Motor, 20,000
RPM, Overhose Assembly, Sanding Disk Holder,
Sanding Disks, 80 Grit, 1.0 Inch Diameter, Cutting
Wheel, Diamond Coated, 80 Grit, 1.0 Inch Diam-
eter, Temperature/Vacuum Controller, Heat Blanket,
Adhesive Comb, Flash breaker Tape, Silicon Carbide
Abrasive Paper, Wiping cloth, Release Film, Spat-
ula, Adhesive, Liquid (See System Specific Technical
Manual), Fabric (See System Specific Technical Man-
ual), Lightning Mesh (See System Specific Technical
Manual), Vacuum Bag Repair Materials Kit, Copper
Sheet.
(2) Partial Thickness Scarf Repair
Procedure.
DO NOT use oil or oil based materials
as NDI couplants on advanced composite
components. Use only water or water based
materials. Disbonds may result and loss of
structural integrity may occur.
(a) Remove dirt, grease and aircraft fluids
from repair area as described in para-
graph 6-5.
(b) Define both the depth and extent of the
damage using NDI according to para-
graph 5-2 and the system specific tech-
nical manual. Lay out the damage as
described in paragraph 6-4.
(c) Remove NDI couplant by wiping with
clean, water moistened cloth.
DO NOT sand into laminate when removing
paint. When working on a carbon fiber lami-
nate, a black colored dust on the sandpaper
indicates that sanding into the laminate has
occurred and carbon fiber is being removed.
If this occurs, the sanding process should
be stopped immediately. A loss of structural
integrity may occur if fibers are exposed or
damaged.
(d) Remove paint from skin in the repair
area by sanding as described in para-
graph 6-1.
(e) Remove partial thickness damage as
described in paragraph 6-4 and as
shown in figure 6-4. Use the scarf ratio

from the system specific technical man-
ual.
(f) Reinspect the damage removal area
using NDI to ensure no skin delamina-
tions remain below the damage area.
(g) Dry repair area as described in para-
graph 6-6 using a heat blanket to
remove subsurface moisture.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
Failure to observe the correct number of repair
plies, the correct repair ply orientation, the
correct repair ply overlap and removal of all
pieces of vacuum bagging film will reduce the
strength of the repair and may result in the
loss of structural integrity.
(h) Clean the repair area in accordance
with paragraph 6-7 in preparation to
replacement of the filler plies.
(i) Prepare the repair filler plies in accor-
dance with paragraph 6-16, Wet Layup,
and place stacked, oriented patch on
the damaged site. Refer to the system
specific technical manual for the repair
fiber, resin, number of plies, ply orienta-
tion, ply size and overlap.
(j) Determine and apply cure hardware
and vacuum bagging materials in accor-
dance with paragraph 6-18, Vacuum
Bagging. Refer to the system specific
technical manual for the porous release
film, bleeder material and the number
of bleeder plies.
TM 1-1500-204-23-11
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
(k) Cure the repair patch in accordance
with paragraph 6-19, Curing Advanced
Composites.
(l) NDI Patch Bond(s).
1 Visually inspect adhesive squeeze
out at patch edge as described in
paragraph 5-2. See figure 6-45.
2 Perform NDI of patch to skin and
patch to filler bond areas to verify
bondline integrity.
DO NOT sand into laminate near patch edge
when sanding adhesive squeeze out.
(m) If applicable, repair the outer lightning
mesh according to paragraph 7-12 and
the system specific technical manual.
(n) Refinish.
1 Sand the area smooth with 180 grit
abrasive paper. Vacuum sanding
dust from repair area. Wipe with
clean, dry wiping cloth to remove
sanding residue.
2 Apply finish system in accordance
with paragraph 7-13b or the system
specific technical manual.
7-4. PENETRATION DAMAGE REPAIR. Penetration
damage repair involves damage to the entire thickness
of the laminate. These procedures can be used for
facesheet repair after the core has been repaired in
sandwich structure. The following repair procedures
involve wet lay-up patches integral to the structure.
Precured patches that are secondarily bonded or
bolted are covered in paragraph 7-6 and paragraph
7-7. This paragraph identifies the facilities, equipment
and materials required to perform a full thickness scarf
repair, full thickness scab repair, full thickness step
repair, and full thickness bonded repair.
7-13
TM 1-1500-204-23-11
a. Full Thickness Scarf Repair. Full thickness
scarf repairs are accomplished using the same pro-
cedures for a partial thickness repair per paragraph
7-3b with the exception that a taper ratio of 20
to 1 is typical. Full thickness repairs may require
installation of a backside seal (see paragraph 6-18e).
Scarf repairs are typically used to repair laminates on
highly-loaded structures. The size of the repair area
depends on the thickness of the skin and the required
scarf ratio. Thicker structures require larger patches
relative to the original damage area. Highly-loaded
structures require high scarf ratios (e.g., 80 to 1),
therefore, large patch areas in order to carry the
necessary loads. As a result, patch areas may be
very large. Scarf ratios are determined according to
the loads that must be transferred. The scarf ratio for
any repair in a given weapon system will be called
out in the system specific technical manual or other
authorizing document. Scarf repairs can be used on
all glass, carbon, and aramid composite materials.
Full thickness repairs generally use scarf ratios of 20
to 1 while partial depth scarf ratios are generally 30 to
1. This repair procedure is not necessarily applicable
to a particular weapon system. The applicability of
this repair depends upon additional factors such as
loading conditions and laminate thickness. Refer to
figure 7-7 for the Process Flow Diagram for Pene-
tration Damage Repair. Consult the system specific
technical manual or engineering for further guidance.
Figure 7-7. Process Flow Diagram for Penetration
Damage Repair
(1) Facilities, Equipment and Materials. The
following equipment and materials are required: Vac-
uum Cleaner, HEPA Filter, Dual Action Sander or
90 degree die-grinder, Overhose Assembly, Sand-
ing Disk Holder, Sanding Disks, Temperature/Vacuum
Controller, Heat Blanket, Flash Breaker Tape, Sili-
con Carbide Abrasive Paper, Wiping Cloth, Release
Film, Spatula, Adhesive, Liquid (See System Specific
7-14
Technical Manual), Fabric (See System Specific Tech-
nical Manual), Lightning Mesh (See System Specific
Technical Manual), Vacuum Bag Repair Materials Kit,
Copper Sheet.
(2) Full Thickness Scarf Repair Procedure.
(a) Remove dirt, grease and aircraft fluids
from repair area as described in para-
graph 6-5.
DO NOT use oil or oil based materials
as NDI couplants on advanced composite
components. Use only water or water based
materials. Disbonds may result and loss of
structural integrity may occur.
(b) Define both the depth and extent of the
damage using NDI according to para-
graph 5-2 and the system specific tech-
nical manual. Lay out the damage as
described in paragraph 6-4.
(c) Remove NDI couplant by wiping with
clean, water moistened cloth.
DO NOT sand into laminate when removing
paint. When working on a carbon fiber lami-
nate, a black colored dust on the sandpaper
indicates that sanding into the laminate has
occurred and carbon fiber is being removed.
If this occurs, the sanding process should
be stopped immediately. A loss of structural
integrity may occur if fibers are exposed or
damaged.
(d) Remove paint from skin in the repair
area by sanding as described in para-
graph 6-1.
(e) Remove damage as described in para-
graph 6-15 and as shown in figure 6-4.
Use the scarf ratio from the system spe-
cific technical manual.
(f) Dry repair area as described in para-
graph 6-6 using a heat blanket to
remove subsurface moisture.
(g) Clean the repair area in accordance
with paragraph 6-7 in preparation for
replacement of the plies.
(h) Seal the backside of the damaged area,
if applicable, according to paragraph

6-18e and the system specific technical
manual.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
Failure to observe the correct number of repair
plies, the correct repair ply orientation, the
correct repair ply overlap and removal of all
pieces of vacuum bagging film will reduce the
strength of the repair and may result in the
loss of structural integrity.
(i) Prepare the repair plies in accordance
with paragraph 6-16, Wet Layup, and
place stacked, oriented patch on the
damaged site. Refer to the system spe-
cific technical manual for the repair fiber,
resin, number of plies, ply orientation,
ply size and overlap.
(j) Determine and apply cure hardware
and vacuum bagging materials in accor-
dance with paragraph 6-18. Refer to
the system specific technical manual for
the porous release film, bleeder mate-
rial and the number of bleeder plies.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
(k) Cure the repair patch in accordance
with paragraph 6-19, Curing Advanced
Composites.
(l) NDI Patch Bond(s).
TM 1-1500-204-23-11
1 Visually inspect adhesive squeeze
out at patch edge as described in
paragraph 5-2. See 6-45.
2 Perform NDI of patch to skin and
patch to filler bond areas to verify
bondline integrity.
(m) If applicable, repair the outer lightning
mesh according to paragraph 7-12 and
the system specific technical manual.
(n) Refinish.
DO NOT sand into laminate near patch edge
when sanding adhesive squeeze out.
1 Sand the area smooth with 180 grit
abrasive paper. Vacuum sanding
dust from repair area. Wipe with
clean, dry wiping cloth to remove
sanding residue.
2 Apply finish system in accordance
with paragraph 7-13b or the system
specific technical manual.
b. Full Thickness Scab Repair. Scab repairs are
similar to scarf repairs but easier to complete since
they do not require machining the scarf. Filler plies
are used in the damaged area and the patch is
applied to the surface. Exterior scab repairs are used
when the protrusion of the patch does not impact the
aerodynamics on the surface of the structure. They
may be used when an adhesively bonded metallic
or pre-cured composite patch cannot be used due to
excessive part curvature. The size of the repair area
depends on the thickness and number of plies of
the skin and the required overlap. Thicker structures
require larger patches relative to the original damage
area. Ply overlap is determined according to the
loads that must be transferred. The ply overlap
for any repair in a given weapon system will be
called out in the system specific technical manual
or other authorizing document. Refer to the system
specific technical manual for applicable damage limits.
Scab repairs can be used on all glass, carbon, and
aramid composite materials. This repair procedure
is not necessarily applicable to a particular weapon
system. The applicability of this repair depends upon
additional factors such as loading conditions and
laminate thickness. Refer to figure 7-7 for the Process
Flow Diagram for Penetration Damage Repair. Consult
the system specific technical manual or engineering
for further guidance.
7-15
TM 1-1500-204-23-11
(1) Facilities, Equipment and Materials. The
following equipment and materials are required: Vac-
uum Cleaner, HEPA Filter, Dual Action Sander or
90 degree die-grinder and sanding mandrel, Tem-
perature/Vacuum Controller, Heat Blanket, Scissors,
Marker, Flash breaker Tape, Silicon Carbide Abrasive
Paper, Wiping Cloth, Release Film, Spatula, Adhe-
sive, Liquid (See System Specific Technical Manual),
Fabric (See System Specific Technical Manual), Light-
ning Mesh (See System Specific Technical Manual),
Vacuum Bag Repair Materials Kit, Copper Sheet.
(2) Full thickness Scab Repair Procedure.
DO NOT use oil or oil based materials
as NDI couplants on advanced composite
components. Use only water or water based
materials. Disbonds may result and loss of
structural integrity may occur.
(a) Remove dirt, grease and aircraft fluids
from repair area as described in para-
graph 6-5.
(b) Define both the depth and extent of the
damage using NDI according to para-
graph 5-2 and the system specific tech-
nical manual. Lay out the damage as
described in paragraph 6-4 .
(c) Remove NDI couplant by wiping with
clean, water moistened cloth.
(d) Remove paint from skin in the repair
area by sanding as described in para-
graph 6-1.
(e) Remove damage as described in para-
graph 6-4.
DO NOT sand into laminate near patch edge
when sanding adhesive squeeze out.
(f) Dry repair area as described in para-
graph 6-6 using a heat blanket to
remove subsurface moisture.
(g) Clean the repair area in accordance
with paragraph 6-7 in preparation for
replacement of the plies.
(h) Seal the backside of the damaged area,
if applicable, according to paragraph
6-18e and the system specific technical
manual.
7-16
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
Failure to observe the correct number of repair
plies, the correct repair ply orientation, the
correct repair ply overlap and removal of all
pieces of vacuum bagging film will reduce the
strength of the repair and may result in the
loss of structural integrity.
(i) Prepare the repair plies in accordance
with paragraph 6-16, Wet Layup, and
place stacked, oriented patch on the
damaged site. Refer to the system spe-
cific technical manual for the repair fiber,
resin, number of plies, ply orientation,
ply size and overlap.
(j) Determine and apply cure hardware
and vacuum bagging materials in accor-
dance with paragraph 6-18. Refer to
the system specific technical manual for
the porous release film, bleeder mate-
rial and the number of bleeder plies.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
(k) Cure the repair patch in accordance
with paragraph 6-19, Curing Advanced
Composites.
(l) NDI Patch Bond(s).
1 Visually inspect adhesive squeeze
out at patch edge as described in
paragraph 5-2. See figure 6-45 .

2 Perform NDI of patch to skin and
patch to filler bond areas to verify
bondline integrity.
DO NOT sand into laminate near patch edge
when sanding adhesive squeeze out.
(m) If applicable, repair the outer lightning
mesh according to paragraph 7-12 and
the system specific technical manual.
(n) Refinish.
1 Sand the area smooth with 180
grit abrasive paper. Vacuum the
sanding dust from the repair area.
Wipe with clean, dry wiping cloth to
remove sanding residue.
2 Apply finish system in accordance
with paragraph 7-13b or the system
specific technical manual.
c. Full Thickness Step Repair. The step (or step-
lap) repair is almost identical to the scarf repair
except that each ply is removed separately and is
stepped or terraced accordingly. A stepped repair is
used primarily on boron, aramid, and polyethylene
Figure 7-8. Cross Section of Typical Stepped Repair
(1) Facilities, Equipment and Materials. The
following equipment and materials are required: Vac-
uum Cleaner, HEPA Filter, Dual Action Sander or 90
degree die-grinder and sanding mandrel, Utility Knife
or Single Edge Razor Blade, Temperature/Vacuum
Controller, Heat Blanket, Flash breaker Tape, Sili-
con Carbide Abrasive Paper, Wiping Cloth, Release
Film, Spatula, Adhesive, Liquid (See System Specific
Technical Manual), Fabric (See System Specific Tech-
nical Manual), Lightning Mesh (See System Specific
TM 1-1500-204-23-11
materials figure 7-8 shows a cross section of a
typical stepped repair. Cutting steps in a laminate of
unidirectional plies can take three to four times as
long as sanding a comparable scarfed joint. Even with
careful workmanship and frequent micrometer depth
measurements, steps typically fail to fall on the correct
ply by one to three plies. A router can be used for any
step repair and must be used on boron. A stepped
repair is usually not performed in unidirectional plies
of fiberglass. In this method, the plies are removed in
a stepped pattern (figure 6-23) rather than the tapered
pattern used in the scarf method. The step can be
achieved by physically cutting and peeling the plies
or by machining with a router and template. The field
will generally only perform the step repair by cutting
and peeling which can be performed on laminates
made with woven materials. Laminates made with
unidirectional materials have a tendency to separate
within a ply; therefore, the plies should be removed by
machining with a controlled depth router and templates
to ensure the proper step depth and length is achieved.
The router method is difficult to perform on complex
contours and is usually limited to depot level repairs.
This repair procedure is not necessarily applicable to
a particular weapon system. The applicability of this
repair depends upon additional factors such as loading
conditions and laminate thickness. Refer to figure 7-7
for the Process Flow Diagram for Penetration Damage
Repair. Consult the system specific technical manual
or engineering for further guidance.
Technical Manual), Vacuum Bag Repair Materials Kit,
Copper Sheet.
(2) Full Thickness Step Repair Procedure.
(a) Remove dirt, grease and aircraft fluids
from repair area as described in para-
graph 6-5.
7-17
TM 1-1500-204-23-11
DO NOT use oil or oil based materials
as NDI couplants on advanced composite
components. Use only water or water based
materials. Disbonds may result and loss of
structural integrity may occur
(b) Define both the depth and extent of the
damage using NDI according to para-
graph 5-2 and the system specific tech-
nical manual. Lay out the damage as
described in paragraph 6-4.
(c) Remove NDI couplant by wiping with
clean, water moistened cloth.
DO NOT sand into laminate when removing
paint. When working on a carbon fiber lami-
nate, a black colored dust on the sandpaper
indicates that sanding into the laminate has
occurred and carbon fiber is being removed.
If this occurs, the sanding process should
be stopped immediately. A loss of structural
integrity may occur if fibers are exposed or
damaged.
(d) Remove paint from skin in the repair
area by sanding as described in para-
graph 6-1.
(e) Remove damage as described in para-
graph 6-15 and as shown in figure 6-24.
Use the step length from the system
specific technical manual.
(f) Dry repair area as described in para-
graph 6-6 using a heat blanket to
remove subsurface moisture.
(g) Clean the repair area in accordance
with paragraph 6-7 in preparation for
replacement of the plies.
(h) Seal the backside of the damaged area
according to paragraph 6-18.e and the
system specific technical manual.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
7-18
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
Failure to observe the correct number of repair
plies, the correct repair ply orientation, the
correct repair ply overlap and removal of all
pieces of vacuum bagging film will reduce the
strength of the repair and may result in the
loss of structural integrity.
(i) Prepare the repair plies in accordance
with paragraph 6-16, Wet Layup, and
place stacked, oriented patch on the
damaged site. Refer to the system spe-
cific technical manual for the repair fiber,
resin, number of plies, ply orientation,
ply size and overlap.
(j) Determine and apply cure hardware
and vacuum bagging materials in accor-
dance with paragraph 6-18. Refer to the
system specific technical manual for the
porous release film, bleeder material
and number of bleeder plies required.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
(k) Cure the repair patch in accordance
with paragraph 6-19, Curing Advanced
Composites.
(l) NDI Patch Bond(s).
1 Visually inspect adhesive squeeze
out at patch edge as described in
paragraph 5-2. See 6-45.
2 Perform NDI of patch to skin and
patch to filler bond areas to verify
bondline integrity.

DO NOT sand into laminate near patch edge
when sanding adhesive squeeze out.
(m) If applicable, repair the outer lightning
mesh according to paragraph 7-12 and
the system specific technical manual.
(n) Refinish.
1 Sand the area smooth with 180 grit
abrasive paper. Vacuum the repair
area and then wipe with clean wip-
ing cloth to remove sanding dust.
2 Apply finish system in accordance
with paragraph 7-13b or the system
specific technical manual.
d. Full Thickness Bonded Repair. Full thickness
bonded repairs follow the same procedures as para-
graph 7-3, partial thickness bonded repairs. The only
differences are for machining out the damaged area
according to paragraph 6-4 and a backside seal is
required according to paragraph de prior to filler appli-
cation.
7-5. SANDWICH DAMAGE. A large proportion of
composite structures currently in production are of
sandwich construction. For this reason, and because
the thin skins on sandwich components are easily
damaged, many structural repairs will be on sandwich
components. The basic repair principles that apply to
metal-skinned sandwich structures apply to composite
sandwich components as well. MIL-HDBK-337, Adhe-
sive Bonded Aerospace Structure Repair, covers core
repair of metal-bonded structures in detail and should
be referenced for core repair of composite sandwich
TM 1-1500-204-23-11
components. The structural concept is the same, and
the requirements for a sound repair do not differ. The
only new requirement that accompanies the use of
composite skins is the need to pay attention to fiber
direction.
a. Moisture Ingression. Moisture has long been,
and will continue to be, a problem in sandwich struc-
ture. Moisture, either present in the repair environment
or absorbed by the parent structure or any of the
materials used in the repair, is still the major source
of trouble. Nonmetallic core is subject to rapid mois-
ture absorption, which if present during the repair
cure, can destroy adhesion of the laminate to the
core surface by creating porosity in the repair material
and bondline. All moisture must be removed prior to
initiating and completing a repair. See paragraph 6-6
for information and procedures.
b. Core Repairs. Core damage may be repaired
by either a plug made of the same or suitable
substitute core material or by core potting, which
uses a paste compound to fill in the core cutout
area. Parts made with X-Cor® cannot be repaired
with X-Cor® and a different core material, such
as Rohacell or honeycomb, must be used. Never
under any circumstances should non-structural fillers
be used to fill the void of removed core, the core
material must securely attach the two face sheets
together. Refer to the system specific technical manual
or engineering for the required replacement core.
There are three methods for replacing damaged core
sections: the core potting method, the paste adhesive
method and the film/foam method. The core potting
method is limited by damage size. Selection of the
paste adhesive or film/foam method is based on
strength and weight considerations. These methods
for core replacement are shown in paragraph 7-9. The
rationale for method selection is discussed below.
7-19
TM 1-1500-204-23-11
Figure 7-9. Core Replacement Methods
(1) Replacement Core Fit Considerations. O-
ne of the most difficult aspects of replacing core
sections is obtaining a good fit between the replace-
ment core, the opposite skin inner surface and the
part core sidewalls. Figure 7-10 shows a typical blade
fairing or flight control surface trailing edge. Observe
the gaps that exist between the replacement core and
the part core sidewalls if the cell axes are not aligned.
When the cell axes are aligned, a gap exists between
7-20
the opposite skin inner surface and the replacement
core mating surface. The gap conditions shown in
figure 7-10 are for a taper in one direction only.
Unfortunately, blade fairings and flight control surfaces
taper in both the chordwise and spanwise directions
compounding the gap problem. Similar gap problems
are encountered when performing core replacement
on complex contoured parts.
 TM 1-1500-204-23-11

(2) Core Potting Method. This method uses

paste adhesive to replace the removed core and
is limited to damage of 1.5 inches in diameter or
less. Refer to the system specific technical manual
for damage limits For damage beyond this limit,
replace the core using paste adhesive method listed
in paragraph 7-5d.

(3) Paste Adhesive Method. This method uses

paste adhesive to bond the replacement core sections
to the part core sidewalls and to the opposite skin
inner surface (if applicable). It is the quickest and
easiest method for replacement core bonding because
the gaps between the replacement core and the repair
cavity are taken up by the paste adhesive. In addition,
an elevated temperature cure of the splice adhesive is
not required prior to final core machining. This method
has limited use on blade fairings or flight control
surfaces due to repair weight limitations. It is also
limited by the comparatively low bond strength of the
paste adhesive. The procedure for core replacement
using the paste adhesive method is described and
illustrated in paragraph 7-5d.

(4) Film/Foam Method. The film/foam method

uses foaming adhesive for the replacement core to
part core sidewall bond and film adhesive for the
patch bond. The film/foam method is the lightest
of the core bonding methods but the most difficult
and time consuming to perform. A weight compar-
ison between the paste adhesive method and the
film/foam method is shown in figure 7-11. As can be
seen, little weight difference exists between the two
methods for the smaller hole diameters. However,
the difference becomes significant as the diameter
becomes larger. The film/foam method should be
used only when weight limitations or strength limi-
tations dictate. For core replacement on contoured
(tapered and/ or complex contoured) parts, remove
the damage so that both skins have the same size
and shape damage cleanup hole. This eliminates the
difficult machining and fitting required to deal with the
gaps between the replacement core and contoured
part surface. If damage is through one skin only, the
undamaged skin must be removed to the same size
and shape as the damaged cleanup hole. For core
replacement on uncontoured parts and/or parts with
slight tapers, removal of the opposite side undamaged
skin material is not required. Since film and foaming
adhesives typically require frozen shipping and stor-
age which is impractical in the field environment, this
process is usually limited to depot repairs. Refer to
the applicable DMWR for film/foam procedures.

Figure 7-10. Replacement Core Fit

7-21
TM 1-1500-204-23-11

Figure 7-11. Weight Versus Hole Diameter for Two Core Replacement Methods

c. Core Potting and Replacement. Core potting is

the process of filling the core cutout with a curable
paste filler material. If the damage is sustained in
an area with an already potted core, the replacement
core ply should also be potted. If honeycomb or
foam core is damaged, it may be potted rather than
plugged if the damaged area is usually smaller than
1.5 inches in diameter. Refer to the system specific
technical manual for damage limits. For damage
beyond this limit, repair the damaged core using
paragraph 7-5d, paste adhesive method. Figure 7-11
shows typical weight gains using core potting. Figure
7-12 shows the process flow. This repair procedure
is not necessarily applicable to a particular weapon
system. The applicability of this repair depends
upon additional factors such as loading conditions
and laminate thickness. Consult the system specific
technical manual or engineering for further guidance.

Figure 7-12. Process Flow Diagram for Honeycomb

Core Repair

(1) Facilities, Equipment and Materials. The

following equipment and materials are required: Vac-
uum Cleaner, HEPA Filter, Dual Action Sander or
90 degree die-grinder and sanding mandrel, Weights,
Shot Bags, Heat Blanket, Temperature/Vacuum Con-
troller, Flash breaker Tape, Adhesive, Paste (See

7-22

System Specific Technical Manual), Spatula, Cop-
per Sheet, Silicon Carbide Abrasive Paper, Aluminum
Sheet Stock, 0.063 inches or thicker (Local Procure-
ment), Wiping Cloth, Vacuum Bag Repair Materials
Kit.
(2) Honeycomb Core Repair Procedure.
(a) Clean Part. Remove dirt, grease
and aircraft fluids from repair area as
described in paragraph 6-5.
DO NOT use oil or oil based materials
as NDI couplants on advanced composite
components. Use only water or water based
materials. Disbonds may result and loss of
structural integrity may occur.
(b) Define Damage.
1 Define both the depth and extent
of the damage using NDI according
Figure 7-13. Procedure for Core Replacement Using the Core Potting Method
TM 1-1500-204-23-11
to paragraph 5-2 and the system
specific technical manual.
2 Lay out the damage as described
in paragraph 6-4 using a circular
configuration.
3 Remove NDI couplant by wiping
with clean, water moistened cloth.
(c) Damage Removal.
1 Remove skin damage along the
damage layout line as described
in paragraph 6-4. If damage is
through both skins, remove the
damage so that both skins have
the same size and shape damage
cleanup hole.
2 Remove the damaged core as
described in paragraph 6-4. See
figure 7-13, View B.
7-23
TM 1-1500-204-23-11
DO NOT sand into laminate when remov-
ing paint. When working on a carbon fiber
laminate, a black colored dust on the sand-
paper indicates that sanding into the laminate
occurred and carbon fiber is being removed.
If this occurs, the sanding process should
be stopped immediately. A loss of structural
integrity may occur if fibers are exposed or
damaged.
(d) Paint Removal. Remove paint from
skin in the repair area by sanding as
described in paragraph 6-1. Ensure to
vacuum the repair area and then wipe
with clean wiping cloth to remove sand-
ing dust.
(e) If damage is through both skins, cover
the hole on the lower skin with release
film and tape in place. Apply a metal
plate formed to the part contour over
the film and tape in place on the part
surface.
Allow a minimum of 2 hours between 100
gram applications in the repair cavity.
(f) Prepare and Apply Adhesive into Cavity.
1 Select the appropriate potting
adhesive according to the system
specific technical manual.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
2 Mix the potting adhesive according
to paragraph 6-17.
7-24
3 Fill the core cells from the bottom
up to prevent the formation of bub-
bles.
4 If performing a scab repair, fill the
core cavity slightly above the part
surface mold line. If performing
a flush repair, fill the core cav-
ity slightly above the original core
mold line.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
NOTE
Some potting compounds shrink during cure.
If using a mixture that is likely to shrink, build
compound slightly above the part surface.
5 Using a heat lamp or heating blan-
ket, cure the potting compound
according to paragraph 6-19 and
the system specific technical man-
ual. Allow the repair area to cool.
(g) Machine Core Flush with OML(s). Trim
the top of the cured potting compound
flush with either the original core or the
part mold line (as shown in figure 7-13,
View D), depending on the type of repair
being performed.
1 Sand adhesive using an orbital
sander and 180 grit abrasive
paper. The finished surface should
be left comparatively rough (not
smoothed) to improve bonding to
the skin.
2 Vacuum the repair area to remove
sanding dust.
3 Wipe area with clean wiping cloth
to remove sanding dust.
(h) Dry Repair Area. Dry repair area as
described in paragraph 6-6 using a heat
blanket to remove subsurface moisture.
(i) Prepare Skin Surface for Bonding.
Lightly hand sand with 150-180 grit
abrasive paper as described in para-
graph 6-7. Handle prepared surfaces
 TM 1-1500-204-23-11

wearing powder free latex gloves until This repair procedure is not necessarily applicable to
patch bonding is complete. If patch is a particular weapon system. Refer to figure 7-14 for
not to be bonded immediately, cover the Process Flow Diagram for Core Repair, Paste
with clean barrier material and secure Adhesive Method. Consult the system specific tech-
with tape to prevent contamination. nical manual or engineering for guidance on using
this technique.
(j) Fabricate repair patch(es) according to
paragraph 7-4 and the system specific
technical manual. Any of the meth-
ods; cocured, cobonded or secondarily
bonded may be utilized for skin repair.

(k) NDI Patch Bond(s).

1 Visually inspect adhesive squeeze

out at patch edge as described in
paragraph 5-2. See figure 6-45.

2 Perform NDI of patch to skin and

patch to filler bond areas to verify
bondline integrity.

(l) If appropriate, repair lightning mesh

according to paragraph 7-12 and sys-
tem specific technical manual.

DO NOT sand into laminate near patch edge

when sanding adhesive squeeze out.

(m) Refinish.

1 Sand area smooth with 180 grit
abrasive paper. Vacuum the sand-
ing dust from the repair area. Wipe
with clean wiping cloth to remove
sanding residue.
2 Apply finish system in accordance
with paragraph 7-13b or the system
specific technical manual.
d. Paste Adhesive Method. Paste adhesives can
be used to bond replacement core plugs to parent
structure core sidewalls and to opposite skin inner
surfaces (if applicable). This method is typically used
to repair damage sizes larger than 1.5 inches in
diameter and is limited in applicability to blades or
flight control surfaces due to repair weight limitations.
Refer to the system specific technical manual for
damage limits. The applicability of this repair method
depends on several factors such as loading condi-
tions, laminate thickness, and part weight limitations.
Figure 7-14. Process Flow Diagram for Core
Repair, Paste Adhesive Method
(1) Facilities, Equipment and Materials. The
following equipment and materials are required: Vac-
uum Cleaner, HEPA Filter, Dual Action Sander or
90 degree die-grinder and sanding mandrel, Weights,
Shot Bags, Heat Blanket, Temperature/Vacuum Con-
troller, Flash breaker Tape, Adhesive, Paste (See
System Specific Technical Manual), Spatula, , Sili-
con Carbide Abrasive Paper, Aluminum Sheet Stock,
0.063 inches or thicker (Local Procurement), Wiping
Cloth, Vacuum Bag Repair Materials Kit, Core (See
System Specific Technical Manual), Copper Sheet,
Mylar, Clear.
(2) Paste Adhesive Method Procedure.
(a) Clean Part. Remove dirt, grease
and aircraft fluids from repair area as
described in paragraph 6-5.

7-25
TM 1-1500-204-23-11
DO NOT use oil or oil based materials
as NDI couplants on advanced composite
components. Use only water or water based
materials. Disbonds may result and loss of
structural integrity may occur.
(b) Define Damage. Define both the depth
and extent of the damage using NDI
according to paragraph 5-2 and the sys-
tem specific technical manual.
1 Lay out the damage as described
in paragraph 6-4. Use a circular
configuration.
2 Remove NDI couplant by wiping
with clean, water moistened cloth.
(c) Remove Damage.
1 Remove skin damage along the
damage layout line as described
in paragraph 6-4. If damage is
through both skins, remove the
damage so that both skins have
the same size and shape damage
cleanup hole.
2 Remove the damaged core as
described in paragraph 6-4. See
figure 7-15, View B.
DO NOT sand into laminate when remov-
ing paint. When working on a carbon fiber
laminate, a black colored dust on the sand-
paper indicates that sanding into the laminate
occurred and carbon fiber is being removed.
If this occurs, the sanding process should
be stopped immediately. A loss of structural
integrity may occur if fibers are exposed or
damaged.
3 Remove paint from skin in
the repair area by sanding as
described in paragraph 6-1.
4 Vacuum the repair area and then
wipe with clean wiping cloth to
remove sanding dust.
5 If damage is through both skins,
cover the hole on the lower skin
with release film and tape in place.
Apply a metal plate formed to the
7-26
part contour over the film and tape
in place on the part surface.
(d) Fabricate Replacement Core.
1 Determine part core density and
ribbon direction by referring to the
system specific technical manual.
2 Select a replacement core mate-
rial specified in the system specific
technical manual. If no core is
specified, use core of the same or
higher density and the same mate-
rial. Ensure that it is thicker than
the maximum depth of the core
cavity. If a core splice exists in the
area being repaired (as indicated
by the presence of core splice
material), select the higher density
core section to be the replacement
core.
3 Fabricate a template containing the
damage cutout shape using Mylar.
Mark the part core ribbon direction
on the Mylar.
Core ribbon direction must be maintained
within ±2 degree. Incorrect alignment of core
ribbon result in reduced strength and loss of
structural integrity may occur.
4 Orient the template on the replace-
ment core. Match the replacement
core ribbon direction on the tem-
plate. Using a core slicer and
slicing along the cell axis, cut the
replacement core to the damage
cutout shape using the template as
a guide as described in paragraph
6-13. Trim the sides of the core
plug to a loose fit; approximately
1/8 inch smaller than the routed
cavity. Trim the plug height so the
top of the plug sits approximately
1/8 to 1/4 inch higher than the level
of the original mold line. The core
will compress and set during cure
thereby requiring the extra height.
5 Carefully insert the replacement
core into the cavity to check the fit.
Align the ribbon direction with the
part ribbon direction. Use a vac-
uum to remove any dust remaining
on the core plug.

Do not clean replacement foam cores such
as Rohacell or K-Cor®.
Wear powder free latex gloves when handling
cleaned honeycomb core to prevent contam-
ination due to skin oils.
6 Remove replacement honeycomb
core and clean by flushing with
a squirt bottle filled with solvent.
Allow to air dry until solvent has
completely evaporated.
7 Wrap the core plug in clean nylon,
polyethylene or wax-free barrier
paper until needed for assembly.
8 Prepare the opposite skin inner sur-
face. If the opposite side skin was
not removed, prepare the opposite
skin inner surface for bonding by
lightly hand sanding with 150-180
grit abrasive paper as described in
TM 1-1500-204-23-11
paragraph 6-7. Handle prepared
surfaces wearing powder free latex
gloves until bonding is complete.
If replacement core plug is not to
be bonded immediately, cover the
area with clean barrier material and
secure with tape to prevent con-
tamination.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
7-27
TM 1-1500-204-23-11
Figure 7-15. Procedure for Core Replacement Using the Paste Adhesive Method
(e) Bond Replacement Core Plug.
1 Prepare paste adhesive per para-
graph 6-17. Mix a sufficient amount
of paste adhesive for the repair
application in accordance with the
system specific technical manual
of Part A to Part B. The volume of
paste adhesive material required
can be estimated by multiplying
0.25 times the amount of core cav-
ity surface area (in square inches)
to be covered.
2 Using a spatula, apply paste adhe-
sive approximately 0.1 inch thick to
7-28
opposite skin inner surface (if appli-
cable) and on part core cell walls
in repair cavity (the surface that
mates with the replacement core).
If a partial depth core plug repair
is being performed, a metallic or
pre-cured composite disc is typi-
cally placed at the bottom of the
cavity to prevent the adhesive from
filling up the core cells. If a metal-
lic disc is used, the metal surface
must be prepared for bonding per
the system specific technical man-
ual.

3 Apply paste adhesive to bottom
and sides of replacement core
using a spatula. (See figure 7-15,
View C). If damage is through both
skins, apply adhesive to sides of
replacement core only.
4 Carefully insert replacement core
into repair cavity. Ensure part and
replacement core ribbon directions
are aligned. Push core against
opposite side skin inner surface or
metal plate as applicable.
5 Visually inspect part core to
replacement core sidewall area
for adequate filling of adhesive. If
voids or gaps exist, fill a sealant
gun with adhesive and inject more
adhesive into gaps/voids.
6 Place a metal caul plate on top of
replacement core. Apply external
weight (3-5 pounds) on top of caul
plate (See figure 7-15, View D).
Remove excess adhesive by wip-
ing with a clean wiping cloth.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
7 Using a heat lamp or heating blan-
ket, (if applicable), cure the paste
adhesive according to paragraph
6-19 and the system specific tech-
nical manual or the manufacturer’s
recommended cure cycle per engi-
neering direction. Allow the repair
area to cool. If room temperature
curable, allow it to set until machin-
able (approximately 8 hours).
8 Remove weight and caul plate.
Remove the release film (and metal
plate, if installed).
(f) Trim the top of the cured core flush with
either the original core or the part mold
line, depending on the type of repair
being performed. The finished surface
should be left comparatively smooth
and match the contours being repaired.
See figure 7-15, View E.
TM 1-1500-204-23-11
(g) Dry repair area as described in para-
graph 6-6 using a heat blanket to
remove subsurface moisture.
(h) Prepare repair area for bonding by
lightly hand sanding with 150-180 grit
abrasive paper as described in para-
graph 6-7. Vacuum sanding dust from
repair area and wipe with clean wiping
cloth. Handle prepared surfaces wear-
ing powder free latex gloves until patch
bonding is complete. If patch is not
to be bonded immediately, cover with
clean barrier material and secure with
tape to prevent contamination.
(i) Fabricate repair patch(es) according to
paragraph 7-4 and the system specific
technical manual. Any of the meth-
ods; cocured, cobonded or secondarily
bonded may be utilized for skin repair.
(j) NDI Patch Bond(s).
1 Visually inspect adhesive squeeze
out at patch edge as described in
paragraph 5-2. See figure 6-45.
2 Perform NDI of patch to skin and
patch to filler bond areas to verify
bondline integrity.
(k) If appropriate repair lightning mesh per
paragraph 7-12 and the system specific
technical manual.
DO NOT sand into laminate near patch edge
when sanding adhesive squeeze out.
(l) Refinish.
1 Sand area smooth with 180 grit
abrasive paper. Vacuum the sand-
ing dust from repair area. Wipe
with clean, dry cloth to remove
sanding residue.
2 Apply finish system in accordance
with paragraph 7-13b or the system
specific technical manual.
e. Rapid Densification. Rapid densification of
sandwich structure is necessary when the structure
requires repair with fasteners or modification to install
external equipment, such as an antenna. It is applica-
ble to honeycomb, foam or X-Cor®/K-Cor® sandwich
structures. The procedure is similar to potting the core
7-29
TM 1-1500-204-23-11
and strengthens the structure to withstand clamp-up
loads from fasteners. This type of repair can also be
used for small skin to core disbonds. The size of the
hole and densified area will depend on a number of
factors such as loading conditions, laminate thickness,
and part weight limitations. This repair procedure
is not necessarily applicable to a particular weapon
system. Refer to the system specific technical manual
for particular repair applications and limits. Refer to
figure 7-16 for the Process Flow Diagram for Rapid
Densification. Consult the system specific technical
manual or engineering for guidance on using this
technique.
Figure 7-16. Process Flow Diagram for Rapid
Densification
(1) Facilities, Equipment and Materials. The
following equipment and materials are required: Vac-
uum Cleaner, HEPA Filter, Drill Motor, Drill bit the
size of the fastener to be used, Core Cutter or mod-
ified Allen wrench that fits through the fastener size
hole (local manufacture), Hand vice or pliers/vice grip,
Guide plate, aluminum or composite sheet, approxi-
mately .030” thick (Local Manufacture), Injection Gun,
Metallic Retainer Barrel, Putty knife, Allen wrench,
Heat Blanket, Temperature/Vacuum Controller, Flash
breaker Tape, Adhesive, Paste (See System Specific
Technical Manual), Injection Cartridge, Disposable,
Injection Nozzle, Disposable, Syringe, Solvent, Sili-
con Carbide Abrasive Paper, Wiping Cloth, Double
Faced Tape.
(2) Rapid Densification Procedure Perform
the following steps for rapid densification (See figure
6-12 and figure 7-16).
(a) Determine the fastener location accord-
ing to the system specific technical
manual.
(b) Remove dirt, grease and aircraft fluids
from repair area as described in para-
graph 6-5.
(c) Drill the fastener size hole through one
skin. Refer to paragraph 6-8 for drilling
7-30
procedures. Insure that the full diameter
of the drill bit can be reached without
drilling into the opposite facesheet.
(d) Vacuum the repair area and then wipe
with clean wiping cloth to remove drilling
dust.
(e) Drill the fastener size hole through the
aluminum or composite guide plate.
(f) Double face tape the drilled plate over
the hole in the skin. Align the holes
using alignment pins or the back of the
drill bit.
Failing to use a guide plate will result in
elongating the hole in the laminate and result
in additional damage.
(g) Insert the core cutter through the hole
and rotate from the top skin down to the
bottom skin to disrupt the core mate-
rial from the skin surfaces. Refer to on
spoiling core and local manufacture of
an internal core cutter.
(h) Remove the guide plate using a putty
knife or similar tool, taking care not to
damage the laminate.
(i) Remove the disrupted core material
through the drilled skin hole using a
vacuum cleaner.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
(j) Mix adhesive. Refer to paragraph 6-17
for mixing adhesive.

(k) Install prepackaged adhesive into the
dispensing gun or pour adhesive into
plastic syringe.
(l) Insert the tip of the nozzle all the way
into the hole.
(m) Dispense adhesive into the cavity from
the bottom of the cavity working up to
the skin hole.
(n) Once the cavity is filled continue to
dispense the adhesive into the hole
so that excess flows out of the hole
along the side of the nozzle bringing out
entrapped air.
(o) Completely remove the nozzle from the
hole while dispensing adhesive.
(p) Remove excess adhesive from the sur-
face of the panel with a clean wiping
cloth and solvent.
(q) Place a small piece of flash breaker tape
over the hole.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
(r) Using a temperature controller and heat
blanket, cure according to paragraph
6-19 the system specific technical man-
ual or the manufacturer’s cure profile
per engineering disposition. An alter-
nate cure is at room temperature for the
time specified from the system specific
technical manual or adhesive manufac-
turer per engineering.
(s) Drill appropriate sized hole for fastener.
(t) Vacuum the repair area and then wipe
with clean wiping cloth to remove drilling
dust.
(u) Perform NDI of densified area according
to paragraph 5-2 and the system spe-
cific technical manual to verify integrity.
TM 1-1500-204-23-11
7-6. ADHESIVE BONDED JOINTS. To ensure the
paste adhesive adequately wets the surfaces to be
bonded, it is important to apply paste adhesive to both
surfaces. Bondline thickness is important to control
when using paste adhesives to preclude reduced
strength and unacceptable porosity. After applying
adhesive to the part and patch surfaces, an adhesive
comb (see figure 3-27) is used to remove excess
adhesive and provide the correct amount of adhesive
on the surfaces to be bonded. On some adhesives
scrim cloth is applied over the adhesive on the
part surface prior to installing the patch to prevent
excessive adhesive squeeze out during the cure cycle.
Refer to the system specific technical manual on
whether scrim cloth is required. Refer to paragraph
7-3, paragraph 7-5, or paragraph 6-5 for Process
Flow Diagrams for adhesive bonded repairs.
a. Facilities, Equipment and Materials. The fol-
lowing equipment and materials are required: Vacuum
Cleaner, HEPA Filter, Heat Blanket, Temperature/Vac-
uum Controller, Adhesive Comb, Flash breaker Tape,
Adhesive, Paste (See System Specific Technical Man-
ual), Patch (See System Specific Technical Manual),
Scrim Cloth, if required, Solvent, Silicon Carbide Abra-
sive Paper, Wiping Cloth.
b. Adhesive Bonded Joints Procedure.
(1) If the paste adhesive is in refrigerated stor-
age, remove and allow the material to reach
room temperature before opening the con-
tainers.
NOTE
Ensure expiration of the shelf life marked
on paste adhesive containers has not been
exceeded.
(2) If required and using the patch as a guide,
cut a piece of scrim cloth 0.25 inch larger
than the repair patch periphery. If stacked
patches are required for the repair, cut sep-
arate layers of scrim cloth 0.25 inch larger
than each succeeding patch in the stack.
(3) Apply solvent to a clean, dry wiping cloth.
Wipe clean the adhesive comb. Allow to air
dry for 30 minutes.
(4) Prepare the part and patch surface for bond-
ing according to paragraph 6-7 and the sys-
tem specific technical manual.
(5) Prepare approximately 50 grams of paste
adhesive for patch bond as described in
paragraph 6-17.
7-31
TM 1-1500-204-23-11
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Apply adhesive on part surface to obtain the
required patch overlap or reduced strength
will result.
(6) Using a spatula, apply a thin layer of paste
adhesive on the part surface. The adhe-
sive should extend a minimum of 0.25 inch
beyond the patch surface. Apply additional
adhesive over any exposed honeycomb
core.
(7) Draw adhesive comb over the part surface to
remove excess adhesive. After each stroke,
remove the excess adhesive from the comb
with a clean wiping cloth. Ensure the comb
remains perpendicular to the surface during
use. Avoid resin starving any areas of the
part surface during the combing operation.
(8) If required, apply the scrim cloth that was cut
in paragraph (2) above to the paste adhe-
sive on the part surface. Press the scrim
cloth into the part surface with the spatula
and work out any wrinkles.
(9) Using a spatula, apply a thin layer of paste
adhesive to the bond surface of the patch.
(10) Draw adhesive comb over the bond surface
of the patch to remove excess adhesive.
After each stroke, remove the excess adhe-
sive from the comb with a clean, dry wiping
cloth. Ensure the comb remains perpendic-
ular to the surface during use. Avoid resin
starving any areas of the patch surface dur-
ing the combing operation.
7-32
Part to patch alignment must be main-
tained within ±2 degree. Fabricated com-
posite patches are orientation sensitive from
a strength standpoint. Incorrect alignment
of part and patch during layup will result in
reduced strength and loss of structural integrity
may occur.
(11) Determine the part 0 degree direction (or pri-
mary load direction) from the system specific
technical manual. Align the patch 0 degree
direction (if applicable) with the part 0 degree
direction during layup.
Use only flash breaker tape under the vacuum
bag to prevent contamination of bondline.
(12) Apply the patch containing adhesive to
the part surface containing the adhesive.
Ensure the patch is aligned on part surface
to maintain the required patch overlap. Tape
patch in place using flash breaker tape.
(13) If multiple stacked patches are required,
stack the largest patch on the part sur-
face followed by increasingly smaller size
patches. Apply scrim cloth and adhesive
between each patch in the stack. See figure
7-5.
Figure 7-17. Layup of Stacked Patches and
Adhesive
(14) Layup the heat blanket and vacuum bag
materials as described in paragraph 6-18
and the system specific technical manual.

Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
(15) Remove any residual adhesive on the adhe-
sive comb by wiping with clean, dry wiping
cloth. Apply solvent to another clean, dry
wiping cloth. Wipe the adhesive comb clean.
Allow to air dry for 30 minutes. Ensure adhe-
sive comb is free of adhesive residue.
7-7. MECHANICALLY FASTENED JOINTS. Mecha-
nically fastened joints in composites are significantly
TM 1-1500-204-23-11
different than similar joints in metal structure. Local
regions of high stress concentrations occur which
require special attention. Composite joints are also
more sensitive to edge distance and hole spacing,
and have different considerations in fastener selec-
tion and galvanic corrosion than similar metal joints.
Mechanically fastened joints are often preferred over
bonded joints, since mechanically fastened joints can
be disassembled and the structural integrity can be
more easily guaranteed. Three commonly used bolted
repair joints are shown in figure 7-18. For all compos-
ite bolted joints, consult the system specific technical
manual or engineering for additional guidance. Engi-
neering guidance for bolted joints can also be found
in Chapter 11, Structural Behavior of Bolted Joints
of CMH-17, Volume 3, Materials Usage, Design and
Analysis.
7-33
TM 1-1500-204-23-11
Figure 7-18. Basic Repair Joints (Bolted)
a. Fastener Considerations. A common miscon-
ception is that the purpose of the fasteners is to
hold the patch in place. The fasteners do provide
clamp-up between the plate and the part surface,
but their primary purpose is to allow the load to be
transferred from the original part surface through the
patch. This load is transferred through the fasteners
7-34
and patch by shear forces as the fasteners contact
the loaded structure and the plate at the edge of
the fastener hole. These forces are transferred more
efficiently with tighter fastener hole tolerances. For
fastener holes other than interference fit fasteners, a
deflection in the structure and plate is required for
the fasteners to contact the loaded structure and the

plate. A smaller deflection is required to load the
adjoining structure for fasteners with smaller initial
clearances than another hole with a larger fastener
clearance. However, interference fit fasteners should
not be used in composite structures. The composite
matrix may crack or delaminate resulting in strength
degradation as the interference fit fastener is pressed
into place. A Class II fit (clearance of +0.0025/-0.000
inch) is normally specified for structural fasteners in
composite materials.
(1) Galvanic Corrosion. Galvanic corrosion
between aluminum and carbon has led most com-
posite fasteners to be made of stainless steel or
titanium.
(2) Multiple Row Fastener Patterns. Multiple
row fastener patterns are required to gradually intro-
duce load from the part being repaired into the repair
patch. It is virtually impossible to distribute the load
evenly between all the fasteners in a multiple row pat-
tern. In general, the load in the fasteners increases
with their distance from the center of the damage
cleanup hole, with the load being the highest in the
outermost fasteners. The amount of load shared by
the fasteners in the pattern can be increased by
using close tolerance fasteners and close tolerance
fastener holes patterns. An improperly designed fas-
tener pattern or tapered/stepped patch can result in
premature failure of the repair. Only those fastener
patterns and patches called out in either a system
specific technical manual or by engineering shall be
used for repair.
(3) Large Footprint Fasteners. Large footprint
fasteners should be used. Standard solid rivets or
blind fasteners with bulbed tails will cause damage
in the part, such as surface and subsurface cracking
and delamination. Special wider area fasteners that
distribute the load over the surface, such as two
piece fasteners with a large footprint, and special
blind fasteners designed for composites should be
used. Fastener manufacturers and system specific
guidance should be consulted prior to use.
(4) Edge Distance and Fastener Spacing. E-
dge distance and fastener spacing is often larger in
composites than in similar metal repairs. The industry
rule of thumb for edge distance in composites is to
ensure the distance from the center of the fastener
hole to the edge of the patch is 3 times the fastener
diameter (3D). Changing the repair material, geome-
try or fastener size/type will greatly alter the fastener
spacing and edge spacing. Therefore, if a repair
calls for one fastener and another is substituted, the
fastener spacing and edge distance will need to be
reexamined by an engineer and possibly changed.
TM 1-1500-204-23-11
(5) Hole Sizes. Hole sizes should be large
enough to avoid interference fits, which will cause
damage to the composite structure. Refer to para-
graph 6-8 for additional details. See paragraph 7-7e
below for locating blind holes.
b. Fastener Installation. Different installation and
inspection procedures are required for the different
types of fasteners. The following is the installation
instructions for Hi-Lok® and blind fasteners.
(1) Installation of Hi-Lok® Fasteners. Hi-Lo-
ks® are designed to be installed with either spe-
cially designed Hi-Lok® tooling or standard hand or
power tools with Hi-Lok® adapters. Refer to TM
1-1500-204-23-10, Chapter 7 or the system specific
technical manual for additional information on Hi-Lok®
with these additional provisions.
(a) Secure the structures to be joined with
temporary fasteners.
(b) Measure the panel thickness and
determine grip length of the pin to be
installed.
(c) Wet the grip surface of the pin with
sealant then insert.
(d) Ensure pin protrusion limits are per TM
1-1500-204-23-10, Chapter 7 or the
system specific technical manual.
(e) Install collar with the appropriate pneu-
matic tooling or ratchet wrench.
(f) Torque ratchet wrench until wrenching
device shears from collar.
(2) Installation of Blind Fasteners. The tool-
ing required for installing Visu-Lok® or Composi-Lok®
blind fasteners are found in tables 3-4 through 3-6.
Refer to TM 1-1500-204-23-10, Chapter 7 or the sys-
tem specific technical manual for additional information
on Visu-Lok® with these additional provisions.
(a) Secure the structures to be joined with
temporary fasteners.
(b) Use a fastener grip gauge (figure 3-11)
inserted through the fastener hole
to measure the material thickness to
determine the blind bolt length required.
Take numerous measurements around
the fastener hole. If the skin is tapered,
the grip length must be determined by
the depth at the centerline of the hole.
7-35
TM 1-1500-204-23-11

(c) Wet the blind bolt with MIL-PRF-81733 (e) Inspect the fastener for acceptable
sealant. The sealant should be spread installation per the requirements of table
around the nut of the fastener. 7-2 and 7-3. Use the break-off gauge
as demonstrated in figure 3-11.
(d) Install the wet blind bolt using pneu-
matic or hand tools listed in tables
3-4 through 3-6 for the corresponding
fastener. Hold installation tooling per-
pendicular to the repair surface while
installing the fastener.

Table 7-2. Blind Fastener Inspection Requirements (VISU—LOK®)

VISU-LOK® & VISU-LOK® II

GAGE NEEDED
VISU-LOK VISU-LOK II BREAK-OFF
DIAMETER MONOGRAM STANDARD
PART NUMBER PART NUMBER LIMITS
GAUGE GAUGE
-5 MGF-5 4F5 +.020/-.068
PLT110 PLT5110 -6 MGF-6 4F6 +.015/-.073
PLT150 PLT5150 -8 MGF-8 4F8 +.010/-.088
PLT170 PLT5170 -10 MGF-10 4F10 +.010/-.083
-12 MGF-12 4F12 +.010/-.093
-5 MGFA-5 A4F5LS +.082/-.006
-6 MGFA-6 A4F6LS +.072/-.016
PLT120 PLT5120 -8 MGFA-8 A4F8LS +.072/-.026
-10 MGFA-10 A4F10LS +.072/-.031
-12 MGFA-12 A4F12LS +.072/-.031
-5 MGP-5 3P5 +.088/+.000
PLT130 PLT5130 -6 MGP-6 3P6 +.098/+.010
-8 MGP-8 3P6 +.098/+.010
-5 MGP-5 +.088/+.000
3P5
PLT210 PLT5210 -6 MGP-6 +.098/+.010
3P6
PLT250 PLT5250 -8 MGP-8 +.135/+.047
3P8
PLT270 PLT5270 -10 MGP-10 +.146/+.043
3P10
-12 MGP-12 +.152/+.049
-5 MGP-5 A3P5 +.088/+.000
-6 MGPA-6 A3P6 +.103/+.015
PLT220 PLT5220 -8 MGPA-8 A3P8 +.130/+.032
-10 MGPA-10 A3P10 +.130/+.027
-12 MGPA-12 A3P12 +.130/+.027
-5 MGP-5 3P5 +.088/+.000
PLT230 PLT5230 -6 MGPA-6 3PA6 +.103/+.015
-8 MGP-8 3P8 +.135/+.047

7-36
 TM 1-1500-204-23-11

Table 7-3. Blind Fastener Inspection Requirements (COMPOSI-LOK®)

COMPOSI-LOK® & COMPOSI-LOK® II

MONOGRAM PART NUMBER
SCREW BREAK-OFF
FASTENER SIZE FLUSH HEAD BARREL PROTRUDING HEAD LIMITS
GAUGE LEAF GAUGE
5/32 (-5) MGFCL-5
3/16 (-6) MGFCL-6
7/32 (-7) MGFCL-7
1/4 (-8) MGFCL-8 +.103
MGPCL
9/32 (-9) MGFCL-9 +.000

5/16 (-10) MGFCL-10

11/32 (-11) MGFCL-11
3/8 (-12) MGFCL-12
COMPOSI-LOK® IIa
MONOGRAM PART NUMBER
SCREW BREAK-OFF
FASTENER SIZE FLUSH HEAD BARREL PROTRUDING HEAD LIMITS
GAUGE LEAF GAUGE
5/32 (-5) MGFCL-5a
3/16 (-6) MGFCL-6
7/32 (-7) MGFCL-7
+.103
1/4 (-8) MGFCL-8 MGPCL
+.000
5/16 (-10) MGFCL-10
11/32 (-11) MGFCL-11
3/8 (-12) MGFCL-12

c. Fastener Removal. Fastener removal is accom- by both specialty tooling and common hand tools.
plished using specialty tools or common hand tools. Refer to TM 1-1500-204-23-10, Chapter 7 for addi-
Figure 7-19 demonstrates Hi-Lok® fastener removal tional information on removing fasteners.

7-37
TM 1-1500-204-23-11
Figure 7-19. Hi-Lok® Removal
(1) Removal of Hi-Lok® Fasteners. Hi-Loks®
should be removed using special tools for fastening
removal. (See figure 7-19 , View A) A chisel and
hammer are not acceptable tools for Hi-Loks® fastener
removal. Perform the following steps to remove
Hi-Lok® fasteners.
(a) Match the size of the HLH128 collar
removal tool with the size of the collar
being removed.
(b) Place the tool over the collar until it bot-
toms on the structure.
(c) Rotate the cam jaw until the serrations
grip the collar base.
(d) Connect an appropriate flexible handle
and extension to the collar removal tool.
(e) Insert a hex Allen wrench of the proper
size in the hex recess the threaded end
of the pin.
(f) Rotate the handle and tool counter-
clockwise until the collar is loosened.
(2) Common Hand Tooling. Perform the fol-
lowing steps to remove Hi-Lok® fasteners using com-
mon hand tools. (See figure 7-19, View B).
(a) Insert a hex Allen wrench of the proper
size in the hex recess in the threaded
end of the pin.
7-38
(b) Secure pliers around the collar.
(c) While holding the hex Allen wrench sta-
tionary, rotate the pliers counterclock-
wise to loosen the collar.
(3) Removal of blind fasteners. Blind fasten-
ers may be removed with common composite hand
tools if a fastener removal kit is unavailable. How-
ever, extreme care must be taken not to damage the
laminate surrounding the fastener hole. If a fastener
removal kit is not used, the fastener hole must be
inspected for damage. If damage is detected, a fas-
tener hole repair must be performed per paragraph
7-9 or the next larger sized fastener must be installed.
(a) Perform the following steps to remove
tightly clamped blind fasteners. Refer to
figure 7-20.
1 Select a drill with a motor that does
not turn over 500 rpm.
2 Determine the pilot and shank drill
bits required that corresponds to
the size of blind fasteners being
removed. Carbide drill bits must
be used to remove titanium or steel
fasteners from table 7-4.
 TM 1-1500-204-23-11

Figure 7-20. Removal of Tightly Clamped Blind Fasteners

Table 7-4. Pilot and Shank Drill Sizes for Blind Fastener Removal

FASTENER DIAMETER PILOT DRILL SIZE SHANK DRILL SIZE

0.1635 0.0980 (No. 40) 0.1540 (No. 23)
0.1980 0.1285 (No. 30) 0.1890 (No. 12)
0.2590 0.1590 (No. 21) 0.2460 (D)
0.3105 0.1730 (No. 17) 0.2950 (M)

3 With a round carbide burr, grind an 6 With a hammer and minimal size
indentation in the center of the fas- punch, sever the head and drive
teners to be removed. out the shank and blind head.

4 Using the pilot drill and a drill guide, (b) Perform the following steps to remove
drill on the centerline of the fastener fasteners that turn when drilling. Refer
to be removed. Drill to below the to figure 7-21.
head-to-shank juncture.

5 Using the shank drill and drill guide,

drill in each fastener hole to the
depth of the pilot hole.

7-39
TM 1-1500-204-23-11
Figure 7-21. Removal of Loose Blind Fasteners
NOTE
Supporting the structure from the far side
may be necessary on thin materials to avoid
damaging the surrounding laminate.
1 Secure the blind fastener in place
from turning.
2 Engage the countersunk installa-
tion tools nose adapter in the fas-
tener head recesses for a counter-
sunk fastener. Use a wrench for
securing protruding head blind fas-
teners.
3 Determine the required pilot drill bit
that corresponds to the size of blind
fastener being removed.
4 Using the pilot drill, drill through the
shank of the blind fastener, sever-
ing the head of blind fastener.
5 Pick out the countersink remains
from the fastener with a punch.
d. Patch Preparation. Cutting, forming and shap-
ing a metallic repair patch must be accomplished
before attaching the patch to the damaged structure.
On other aircraft, the patches must be formed from
sheet stock if not supplied pre-shaped. The methods
used to fabricate, shape and drill the repair patch
will depend upon the type of patch material. Refer to
TM 1-1500-204-23-10 for metal working practices for
the metal being used. For bolted repairs on carbon
composite structures, an aluminum alloy or titanium
7-40
alloy is preferred. The use of stainless steels as a
substitute for aluminum or titanium is generally accept-
able. Refer to the system specific technical manual
or engineering for suitable substitute patch materials.
e. Blind Side Drilling. Locating and drilling blind
holes can be difficult. These holes must be accu-
rately transferred from the original structure to the
replacement part or repair. Five different methods of
blind side drilling are described below. Each method
has distinct features that offer advantages over an
alternate method depending upon surface geometry,
number of holes being drilled and part rigidity. The
methods described are the hole finder method, blind
hole transfer punches, measuring and scaling method,
mold method, and the arc method. The hole finder
and blind hole transfer punches are generally used
on relatively flat parts such as replacement skins.
Holes in parts with compound curvature or extrusions
can be accurately transferred using the measuring
and scaling method. The mold method is used when
close tolerances must be maintained. When drilling
through composites, guidelines specified in paragraph
6-8 should be followed. Use an approved drill guide
for all drilling operations. The drill guide along with
a sharp carbide drill will help reduce splintering on
the drill exit side by controlling the breakout force of
the drill.
(1) Hole Finder Method. The hole finder can
be constructed in a variety of special shapes, sizes
and materials. Temporary, one time use tools can
be quickly assembled from scraps of a hardened
aluminum alloy and a rivet of the desired size. If
a large number of holes are to be drilled, use a
prefabricated tool or construct the hole finder from
 TM 1-1500-204-23-11

steel with a steel drill bushing. Figure 7-22 shows finder. The following procedures describe how to
a general design for constructing and using a hole locate blind holes with a hole finder.

Figure 7-22. Hole Finder

(a) Locate blind holes when the replace- 2 Place the replacement part on the
ment part with pilot holes. structure.

1 Fabricate the hole finder using fig- 3 Install temporary fasteners in any
ure 7-22 as a guide. full size holes in the replacement

7-41
TM 1-1500-204-23-11
part. If no full size holes are drilled,
secure the part in place with tape.
4 Use the hole finder to check the
alignment of each pilot hole with the
corresponding hole in the structure.
5 Remove the part from the structure
and enlarge several pilot holes to
full size. Use several intermediate
size drills to bring holes to final size.
Be careful to keep drills centered
on the fastener holes.
6 Reinstall the replacement part on
the structure with temporary fasten-
ers in the full size holes. Recheck
the part for hole alignment.
Make sure drill bit does not damage substruc-
ture.
7 Using the hole finder, locate and
drill any remaining pilot hole loca-
tions on the replacement part.
8 Remove the replacement part
from the structure and enlarge the
remaining pilot holes to full size.
Use several intermediate size drills
to bring holes to final size. Be care-
ful to keep drills centered on the
fastener holes.
9 Deburr any holes drilled in metal.
(b) Locate blind holes when the replace-
ment part without pilot holes.
1 Fabricate the hole finder using fig-
ure 7-22 as a guide.
2 Place the replacement part on the
structure.
Make sure drill bit does not damage substruc-
ture.
7-42
3 Install temporary fasteners in any
full size holes in the replacement
part. If no full size holes are drilled,
secure the part in place with tape.
4 Using the hole finder, locate and
drill several pilot hole locations on
the replacement part.
5 Remove the replacement part from
the structure and enlarge the pilot
holes to full size. Use several inter-
mediate size drills to bring holes to
final size. Be careful to keep drills
centered on the fastener holes.
6 Reinstall the replacement part on
the structure with temporary fasten-
ers in the full size holes. Recheck
the part for hole alignment.
Make sure drill bit does not damage substruc-
ture.
7 Using the hole finder, locate and
drill any remaining pilot hole loca-
tions on the replacement part.
8 Remove the replacement part
from the structure and enlarge the
remaining pilot holes to full size.
Use several intermediate size drills
to bring holes to final size. Be care-
ful to keep drills centered on the
fastener holes.
9 Deburr any holes drilled in metal.
(2) Blind Hole Transfer Punches. The blind
hole transfer punch method is a simple, easy method
of accurately transferring blind holes into a part. This
method uses prick punches inserted into the existing
fastener holes. The replacement part is positioned
over the punches such that the hole centerline is
transferred to the new part. Figure 7-23 graphically
depicts this hole transfer method. This should only
be used on metal replacement parts.

Figure 7-23. Blind Hole Transfer Punch
(a) Gauge fastener holes to determine the
hole sizes in the existing structure.
(b) Find the part number of the blind hole
transfer punches from figure 7-23 cor-
responding in size to the hole diameter.
(c) Insert the proper punches into the fas-
tener holes to be transferred.
(d) Align the new part over the transfer
punches.
(e) Lightly tap the part over each transfer
punch.
(f) Remove the part from the structure and
pilot drill each transfer punch location.
TM 1-1500-204-23-11
(g) Enlarge the pilot holes to full size. Use
several intermediate size drills to bring
holes to final size. Be careful to keep
drills centered on the fastener holes.
(h) Deburr the holes in the new part.
(3) Measuring and Scaling Method. The mea-
suring and scaling method provides an accurate
method of transferring blind holes from parts with
complex curvature and extruded shapes. This tech-
nique uses either a line passing through the center
of a hole with markings measured a predetermined
distance from the center point or two lines passing
through the center of a hole to locate blind holes.
Figure 7-24 illustrates this method as described below.
7-43
TM 1-1500-204-23-11
Figure 7-24. Measuring and Scaling Method of Transferring Blind Holes
(a) Using a marking pen or pencil, complete
one of the following:
1 Draw a line through the center of
each existing fastener hole in the
structure. Mark off a measured dis-
tance on each line from the center
of each existing hole.
2 At each fastener hole, draw two
lines intersecting at the hole center.
(b) Position and align the new part on the
structure.
(c) Install temporary fasteners in any full
size fastener holes in the replacement
part to secure the part in position. If
no full size fastener holes exist in the
replacement part, tape the part in posi-
tion.
(d) Place a straight edge along each of the
uncovered lines previously marked and
transfer these lines onto the replace-
ment part. If the two intersecting lines
method in paragraph 7-7e3(a)2 was
used, the fastener locations on the
replacement part are at the intersect-
ing lines on the replacement part. If
the measuring method in paragraph
7-44
7-7e3(a)1 was used, mark the fastener
hole locations on the replacement part
by transferring the measured distance
onto the projected lines.
(e) If any pilot or full size holes exist in the
replacement part, inspect and compare
the alignment of each hole location in
the new part to the holes in the original
structure. If only pilot holes exist in the
new part, adjust the part so as many of
the pilot holes as possible are located
in the center of the existing holes in the
structure. If adjusted, repeat the para-
graph above to ensure all hole center-
lines are properly located.
(f) If the new part has previously drilled
pilot holes, complete the following:
1 Remove the part from the structure.
2 Enlarge the pilot holes to full size.
Use several intermediate size drills
to bring holes to final size. Be care-
ful to keep drills centered on the
fastener holes.
3 Reinstall part with temporary fas-
teners.
 TM 1-1500-204-23-11

DO NOT center punch advanced composites.

(g) If the new part is made from advanced

composites, pilot drill 0.098 inch diam-
eter holes at the intersection marks. If
the new part is metal, center punch the
intersection mark.

(h) Remove the part from the structure.

(i) Enlarge the pilot holes to full size. Use

several intermediate size drills to bring
holes to final size. Be careful to keep
drills centered on the fastener holes.

(j) If the replacement part is metal, deburr

holes. If the part is advanced compos-
ites, no additional steps are required.

(4) Mold Method. This method can success-

fully transfer blind holes and maintain a Class II
tolerance (+0.0025/-0.000 inch). This method uses
Hydrocal plaster to form a rigid drill blanket from the
part being repaired or replaced. Figure 7-25 illus-
trates how this method is used with the following
procedures:

Figure 7-25. Mold Method of Transferring Blind

Holes

(a) Remove fasteners from the damaged

part.

(b) Inspect the fastener holes to insure the

holes are within tolerance.

7-45
TM 1-1500-204-23-11
(c) Identify the nearest fastener holes out-
side the damaged region. Locate a
fastener location outside of the dam-
age region at each end of each fastener
line to be transferred. These will be
the index holes for the hydrocal blanket.
Refer to figure 7-25.
(d) Remove fasteners from the index holes.
(e) Clean repair area with a clean, dry wip-
ing cloth saturated with solvent.
(f) Apply tape over any drain holes in the
area to be drilled.
(g) Apply petrolatum over an area approx-
imately 3 inches wide on each side of
the fastener rows. The petrolatum acts
as a release agent to keep the Hydrocal
from sticking to the part.
(h) Install drill bushings into the fastener
and index holes. Ensure bushing size
corresponds with hole size.
(i) Install fasteners through the drill bush-
ings as follows:
1 For fastener holes requiring
threaded fasteners, install the
proper size bolt into the bushing.
Washers may be used under the
bolt heads to get the correct grip
length, if required. Engage the nuts
and tighten.
2 For fastener holes requiring perma-
nent fasteners, install a temporary
sheet metal fastener through the
bushing and tighten.
(j) Mix hydrocal or other molding com-
pound and water using a 2:1 ratio to a
putty consistency. Mix an amount suffi-
cient to cover 2 inches on each side of
the bushings and be approximately 0.5
inches thick.
(k) Apply an initial layer of the hydrocal mix-
ture on the surface around the bush-
ings.
7-46
(l) Apply a layer of cheesecloth on the
hydrocal mixture.
(m) Apply an additional layer of the hydrocal
mixture over the cheesecloth.
(n) Clean any putty mixture from around the
fastener heads.
(o) Allow the putty mixture to cure at room
temperature for one hour.
(p) Inspect the hydrocal mixture to ensure
the material has solidified.
(q) Remove all fasteners from the bush-
ings.
(r) Carefully remove the hydrocal drill blan-
kets from the surface.
(s) Remove the damaged part.
(t) Clean the damaged and surrounding
area as required.
(u) Inspect the fastener holes in the mating
structure to insure the holes are within
tolerance.
(v) Position and temporarily secure the
replacement part on the structure. Trim
the new part as required.
(w) Once part is trimmed to size and prop-
erly positioned, align the hydrocal drill
blankets on the surface using the index
holes.
(x) Insert fasteners through the index hole
bushings and tighten.
(y) Drill fastener holes in new part.
(z) Remove the fasteners from the drill
blanket and remove the drill blanket.
(aa) If the holes were transferred to metal
structure, remove the part and deburr
the holes.
 TM 1-1500-204-23-11

(5) Arc Method. This method uses a pair of the fastener location. This technique is very accurate
dividers to scribe an arc; from the initial arc, two other and easy to perform. Figure 7-25 represents the arc
arcs are scribed; where they intersect is the center of method.

Figure 7-26. Arc Method of Locating Blind Fastener Holes (Sheet 1 of 3)

7-47
TM 1-1500-204-23-11

Figure 7-26. Arc Method of Locating Blind Fastener Holes (Sheet 2 of 3)

7-48

Figure 7-26. Arc Method of Locating Blind Fastener Holes (Sheet 3 of 3)
(a) Set the distance on the dividers large
enough to permit an adequate arc.
(b) Lock the adjustment knob on the
dividers. Use a locknut, Loctite or
equivalent. The accuracy is dependent
on the adjustment being locked.
(c) Ensure the tips of the dividers are fairly
sharp.
(d) Place a piece of speed tape out of the
area or use a scrap piece of metal and
clearly mark the center point and scribe
an arc. This control will be used later
to verify the adjustment on the dividers
has not changed.
(e) Carefully place speed tape around the
periphery of the panel location. Ensure
TM 1-1500-204-23-11
tape is free of wrinkles. The speed
tape protects the base material from
being damaged when the arcs are
scribed. Additionally, the arcs scribed in
the speed tape create a slight depres-
sion which aid in properly locating the
dividers in later steps.
(f) For each fastener hole to be transferred,
do the following:
1 Place an AD rivet in the fas-
tener hole. Ensure rivet diameter
matches the hole diameter. Use
washers as necessary to adjust
the height of the rivet. The high-
est point of the rivet should be
the same height as the surface
of the replacement panel that will
be placed there. The accuracy of
7-49
TM 1-1500-204-23-11
the new hole depends upon how
closely the rivet fits the hole; if it is
a sloppy fit, select a different type
of fastener with a larger diame-
ter or have a machinist turn down
a larger rivet to the diameter you
need to fill the hole.
Do not scribe directly onto composite or metal.
Loss of structural integrity may occur.
2 Scribe an arc onto the speed tape
(g) Carefully place speed tape around the
periphery of the panel.
(h) Put the replacement panel in place
and adjust the location as necessary to
maintain gap tolerances. Secure the
panel.
Do not scribe directly onto composite or metal.
Loss of structural integrity may occur. See
paragraph 6-20 to prevent galvanic corrosion.
(i) From each of the arcs previously
scribed, scribe two arcs onto the panel.
The intersection of the two arcs is the
center of the fastener hole. Trans-
fer four fastener holes onto the panel,
preferably one near each corner.
NOTE
The accuracy will be best when the two arcs
are scribed from locations that are 90 degrees
apart on the initial arc.
(j) Remove the panel, pilot drill initial fas-
tener locations, and drill to final size per
paragraph 6-8.
(k) Install the replacement panel with fas-
teners or temporary fasteners in the ini-
tial holes.
Do not scribe directly onto composite or metal.
Loss of structural integrity may occur.
(l) Transcribe the remainder of the fastener
locations using the arc method. Period-
ically, check the setting on the dividers
7-50
against the control created in step (d) to
ensure the adjustment has not changed.
(m) Drill the fastener holes. Pilot drill and
drill to final size per paragraph 6-8.
f. Example Procedure For A Bolted Repair.
If an aluminum patch plate is installed as a
permanent repair on a carbon structure, a
corrosion barrier, such as a ply of fiberglass
cloth or an approved sealant, must be installed
between the aluminum patch and the carbon
epoxy structure. Refer to the system specific
technical manual for galvanic isolation of
aluminum.
NOTE
The following drill procedure does not consider
curvature of the structure. Slight modifications
of the procedure may be required if more than
one patch layer is required.
This paragraph represents the basic procedure
for drilling a bolted patch to an existing structure
where there are no existing fastener locations to
pick up and where no back side access exists.
If existing fastener locations exist, see the above
procedures for locating these fastener holes on the
patch plate. This procedure is applicable for repair of
skin penetration damage occurring in thick monolithic
composite structures. Modifications are necessary for
application to sandwich structure. This procedure uses
an external patch. See the system specific technical
manual for using this procedure for external/internal
or internal only patches. Fastener holes must be
drilled in the patch and skin to complete a bolted
repair. Through these fastener holes, the repair
plate will be attached to the damaged area with
mechanical fasteners. For efficient load transfer, a
Class II tolerance (+0.0025/-0.000 inch) is generally
recommended for structural repairs in composites. The
following procedures and the guidelines in paragraph
6-8 for drilling and reaming are suggested for obtaining
the best quality holes. This repair procedure is
not necessarily applicable to a particular weapon
system. The applicability of this repair depends
upon additional factors such as loading conditions
and laminate thickness. Consult the system specific
technical manual or engineering for further guidance.
Process Flow Diagram. Refer to figure 7-27 for the
Process Flow Diagram for Penetration Damage Bolted
Repair, External Patch.

Figure 7-27. Process Flow Diagram for Penetration
Damage Bolted Repair, External Patch
(1) Facilities, Equipment and Materials. The
following equipment and materials are required: Drill
motor, Drill guide, Drill bits, high-speed steel, Drill
reamer, carbide, straight flute or Drill bits, 8 Faceted,
Center punch, Temporary fasteners, Approved marker,
Grip Length Gauge, Vacuum Cleaner, HEPA Filter,
Composite Fasteners Installation Tooling, Patch mate-
rial (See System Specific Technical Manual), Silicon
Carbide Abrasive Paper, Wiping Cloth, Composite
Blind Fastener (see System Specific Technical Man-
ual).
NOTE
The following procedure assumes the sys-
tem specific technical manual or engineering
has provided a fastener layout based upon
the repair design and/or criteria. Use an
approved drill guide for all drilling operations.
Consult the system specific technical manual
for guidance.
(2) Procedure for A Bolted Repair.
(a) Remove dirt, grease and aircraft fluids
from repair area as described in para-
graph 6-5.
TM 1-1500-204-23-11
DO NOT use oil or oil based materials
as NDI couplants on advanced composite
components. Use only water or water based
materials. Disbonds may result and loss of
structural integrity may occur.
(b) Define both the depth and extent of the
damage using NDI according to para-
graph 5-2 and the system specific tech-
nical manual. Lay out the damage as
described in paragraph 6-4. Mark cen-
terlines to be used as reference marks
for positioning patch.
(c) Remove NDI couplant by wiping with
clean, water moistened cloth.
DO NOT damage inner surface of opposite
skin or internal structure during machining or
drilling.
(d) Remove skin damage along the dam-
age layout line as described in para-
graph 6-4. Vacuum the cavity to remove
machining residue.
(e) Fabricate metallic patch as described
in TM 1-1500-204-23-10 or the system
specific technical manual. Refer to the
system specific technical manual for
specific patch geometry/material, and
fastener hole pattern layout.
1 Lay out patch on required material.
2 Cut out patch and chamfer edges.
3 Form contour in patch if required.
(f) Install sump (see figure 7-28) as
required to contain composite residue.
Moistened wiping cloth may be used as
an alternative.
7-51
TM 1-1500-204-23-11
Figure 7-28. Sump Removal and Installation
(g) Lay out pilot hole pattern on patch.
(h) Position patch over damaged area,
using reference marks on skin as a
guide. Outline patch perimeter on skin
and transfer reference marks from skin
to patch.
(i) Remove patch. Identify any skin fasten-
ers covered by the repair patch.
(j) On the drilled patch, mark one piloted
hole in each of the patch corners. These
holes will be used as alignment holes for
aligning and match drilling the patch to
the structure.
(k) If applicable, remove any existing fas-
teners covered by the repair plate as
described in paragraph 4-5d. Transfer
the fastener hole locations to the repair
patch using the methods described in
paragraph e above.
(l) Using a center punch, mark the loca-
tions on the metal patch that require
pilot holes.
7-52
(m) Using a 2000-rpm drill motor, drill guide,
and a No. 30 HSS drill bit and back-
ing plate, drill all the holes. Deburr the
holes.
(n) On the drilled patch, mark one piloted
hole in each of the patch corners. These
holes will be used as alignment holes for
aligning and match drilling the patch to
the structure.
(o) Place the patch onto the repair area in
its proper location and orientation and
mark the first hole to be drilled.
(p) Remove patch and check to ensure fas-
tener hole to edge of damage cleanup
meets the minimum requirement in the
system specific technical manual. If any
fastener hole has less than the required
edge distance, repeat step (k) above,
relocating patch to obtain required edge
distance.
(q) Using a 2000 rpm drill motor, drill guide,
a straight-fluted carbide drill reamer,
and the patch holes as the template or

guide, pilot drill through the alignment
holes into the composite substrate. Drill
the alignment holes in order to ensure
accurate patch location and install tem-
porary fasteners in the holes as they are
drilled to hold the patch firmly in place.
(r) Complete drilling all the pilot holes
through the substrate using the patch
pilot holes as the guide. If the drilling
process begins to slow down or requires
more pressure, the drill reamer has
become dull. Stop and replace the drill
reamer.
(s) If applying the patch to sandwich struc-
ture, pot the core according to para-
graph 7-5.
(t) Disassemble the patch from the sub-
strate.
(u) Using a 2000 rpm drill motor, drill guide,
and a 1/64 undersized HSS drill bit,
drill all the patch holes except for the
marked alignment holes. Deburr the
holes drilled.
(v) Using temporary fasteners in the align-
ment holes, attach the patch onto the
composite substrate.
(w) Using a 2000 rpm drill motor, drill guide,
and a full-sized drill reamer, match drill
the patch/substrate combination.
(x) Remove the patch from the substrate.
(y) Using a 2000-rpm drill motor, drill guide,
and a 1/64-undersized HSS drill bit,
enlarge the alignment holes in the
patch. Deburr the holes.
(z) Attach the patch onto the substrate
with temporary fasteners using full-size
holes that are adjacent to each of the
alignment holes used.
(aa) Using a 2000-rpm drill motor, drill guide,
and a full-sized drill reamer, match drill
the remaining holes in the patch/sub-
strate combination.
(ab) Disassemble and deburr the remaining
holes in the patch.
TM 1-1500-204-23-11
NOTE
Using a grip length gauge, determine fastener
grip length by gauging material thickness after
drilling holes full size.
(ac) Place patch in place and measure the
fastener grip length required in each
fastener hole.
(ad) Prime patch if required as specified in
the system specific technical manual
and paragraph 6-7.
(ae) Remove paint from skin in the repair
area by sanding as described in para-
graph 6-1.
(af) Remove sump or rymple cloth and vac-
uum repair cavity.
(ag) Seal the patch per paragraph 7-7g
below.
(ah) Install fasteners and inspect according
to paragraph 3-4g.
(ai) When repairing weight critical struc-
tures, add weight of repair(s) and zone
location(s) on applicable nameplate.
(aj) Apply finish system in accordance with
paragraph 7-13b or the system specific
technical manual.
g. Sealing Repairs. Sealants are applied to bolted
repairs on composite structure for prevention of
water/moisture intrusion, chemical damage, dissimilar
metal contact and fuel leaks, as well as to provide
contour smoothness.
(1) Facilities, Equipment and Materials. The
following equipment and materials are required: Injec-
tion Gun, Utility Knife, Sealant (See System Specific
Technical Manual), MIL-PRF-81733 Sealant (Local
Procurement), Wiping Cloth, Masking Tape, Brush,
Solvent, Squeegee.
(2) Preparation for Sealing a Repair.
(a) Thoroughly mix the accelerator to a
smooth paste before combining with
base material.
(b) Determine the amount of each part to
mix. Follow the procedures described
in paragraph 6-17 for weighing and mix-
ing the two components. Mix the two
7-53
TM 1-1500-204-23-11
components thoroughly to a smooth
homogenous mixture.
(3) Application of a Sealing Repair. All bolted
repair patches shall be installed with sealant. Sealant
Figure 7-29. Sealing Bolted Repairs
(a) Fay Surface Sealing. For this type of
sealing, sealant is applied between the
contact surfaces of the patch and the
parent skin.
1 Solvent clean patch and parent
skin.
2 If required, cut pieces of scrim cloth
to fit patch(es). Cut holes in scrim
at each fastener hole with a knife.
3 Apply sealant to one mating sur-
face using pneumatic sealant gun
equipped with sealant gun noz-
zle. Apply two continuous beads of
sealant centered between fastener
hole pattern and each edge of part.
4 Place parts in assembly position
immediately after sealant applica-
tion. Install enough temporary fas-
teners to pull faying surfaces into
contact and squeeze out excess
sealant before installing permanent
fasteners. Install permanent fas-
teners with wet sealant.
5 Fair sealant squeeze-out into fillet
around patch periphery.
6 Remove any sealant which
extrudes through fastener holes,
fraying surfaces and/or butt joints
onto exterior with a solvent moist-
ened wiping cloth immediately after
installation of patch.
(b) Fastener Sealing. All permanent
fasteners used for bolted repair
patches shall be installed wet with
MIL-PRF-81733 sealant.
7-54
is to be applied between the contact surfaces of
the patch and parent skin (fay surface sealing) so
that squeeze-out can be used to form a fillet. In
addition, permanent fasteners should be installed wet
with MIL-PRF-81733 sealant. See figure 7-29.
1 Solvent clean dimples, counter-
sinks and surrounding area.
2 Apply small bead or layer of sealant
around fastener shank, counter-
sink, dimple or conical area of
fastener head with brush.
3 Install Fastener. Remove sealant
which extrudes out around fastener
immediately with solvent moist-
ened wiping cloth.
(c) Fillet Seal. Once the repair patch has
been installed, a final seal around the
patch may be required. If the repair is a
lap repair installed on the outer moldline
of the aircraft, the periphery of the patch
should be faired in with the surrounding
area.
1 Clean the parent skin around the
patch periphery with solvent.
2 After the solvent wiped surface is
dry, apply masking tape around the
patch. The tape should be parallel
with the patch edges and allow a
gap of approximately 0.25 inches.
3 Apply sealing compound over the
skin adjacent to the patch. Using a
squeegee, fair the sealant between
the patch and the edge of the tape.
4 Remove tape from skin.
h. Partial Thickness Damage Bolted Repair. This
repair is applicable to surface damage in composite
skins without penetrating the composite skin. It is
also applicable to the repair of unsuccessful adhesive
injection delamination repairs. Typical repairs are

limited to a 4.0 inch diameter area. The blind fasteners
used in this repair must be designed for use on
composite materials. The rationale for these fasteners
is described in paragraph 3-4. This repair procedure
is not necessarily applicable to a particular weapon
system. The applicability of this repair depends
upon additional factors such as loading conditions
and laminate thickness. Consult the system specific
technical manual or engineering for further guidance.
Refer to figure 7-30 for the Process Flow Diagram
for Partial Thickness Bolted Repair.
Figure 7-30. Process Flow Diagram for Partial
Thickness Bolted Repair
(1) Facilities, Equipment and Materials. The
following equipment and materials are required: Drill
motor, Drill guide, Drill bits, high-speed steel, Drill
reamer, carbide, straight flute, Center punch, Tempo-
rary fasteners, Approved marker, Grip Length Gauge,
Vacuum Cleaner, HEPA Filter, Composite Fasten-
ers Installation Tooling, Patch material (See System
Specific Technical Manual), Silicon Carbide Abrasive
Paper, Wiping cloth, Composite Blind Fastener (see
System Specific Technical Manual).
(2) Partial Thickness Bolted Repair
Procedure.
NOTE
The following procedure assumes the sys-
tem specific technical manual or engineering
has provided a fastener layout based upon
the repair design and/or criteria. Use an
approved drill guide for all drilling operations.
Consult the system specific technical manual
for guidance.
(a) Remove dirt, grease and aircraft fluids
from repair area as described in para-
graph 6-5.
TM 1-1500-204-23-11
DO NOT use oil or oil based materials
as NDI couplants on advanced composite
components. Use only water or water based
materials. Disbonds may result and loss of
structural integrity may occur.
(b) Define both the depth and extent of the
damage using NDI according to para-
graph 5-2 and the system specific tech-
nical manual. Lay out the damage as
described in paragraph 6-4. Mark cen-
terlines to be used as reference marks
for positioning patch.
(c) Remove partial thickness damage as
described in paragraph 6-4 and as
shown in figure 6-4.
(d) Reinspect the damage removal area
using NDI to ensure no skin delamina-
tions remain below the damage area.
(e) Remove NDI couplant by wiping with
clean, water moistened cloth.
(f) Fabricate metallic patch as described
in TM 1-1500-204-23-10 or the system
specific technical manual. Refer to the
system specific technical manual for
specific patch geometry/material, and
fastener hole pattern layout.
1 Lay out patch on required material.
2 Cut out patch and chamfer edges.
3 Form contour in patch if required.
(g) Lay out pilot hole pattern on patch.
(h) Position patch over damaged area,
using reference marks on skin as a
guide. Outline patch perimeter on skin
and transfer reference marks from skin
to patch.
(i) Remove patch. Identify any skin fasten-
ers covered by the repair patch.
7-55
TM 1-1500-204-23-11
DO NOT damage inner surface of opposite
skin or internal structure during machining or
drilling.
DO NOT center punch advanced composite.
(j) If applicable, remove any existing fas-
teners covered by the repair plate.
Transfer the fastener hole locations
to the repair patch using the methods
described in paragraph 7-7e.
(k) Using a center punch, mark the loca-
tions on the metal patch that require
pilot holes.
(l) Using a 2000-rpm drill motor, drill guide,
and a No. 30 HSS drill bit and back-
ing plate, drill all the holes. Deburr the
holes.
(m) On the drilled patch, mark one piloted
hole in each of the patch corners. These
holes will be used as alignment holes for
aligning and match drilling the patch to
the structure.
(n) Place the patch onto the repair area in
its proper location and orientation and
mark the first hole to be drilled.
(o) Remove patch and check to ensure fas-
tener hole to edge of damage cleanup
meets the minimum requirement in the
system specific technical manual. If any
fastener hole has less than the required
edge distance, repeat step (n) above,
relocating patch to obtain required edge
distance.
(p) Using a 2000 rpm drill motor, drill guide,
a straight-fluted carbide drill reamer,
and the patch holes as the template or
guide, pilot drill through the alignment
holes into the composite substrate. Drill
the alignment holes in order to ensure
accurate patch location and install tem-
porary fasteners in the holes as they are
drilled to hold the patch firmly in place.
(q) Complete drilling all the pilot holes
through the substrate using the patch
pilot holes as the guide. If the drilling
process begins to slow down or requires
more pressure, the drill reamer has
become dull. Stop and replace the drill
reamer.
7-56
(r) If applying the patch to sandwich struc-
ture, pot the core according to para-
graph 7-5e.
(s) Disassemble the patch from the sub-
strate.
(t) Using a 2000 rpm drill motor, drill guide,
and a 1/64 undersized HSS drill bit,
drill all the patch holes except for the
marked alignment holes. Deburr the
holes drilled.
(u) Using temporary fasteners in the align-
ment holes, attach the patch onto the
composite substrate.
(v) Using a 2000 rpm drill motor, drill guide,
and a full-sized drill reamer, match drill
the patch/substrate combination.
(w) Remove the patch from the substrate.
(x) Using a 2000-rpm drill motor, drill guide,
and a 1/64-undersized HSS drill bit,
enlarge the alignment holes in the
patch. Deburr the holes.
(y) Attach the patch onto the substrate
with temporary fasteners using full-size
holes that are adjacent to each of the
alignment holes used.
(z) Using a 2000-rpm drill motor, drill guide,
and a full-sized drill reamer, match drill
the remaining holes in the patch/sub-
strate combination.
(aa) Disassemble and deburr the remaining
holes in the patch.
NOTE
Using a grip length gauge, determine fastener
grip length by gauging material thickness after
drilling holes full size.
(ab) Place patch in place and measure the
fastener grip length required in each
fastener hole.
(ac) Prime patch if required as specified in
the system specific technical manual
and paragraph 6-7.
(ad) Remove paint from skin in the repair
area by sanding as described in para-
graph 6-1.
(ae) Seal the patch per paragraph 7-7g
above.
 TM 1-1500-204-23-11

(af) Install fasteners and inspect according

to paragraph 3-4g.

(ag) When repairing weight critical struc-

tures, add the weight of the repair(s)
and the zone location(s) to the applica-
ble nameplate.

(ah) Apply finish system in accordance with

paragraph 7-13b or the system specific
technical manual.

7-8. INJECTION REPAIR. Advanced composite

structures often experience damage in the form of
ply delaminations and matrix cracks. The damage
may be either open or closed to an edge (see figure
7-31). Delaminations and cracks which are not open
to an edge are difficult to repair via the injection
method. The method often suggested to repair this
type of damage is to drill a series of holes around the
cracked/delaminated area and inject those holes with
resin (see figure 7-32). This method is usually unsuc-
cessful. Matrix cracks and delaminations are often
too small and are not interconnected. The currently
available resin systems do not possess sufficient flow
capability to infiltrate them (see figure 7-33). Hence,
application of injection repair techniques is limited to
delaminations which are either open to an edge or
involve a clearly defined blister.

Figure 7-31. Types of Delaminations

7-57
TM 1-1500-204-23-11
a. Types of Injection Repair. There are two types
of injection repair: positive pressure injection and
vacuum injection. Positive pressure injection involves
drilling holes into the delaminated area and injecting
them with resin. It is used when a leak path exists,
i.e. a delamination open to an edge or a blister. The
vacuum injection method involves using a vacuum to
remove air from the delaminated area, allowing resin
to flow into the void. It is used in areas where little
or no airflow is possible and the delamination is too
close to an edge to allow drilling injection holes, such
as small area delaminations in and around fastener
holes.
b. Adhesive Characteristics. Injection repairs uti-
lize a low viscosity liquid adhesive to facilitate flow
into tight matrix cracks and delaminations. The vis-
cosity of most adhesives at room temperature is too
high for successful injection. Adhesive viscosity is
Figure 7-32. Impact Damage Injection Repair
Figure 7-33. Injection Repair
c. Damage Classification. NDI must first be per-
formed on the component to determine location,
depth and perimeter of the damage. The informa-
tion obtained from NDI will determine which injection
repair method is to be used.
7-58
reduced at higher temperatures; however, heating the
adhesive causes an increase in the rate of polymer-
ization, reducing the work life of the material. As the
adhesive is mixed and brought up to temperature, the
viscosity drops to its minimum value. For EA 956,
for example, this is about 20 minutes. After reach-
ing minimum viscosity, gelation occurs rapidly. Again
for EA 956 this occurs in about 10 more minutes.
The resin becomes too viscous for successful injec-
tion to occur. There is a trade-off between insuring a
reasonable viscosity for injection and insuring an ade-
quate pot life to complete the injection. Heating the
adhesive to its minimum viscosity temperature before
injection may result in gelation occurring too quickly.
Instead, heat the delaminated area to the minimum
viscosity temperature prior to performing the injection
to facilitate adhesive flow and ensure sufficient work
life prior to adhesive gelation.
d. Positive Pressure Injection Repair. This meth-
od is used when positive airflow through the laminate
is possible. The method involves drilling injection
holes, heating the delaminated area to the minimum
viscosity temperature of the adhesive, and injecting
 TM 1-1500-204-23-11

the resin into an injection hole using positive pres- or engineering for further guidance. Refer to figure
sure. The adhesive is injected into one hole until it 7-34 for the Process Flow Diagram for Delamination
flows out free of bubbles, either from another injection Not Open to an Edge Repair.
hole (in the case of a blister) or out of an open
edge. A lack of bubbles indicates that the air in the
delamination has been replaced by adhesive. The
maximum time allowed for this to occur is the gel time
of the adhesive. External pressure is then applied
to the delaminated area, and the adhesive cured.
NDI is performed again after the repair is complete
to insure successful injection. Refer to the system
specific technical manual for injection temperatures
and times.

e. Vacuum Injection Repair. This method is used

when little or no airflow is possible, such as delami-
nations around fastener holes. The delaminated area
is heated to the minimum viscosity temperature of the
adhesive, then adhesive is added to a vacuum cham-
ber which has been placed over the delaminated area.
The adhesive is maintained at this minimum viscosity
temperature under vacuum to allow outgassing of air
and/or volatiles, then vented to atmosphere to force
the resin into the delaminated area. The vacuum
chamber is then removed and a fastener or clamp is
installed to provide positive pressure for curing the
adhesive. NDI is performed on the delaminated area
when the repair is complete to ensure successful
injection.

f. Resin Injection For Delaminations Not Open To

An Edge Repair. This repair is applicable to a clearly
defined blister through which positive airflow is pos-
sible. It is generally limited to blisters no larger than
2 inches in diameter. This repair procedure is not
necessarily applicable to a particular weapon system.
The applicability of this repair depends upon additional
factors such as loading conditions and laminate thick- Figure 7-34. Process Flow Diagram for
ness. Consult the system specific technical manual Delamination Not Open to an Edge Repair

7-59
TM 1-1500-204-23-11
(1) Facilities, Equipment and Materials. The
following equipment and materials are required:
Weights, Shot Bags, Pressure Regulator, Heat Lamp,
Vacuum Cleaner, HEPA Filter, Drill Motor, 2000 RPM,
Drill Stop (Common Support Equipment), Twist Drill,
Carbide, 1⁄8 Inch Diameter, Temperature/Vacuum Con-
troller, Injection Gun, Metallic Retainer Barrel, 2 1/2
Ounce, Clamps, Flash breaker Tape, Adhesive, Liq-
uid (See System Specific Technical Manual), Injection
Cartridge, 2 1/2 Ounce, Disposable, Injection Nozzle,
Disposable, Silicon Carbide Abrasive Paper, Wiping
Cloth, Release Film, 1/2 Inch Surgical Rubber or
Plastic Tubing ZZ-T-831.
(2) Resin Injection For Delaminations Not
Open To An Edge Repair Procedure.
(a) Remove dirt, grease and aircraft fluids
from repair area as described in para-
graph 6-5.
DO NOT use oil or oil based materials
as NDI couplants on advanced composite
Figure 7-35. Verification of Leak Path: Delamination Repair
7-60
components. Use only water or water based
materials. Disbonds may result and loss of
structural integrity may occur.
(b) Define both the depth and extent of the
delamination using NDI according to
paragraph 5-2 and the system specific
technical manual. Lay out the damage
as described in paragraph 6-4.
(c) Remove NDI couplant by wiping with
clean, water moistened wiping cloth.
(d) Drill 1/8 inch diameter holes at each end
of the delamination. Minimum spac-
ing between holes is 1/2 inch. Drill
to delamination depth plus 0.005 inch
using drill stop.
(e) Vacuum dust and debris from holes.
(f) Verify that a leak path exists between
the disbond and the holes drilled using
the following procedure (see figure
7-35).

Air pressure must not exceed 20 psi if delam-
inations exist in area of honeycomb core. Air
pressure of 40 psi may be applied to delami-
nations between mating skins or between skin
plies not in area of honeycomb core.
1 Fit injection nozzles into the holes
at each end of the delamination.
Tape over the intermediate holes
with flash breaker tape.
2 Attach a piece of tubing to one noz-
zle and submerge the other end in
a container of water.
3 Attach other nozzle to sealant gun
cartridge without plunger and place
cartridge in sealant gun. Attach a
regulated source of compressed air
to sealant gun.
4 Apply pressure with air regulator
set for 20 psi through sealant gun
into the delamination.
5 Check water for bubbles to make
sure airflow exists. If airflow exists
go to step vii below. If airflow does
not exist, go to step 6 and step 7
below.
6 Tape over existing holes and rein-
spect using NDI to map delami-
nated area.
7 Repeat steps d-f above. If airflow
still does not exist, proceed to para-
graph 7-3.
(g) Remove nozzle and tape from holes.
(h) Dry the repair area as described in para-
graph 6-6 for a minimum of 1 hour or as
directed by the system specific techni-
cal manual, at 150 (±10) ºF using a heat
lamp or other suitable heat source.
TM 1-1500-204-23-11
Monitor the repair area temperature to avoid
excessively heating it, as excessive heat can
shorten the pot life of the resin and may
cause it to exotherm. Consult the system
specific technical manual or engineering for
the proper heating temperature.
(i) Heat the delaminated area using a heat
lamp as described in paragraph 6-19h
to the temperature listed in the system
specific technical manual. Monitor tem-
perature to ensure the maximum tem-
perature limit is not exceeded.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
NOTE
Refer to paragraph 6-17, Resin Preparation
and Use, for the proper measuring and mixing
procedures.
(j) Prepare the amount of resin required
to fill the delaminated/repair volume.
Prepare the adhesive per paragraph
6-16(t)2a.
(k) Inject Adhesive. (See figure 7-36).
7-61
TM 1-1500-204-23-11
Figure 7-36. Delamination Repair Not Open to an Edge (Blister)
1 Pour adhesive into injection car-
tridge. Attach nozzle.
2 Tape over intermediate injection
holes with flash breaker tape.
3 Maintain part at the specified injec-
tion temperature.
4 Attach a regulated source of com-
pressed air to sealant gun. Set air
regulator for 20 psi and inject adhe-
sive, using sealant gun and noz-
zle, into one hole and fill until adhe-
sive flows clear from another hole.
Remove tape from one hole at a
time. Inject adhesive into each hole
until it flows freely from the other
holes and is free of bubbles.
5 Remove heat lamp. Wipe off
excess adhesive with clean, dry
wiping cloth.
Too much pressure using a clamping device
may result in resin starved areas. See
paragraph 6-19j, Pressurization.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
(l) Cure Adhesive.
1 Room Temperature Cure Cycle.
7-62
a Apply pressure for a minimum
of 8 hours using weights or
shot bags as described in
paragraph 6-19j.
b Allow to dwell at room
temperature for a minimum of
5 days.
2 Elevated Temperature Cure Cycle.
a Layup the vacuum bag and
heat blanket as described in
paragraph 6-18.
b Cure the adhesive as specified
in paragraph 6-19 and the
system specific technical
manual.
(m) After cure, remove shot bags, or debag.
(n) Reinspect the delaminated area using
NDI.
(o) If delaminations still exist after repair,
refer to the system specific technical
manual to determine if damage is within
negligible damage limits or partial thick-
ness damage limits.
1 If delamination is not within par-
tial thickness damage limits, con-
tact engineering for disposition.
2 If delamination is within partial
thickness damage limits, repair in
accordance with paragraph 7-3.
 TM 1-1500-204-23-11

3 If no delamination exists after

repair, or delamination is within
system specific technical manual
limits for negligible damage, refin-
ish per step (p) below.

(p) Refinish.

1 Sand the area smooth with 180 grit

abrasive paper. Vacuum the sand-
ing dust from repair area. Wipe with
clean, dry wiping cloth.

2 Apply finish system in accordance

with paragraph 7-13b or the system
specific technical manual.

g. Resin Injection For Edge Delamination Repa-

ir. The following describes a positive pressure resin
injection repair process for edge delaminations on
solid laminates. This process only works where the
damaged area is clearly defined and where airflow
out of the panel edge is possible. The procedure
requires positive airflow through the delaminated area.
A clamping device is typically used for pressure dur-
ing cure; the resin being injected can be filled with
micro-balloons to ensure adequate resin remains in
the injected area during clamp-up. This repair tech-
nique usually applies to damages between 1/2 and 4
inches in size. The applicability of this repair depends
upon additional factors such a
s loading conditions and laminate thickness. Consult
the system specific technical manual or engineering
for further guidance. Refer to figure 7-37 for the
Process Flow Diagram for Delamination Open to an
Edge Repair.
Figure 7-37. Process Flow Diagram for
Delamination Open to an Edge Repair
(1) Facilities, Equipment and Materials. The
following equipment and materials are required: Pres-
sure Regulator, Heat Lamp, Vacuum Cleaner, HEPA
Filter, Drill Motor, 2000 RPM, Drill Stop (Common
Support Equipment), Twist Drill, Carbide, 1⁄8 Inch
Diameter, Temperature/Vacuum Controller, Injection
Gun, Metallic Retainer Barrel, 2 1/2 Ounce, Clamps,
Backup Plate (local manufacture), Flash breaker Tape,
Solvent, Adhesive, Liquid (See System Specific Tech-
nical Manual), Injection Cartridge, 2 1/2 Ounce, Dis-
posable, Injection Nozzle, Disposable, Silicon Carbide
Abrasive Paper, Wiping Cloth, Release Film.

(2) Resin Injection For Edge Delamination

Repair Procedure.

(a) Remove dirt, grease and aircraft fluids

from repair area as described in para-
graph 6-5.

7-63
TM 1-1500-204-23-11
DO NOT use oil or oil based materials
as NDI couplants on advanced composite
components. Use only water or water based
materials. Disbonds may result and loss of
structural integrity may occur.
(b) Define both the depth and extent of the
delamination using NDI according to
paragraph 5-2 and the system specific
technical manual. Lay out the damage
as described in paragraph 6-4.
(c) Remove NDI couplant by wiping with
clean, water moistened wiping cloth.
(d) Drill 1/8 inch diameter holes at each end
of the delamination. Minimum spac-
ing between holes is 1/2 inch. Drill
to delamination depth plus 0.005 inch
using drillstop.
(e) Flush the delaminated area by squirting
solvent into the injection holes. Allow
solvent to evaporate a minimum of 30
minutes.
(f) Dry the repair area as described in para-
graph 6-6 for a minimum of 1 hour or as
directed by the system specific techni-
cal manual, at 150 (±10) ºF using a heat
lamp or other suitable heat source.
Monitor the repair area temperature to avoid
excessively heating it, as excessive heat can
shorten the pot life of the resin and may
Figure 7-38. Repair to an Open Edge
7-64
cause it to exotherm. Consult the system
specific technical manual or engineering for
the proper heating temperature.
(g) Heat the delaminated area using a heat
lamp as described in paragraph 6-19h
to the temperature listed in the system
specific technical manual. Monitor tem-
perature to ensure the maximum tem-
perature limit is not exceeded.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
NOTE
Refer to paragraph 6-17, Resin Preparation
and Use, for the proper measuring and mixing
procedures.
(h) Prepare the amount of resin required to
fill the delaminated/repair volume. Pre-
pare the adhesive per the paragraph
6-17 .
(i) Inject Adhesive (See figure 7-38).

1 Pour adhesive into injection car-
tridge. Attach nozzle.
2 Tape over intermediate injection
holes with flash breaker tape.
3 Maintain part at the specified injec-
tion temperature.
4 Attach a regulated source of com-
pressed air to sealant gun. Set air
regulator for 20 psi and inject adhe-
sive, using sealant gun and nozzle,
into one hole and fill until adhesive
flows of part edge and out of the
other drilled holes. The adhesive
must be allowed to flow until it is
free of all air bubbles.
5 Remove heat lamp. Wipe off
excess adhesive with clean, dry
wiping cloth.
Too much pressure using a clamping device
may result in resin starved areas. See
paragraph 6-19j, Pressurization.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
(j) Apply pressure using clamps, release
film and backup plates. See paragraph
6-19j and figure 7-38. Allow adhe-
sive to cure or set at according to the
system specific technical manual or
the manufacturer’s recommended cure
cycle per engineering disposition. Heat
may be applied as required using an
approved heat lamp or other approved
source. Operate heat lamps per para-
graph 6-19h. If room temperature cure
is used, remove clamps, release film
and backup plate after a minimum of 8
hours. Allow to dwell at room tempera-
ture for a minimum of 5 days.
TM 1-1500-204-23-11
(k) Remove any resin flash, deburr, and
clean up the repair area.
(l) Reinspect the delaminated area using
NDI.
1 If no delamination exists after
repair, or delamination is within
system specific technical manual
limits for negligible damage, refin-
ish per step (m) below.
2 If delamination is within edge dam-
age rebuild limits, repair in accor-
dance with paragraph 7–9.b.
3 If delamination exceeds edge dam-
age rebuild limits, contact engi-
neering for disposition.
(m) Refinish.
1 Sand the area smooth with 180 grit
abrasive paper. Vacuum sanding
dust from repair area. Wipe with
clean, dry wiping cloth.
2 Apply finish system in accordance
with paragraph 7-13b or the system
specific technical manual.
h. Skin to Core Disbond. This repair is applicable
to a disbond through which positive airflow is pos-
sible. This would typically be used for honeycomb
core and may not apply to other core types. It is
generally limited to small disbonds.paragraph 7-5e,
rapid densification, can also be used for small skin
to core disbonds. Larger disbonds may be treated
as penetration damage and repaired in accordance
with paragraph 7-5c core potting and replacement, or
paragraph 7-5d, paste adhesive method. Refer to the
system specific technical manual for damage limits.
This repair procedure is not necessarily applicable
to a particular weapon system. The applicability of
this repair depends upon additional factors such as
loading conditions and laminate thickness. Consult
the system specific technical manual or engineering
for further guidance. Refer to figure 7-39 for the
Process Flow Diagram for Disbond Repair.
7-65
TM 1-1500-204-23-11

Cartridge, 2 1/2 Ounce, Disposable, Injection Nozzle,

Disposable, Silicon Carbide Abrasive Paper, Wiping
Cloth, 1/2 Inch Surgical Rubber or Plastic Tubing
ZZ-T-831.

(2) Disbond Repair Procedure.

(a) Remove dirt, grease and aircraft fluids

from repair area as described in para-
graph 6-5.

DO NOT use oil or oil based materials

as NDI couplants on advanced composite
components. Use only water or water based
materials. Disbonds may result and loss of
structural integrity may occur.

(b) Define the extent of the disbond using

NDI according to paragraph 5-2 and the
system specific technical manual. Lay
out the damage as described in para-
graph 7-4.

(c) Remove NDI couplant by wiping with

clean, water moistened wiping cloth.

(d) Drill 1/8 inch diameter holes at each

Figure 7-39. Process Flow Diagram for Disbond
Repair
(1) Facilities, Equipment and Materials. The
following equipment and materials are required: Pres-
sure Regulator, Vacuum Cleaner, HEPA Filter, Drill
Motor, 2000 RPM, Twist or Brad Point Drill, Car-
bide, 1⁄8 Inch Diameter, Drill Stop (Common Support
Equipment), Injection Gun, Metallic Retainer Barrel,
2 1/2 Ounce, Flash breaker Tape, Adhesive, Liq-
uid (See System Specific Technical Manual), Injection
end of the disbond. Minimum spacing
between holes is 1/2 inch. The holes
should be through the disbonded skin
and into the core. Use a drill stop to
ensure proper drill depth.
(e) Vacuum clean dust and debris from
holes.
(f) Verify that a leak path exists between
the disbond and the holes drilled using
the following procedure (see figure
7-40).

7-66

Figure 7-40. Verification of Leak Path: Disbond Repair
1 Fit injection nozzles into the holes
at each end of the delamination.
Tape over intermediate holes with
flash breaker tape.
2 Attach a piece of tubing to one noz-
zle and submerge the other end in
a container of water.
3 Attach other nozzle to sealant gun
cartridge without plunger and place
cartridge in sealant gun. Attach a
regulated source of compressed air
to sealant gun.
Air pressure must not exceed 20 psi.
4 Apply pressure with air regulator
set for 20 psi through sealant gun
into the disbond.
5 Check water for bubbles to make
sure airflow exists. If airflow exists
go to (g) below. If airflow does not
exist, go to step 6 and 7 below.
TM 1-1500-204-23-11
6 Tape over existing holes and rein-
spect using NDI to map disbonded
area.
7 Repeat step 4 to step 6 above. If
airflow still does not exist, proceed
to paragraph 7-5.
(g) Remove nozzle and tape from holes.
(h) Ensure no moisture is present. If
moisture is present, perform moisture
removal per paragraph 6-6.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
7-67
TM 1-1500-204-23-11
(if required) and all necessary vacuum bag
materials prior to mixing resin.
NOTE
Refer to paragraph 6-17, Resin Preparation
and Use, for the proper measuring and mixing
procedures.
Figure 7-41. Disbond Repair
1 Pour adhesive into injection car-
tridge. Attach nozzle.
2 Tape over intermediate injection
holes with flash breaker tape.
3 Attach a regulated source of com-
pressed air to sealant gun. Set air
regulator for 20 psi and inject adhe-
sive, using sealant gun and noz-
zle, into one hole and fill until adhe-
sive flows clear from another hole.
Remove tape from one hole at a
time. Inject adhesive into each hole
until it flows freely from the other
holes and is free of bubbles.
4 Wipe off excess adhesive with
clean, dry wiping cloth.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
7-68
(i) Prepare the amount of resin required to
fill the disbond/repair volume. Prepare
the adhesive per paragraph 6-17.
(j) Inject Adhesive (see figure 7-41).
(k) Cure Adhesive.
1 Tape over all injection holes with
flash breaker tape.
2 Using a clamping device, release
film, and backing plates, apply
pressure to the repair area.
3 Invert the component so that adhe-
sive may fill the disbond area and
not flow down into honeycomb
core. Inverting the component may
cause some adhesive to flow out
of taped injection holes. A small
amount of outflow is acceptable. If
outflow becomes excessive, cover
the area with release film and tape
a metal plate beneath the area.
Allow adhesive to set at ambient
temperature for a minimum of 8
hours. As an alternative, the adhe-
sive/filler may be set using a heat
source.

Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
4 Cure adhesive using the cure
cycle in the system specific tech-
nical manual or specified by the
adhesive manufacturer per engi-
neering.. The component may be
placed right side up after the adhe-
sive has set. Bag according to
paragraph 6-18 and cure per para-
graph 6-19. If room temperature
cure is used, allow to dwell at room
temperature for a minimum of 5
days.
5 After cure remove tape and release
film (if used) or debag.
(l) Reinspect the disbonded area using
NDI.
(m) If the disbond still exists after repair,
refer to the system specific technical
manual to determine if damage is within
negligible damage limits or penetration
damage limits.
1 If disbond is not within penetration
damage limits, contact engineering
for disposition.
2 If disbond is within penetration
damage limits, repair in accor-
dance with paragraph 7-5.
3 If disbond is within technical man-
ual limits for negligible damage,
seal per step (n) below.
(n) Seal the injection holes by repairing the
laminate according to the system spe-
cific technical manual and paragraph
7-4. Any of the methods for laminate
repair; cocured, cobonded or secon-
darily bonded, may be utilized for skin
repair.
(o) Apply finish system in accordance with
paragraph 7-12b or the system specific
technical manual.
TM 1-1500-204-23-11
i. Skin to Closure Member Disbond and Delami-
nations. This repair is applicable to disbonds and
delaminations between a composite skin and a com-
posite closure member which are open to the part
edge. The closure member may be a channel, rib, or
spar; however, this procedure applies to nonmetallic
closure members only. Disbonds between composite
skin and metallic substructure members require engi-
neering disposition due to potential for contamination
or corrosion of the metallic member. Additional sur-
face preparation of the metal may also be required.
This repair is usually limited to disbonds not larger
than 4 inches in length which are contained within
1/2 inch of the part edge. Refer to the system spe-
cific technical manual for damage limits. This repair
procedure is not necessarily applicable to a partic-
ular weapon system. The applicability of this repair
depends upon additional factors such as loading con-
ditions and laminate thickness. Consult the system
specific technical manual or engineering for further
guidance. Refer to figure 7-42 for the Process Flow
Diagram for Skin to Closure Member Disbond and
Delamination Repair.
Figure 7-42. Process Flow Diagram for Skin to
Closure Member
(1) Facilities, Equipment and Materials. The
following equipment and materials are required:
Heat Lamp, Clamps, Temperature/Vacuum Con-
troller, Syringe, Hypodermic, Needles, Hypodermic,
20 Gauge, 1 1/2 Inch, Flash breaker Tape, Adhesive,
Liquid (See System Specific Technical Manual), Sol-
vent, Silicon Carbide Abrasive Paper, Wiping Cloth,
Release Film.
7-69
TM 1-1500-204-23-11
(2) Skin to Closure Member Disbond and
Delamination Procedure.
(a) Remove dirt, grease and aircraft fluids
from repair area as described in para-
graph 6-5.
DO NOT use oil or oil based materials
as NDI couplants on advanced composite
components. Use only water or water based
materials. Disbonds may result and loss of
structural integrity may occur.
(b) Define the extent of the disbond using
NDI according to paragraph 5-2 and the
system specific technical manual. Lay
out the damage as described in para-
graph 6-4.
(c) Remove NDI couplant by wiping with
clean, water moistened wiping cloth.
(d) Flush the disbond/delamination with
solvent using a hypodermic syringe.
Allow solvent to evaporate a minimum
of 30 minutes.
(e) Dry the repair area as described in para-
graph 6-6 for a minimum of 1 hour or as
directed by the system specific techni-
cal manual, at 150 (±10) ºF using a heat
lamp or other suitable heat source.
Monitor the repair area temperature to avoid
excessively heating it, as excessive heat can
shorten the pot life of the resin and may
7-70
cause it to exotherm. Consult the system
specific technical manual or engineering for
the proper heating temperature.
(f) Heat the delaminated/disbonded area
using a heat lamp as described in para-
graph 6-19h to the temperature listed
in the system specific technical manual.
Monitor temperature to ensure the max-
imum temperature limit is not exceeded.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
NOTE
Refer to paragraph 6-17, Resin Preparation
and Use, for the proper measuring and mixing
procedures.
(g) Prepare the amount of resin required to
fill the disbond/repair volume. Prepare
the adhesive per paragraph 6-17.
(h) Inject Adhesive (see figure 7-43).
 TM 1-1500-204-23-11

Figure 7-43. Skin to Closure Member Disbond Repair

7-71
TM 1-1500-204-23-11
1 Pour adhesive into hypodermic
syringe. Attach needle.
2 Maintain part at the specified injec-
tion temperature.
3 Inject adhesive into dis-
bond/delamination. Allow the
adhesive to flow until it is free of
bubbles.
4 Remove heat lamp. Wipe off
excess adhesive with clean, dry
wiping cloth.
5 Cover the injection area with flash
breaker tape.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
Too much pressure using a clamping device
may damage the sandwich panel.
(i) Apply pressure using clamps, release
film and backup plates. See paragraph
6-19h and figure 7-43. Allow adhesive
to cure or set at according to the sys-
tem specific technical manual. Heat
may be applied as required using an
approved heat lamp or other approved
source. Operate heat lamps per para-
graph 6-19h. If room temperature cure
is used, remove clamp, release film
and backup plate after a minimum of 8
hours. Allow to dwell at room tempera-
ture for a minimum of 5 days.
(j) Remove any resin flash, deburr, and
clean up the repair area.
(k) Reinspect the disbonded/delaminated
area using NDI.
7-72
1 If no disbond/delamination exists
after repair, or delamination is
within system specific technical
manual limits for negligible dam-
age, refinish per step (l) below.
2 If disbond/delamination exceeds
negligible damage limits, contact
engineering for disposition.
(l) Refinish.
1 Sand the area smooth with 180 grit
abrasive paper. Vacuum sanding
dust from repair area. Wipe with
clean, dry wiping cloth.
2 Apply finish system in accordance
with paragraph 7-13b or the system
specific technical manual.
7-9. EDGE DAMAGE. Some unique methods are
available for repairing panel edges depending upon
the extent of damage and the type of structure. For
solid laminates, very small repairs may simply require
fairing out the damaged area. Larger repairs for
delaminations may require resin injection or scarfing
and rebuilding of the area. When working with hon-
eycomb panels, the repairs may be similar depending
upon the panel edge configuration. If the extent of
the damage includes the honeycomb core itself, core
replacement techniques must be used in accordance
with paragraph 7-5, Sandwich Damage.
For repairs requiring fairing, scarfing, core replace-
ment, resin injection, and/or laminate rebuilding, pro-
cedures in the applicable section of this technical
manual may be followed. Customizing of the pro-
cesses as they apply to panel edges will be required,
consideration for factors such as envelope bagging,
forming repair plies over the edge, and fastener holes
in the repair area. The following limitations and pro-
cedures provide for repair of composite edge damage.
Composite edge damage includes both delamination
and penetration. The edge damage occurs along the
edges of composite doors, panels, etc. The defect
is open to an edge (see figure 7-44).
 TM 1-1500-204-23-11

Figure 7-44. Repair to an Open Edge

7-73
TM 1-1500-204-23-11
a. Edge Damage Limitations. Edge damage lim-
itations are noted in the specific weapon system
technical manual. The following are limitations spe-
cific to fasteners.
(1) For edge damage that affects fasteners,
redrill holes and replace with proper grip
length fasteners. See paragraph 7-7 for
redrilling fastener holes.
(a) Damage limitations across any two
adjacent zones are provided in the sys-
tem specific technical manual.
(b) Fabricate external, filler, and internal
patches per system specific technical
manual repairable damage table.
b. Edge Damage Rebuild. This repair is applica-
ble when the damage limitations for paragraph 7-8(g),
resin injection of edge delamination repair, have been
exceeded. A scarf joint is incorporated to reduce
inner moldline protrusion for fit up with mating part
surfaces. If fit up is not a consideration, the scarf
joint is unnecessary and should not be used. Edge
damage requiring rebuild in other than lightly loaded
areas (such as hinge locations or load bearing fas-
tener holes) may require engineering disposition and
generally is forwarded to depot for repair. This repair
procedure is not necessarily applicable to a partic-
ular weapon system. The applicability of this repair
depends upon additional factors such as loading con-
ditions and laminate thickness. Consult the system
specific technical manual or engineering for further
guidance. Refer to figure 7-45 for the Process Flow
Diagram for Edge Damage Rebuild.
Figure 7-45. Process Flow Diagram for Edge
Damage Rebuild
7-74
(1) Facilities, Equipment and Materials. The
following equipment and materials are required: Vac-
uum Cleaner, HEPA Filter, Dual Action Sander or 90
degree die-grinder and sanding mandrel, 90 Degree
Router Motor, 20,000 RPM, 0 Degree Router Motor,
20,000 RPM, Overhose Assembly, Router Holder,
Sanding Disks, 80, 150 & 180 Grit, 1.0 & 2.0 Inch
Diameter, Sanding Disk Holder, Cutting Wheel, Dia-
mond Coated, 80 Grit, 1.0 Inch Diameter, Heat Blan-
ket, Temperature/Vacuum Controller, Scissors, Adhe-
sive Comb, Silicon Carbide Abrasive Paper, Flash
breaker Tape, Wiping Cloth, Spatula, Adhesive, Liq-
uid (See System Specific Technical Manual), Adhesive,
Paste (See System Specific Technical Manual), Vac-
uum Bag Repair Materials Kit, Patch (See System
Specific Technical Manual), Dry Woven Cloth (See
System Specific Technical Manual), clamp, temporary
fasteners.
(2) Edge Damage Rebuild Procedure.
(a) Remove dirt, grease and aircraft fluids
from repair area as described in para-
graph 6-5.
DO NOT use oil or oil based materials
as NDI couplants on advanced composite
components. Use only water or water based
materials. Disbonds may result and loss of
structural integrity may occur.
(b) Define the extent of the disbond using
NDI according to paragraph 5-2 and the
system specific technical manual. Lay
out the damage as described in para-
graph 6-4.
(c) Remove NDI couplant by wiping with
clean, water moistened wiping cloth.
(d) Damage Removal.
1 Cut the damaged skin on both
moldline surfaces along the dam-
age layout line defined above using
a 90 degree router motor and a
diamond coated cutting wheel as
described in paragraph 6-4.
2 Remove damaged skin material.
(e) Remove paint from skin in the repair
area by sanding as described in para-
graph 6-1.
(f) Vacuum and wipe with clean, dry wiping
cloth to remove dust and debris.

(g) Machine Repair Joint. For this repair,
interference between an externally
bonded patch on the part IML surface
and the mating surface on the aircraft
necessitates the use of a flush repair.
Select a scarf joint due to ease of
machining.
1 Machine a scarf joint on the IML
skin only. In the edge band area,
stop the scarf joint at the IML to
OML adhesive bondline. Use a
scarf slope as specified in the sys-
tems specific technical manual.
Refer to paragraph 6-15.
2 Inspect the scarf surface as
described in the criteria of para-
graph 6-15.
(h) Dry the repair area to remove subsur-
face moisture using per paragraph 6-6.
Use an envelope vacuum bag. Operate
the oven using the guidelines provided
in paragraph 6-6.
(i) Clean per paragraph 6-5. Handle the
prepared surface of the part wearing
powder free latex gloves until after
patch/filler application is complete. If
patch/filler is not to be applied immedi-
ately, cover with clean barrier material
and secure with preservation tape to
prevent contamination.
Part to patch alignment must be main-
tained within ±2 degree. Fabricated com-
posite patches are orientation sensitive from
a strength standpoint. Incorrect alignment
of part and patch during layup will result in
reduced strength and loss of structural integrity
may occur.
NOTE
If part curvature precludes the use of a
pre-cured patch for the OML patch, a wet layup
patch must be fabricated using an undamaged
part as a tool.
(j) Fabricate and bond OML repair patch
according to paragraph 7-6. Refer to
the system specific technical manual for
patch selection.
(k) Calculate the number of filler patch plies
required per system specific technical
manual.
TM 1-1500-204-23-11
Pressure must be applied to adhesive within
pot life of the resin. For ambient temperatures
in excess of 90 °F, decrease this time by 50%.
An unsatisfactory repair will result if the resin
gels before adequate pressure is applied and
may result in loss of structural integrity. Select
and prepare a heat blanket (if required) and
all necessary vacuum bag materials prior to
mixing resin.
Failure to observe the correct number of repair
plies, the correct repair ply orientation, the
correct repair ply overlap and removal of all
pieces of vacuum bagging film will reduce the
strength of the repair and may result in the
loss of structural integrity.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
(l) Fabricate & cure the filler patch and
inner patch per the system specific tech-
nical manual and paragraph 6-16.
(m) Using the part as a guide, edge trim
the OML and IML patches according
to paragraph 6-8 to match part dimen-
sions.
NOTE
When fastener holes are affected, redrill fas-
tener holes.
(n) Drill fastener holes, if required, in accor-
dance with the system specific technical
manual and paragraph 6-8.
(o) Vacuum and wipe with clean, dry wiping
cloth to remove dust and debris.
(p) NDI Patch Bond(s).
1 Visually inspect adhesive squeeze
out at patch edge as described in
paragraph 5-2. See figure 6-45.
2 Perform NDI of patch to skin and
patch to filler bond areas to verify
bondline integrity.
(q) If applicable, repair lightning mesh per
paragraph 7-12 and the system specific
technical manual.
7-75
TM 1-1500-204-23-11

DO NOT sand into laminate near patch edge

when sanding adhesive squeeze out.

(r) Refinish.

1 Sand the area smooth with 180 grit

abrasive paper. Vacuum sanding
dust from repair area. Wipe with
clean, dry wiping cloth to remove
sanding residue.

2 Apply finish system in accordance

with paragraph 7-13b or the system
specific technical manual.

c. Trailing Edge Repair. This repair is applicable

to structure consisting of composite skins bonded
to composite ribs with damage to the trailing edge
corner of the assembly. The procedure provided is
for a trailing edge corner repair but is also applicable
to a full trailing edge. This repair procedure is
not necessarily applicable to a particular weapon
system. The applicability of this repair depends
upon additional factors such as loading conditions
and laminate thickness. Consult the system specific
technical manual or engineering for further guidance.
Refer to figure 7-46 for the Process Flow Diagram
for Flush Corner Repair.

Figure 7-46. Process Flow Diagram for Flush

Corner Repair

7-76

(1) Facilities, Equipment and Material. follow-
ing equipment and materials are required: Vacuum
Cleaner HEPA Filter, Dual Action Sander, Drill Motor,
2000 RPM, Drill Bit, 1⁄8 Inch Diameter, 90 Degree
Router Motor, 20,000 RPM, 0 Degree Router Motor,
20,000 RPM, Overhose Assembly, Router Holder,
Temporary Fasteners, Sanding Disks, 80, 150 &
180 Grit, 1.0 & 2.0 Inch Diameter, Sanding Disk
Holder, Repair Rib Tool (Local Manufacture), Cutting
Wheel, Diamond Coated, 80 Grit, 1.0 Inch Diame-
ter, Clamps, Heat Blanket, Temperature/Vacuum Con-
troller, Weights, Shot Bags, Marking Pen, Scissors,
Heat Lamp, Adhesive Comb, DVD tool, Silicon Car-
bide Abrasive Paper, Wiping cloth, Spatula, Adhesive,
TM 1-1500-204-23-11
Liquid (See System Specific Technical Manual), Adhe-
sive, Paste (See System Specific Technical Manual),
Release Liquid, Vacuum Bag Repair Materials Kit,
High Temperature Tape, Dry Woven Cloth, (See Sys-
tem Specific Technical Manual), Patch (See System
Specific Technical Manual), Release Film, Acetate,
Clear, Aluminum Sheet Stock, 0.063 inches or thicker
(Local Procurement).
(2) Trailing Edge Repair Procedure. Typical
steps required to rebuild damaged corners are shown
in figure 7-47.
7-77
TM 1-1500-204-23-11

Figure 7-47. Flush Corner Repair Sequence (Only Bonding on Upper Moldline is Shown for Clarity)
(Sheet 1 of 2)

Figure 7-47. Flush Corner Repair Sequence (Only Bonding on Upper Moldline is Shown for Clarity)
(Sheet 2 of 2)

7-78

(a) Remove dirt, grease and aircraft fluids
from repair area as described in para-
graph 6-5.
DO NOT use oil or oil based materials
as NDI couplants on advanced composite
components. Use only water or water based
materials. Disbonds may result and loss of
structural integrity may occur.
(b) Define the extent of the disbond using
NDI according to paragraph 5-10 and
the system specific technical manual.
Lay out the damage as described in
paragraph 6-4.
(c) Remove NDI couplant by wiping with
clean, water moistened wiping cloth.
(d) Damage Removal.
1 Cut through the rib and the dam-
aged skin on both moldline sur-
faces along the damage layout line
defined above. Use a 90 degree
router motor and a diamond coated
cutting wheel as described in para-
graph 6-4.
2 Remove damaged rib and skin
material.
(e) Remove paint from skin in the repair
area by sanding as described in para-
graph 6-1.
(f) Vacuum and wipe with clean, dry wiping
cloth to remove dust and debris.
(g) Fabricate Repair Rib.
1 Cut one piece of dry woven cloth
large enough to provide enough
plies of the required ply orienta-
tion. The required repair rib length
needs to provide the required over-
lap between the repair rib and the
parent rib. Make the rib twice this
required length to allow for trim-
ming and for fabrication of two rib
spacers. Size rib caps 1.0 inch
wider than parent rib cap for trim-
ming.
2 Fabricate a cutting template for
repair rib plies based upon the
TM 1-1500-204-23-11
above dimensions using the proce-
dures described in paragraph 5-6f.
Use the ply orientation specified in
the system specific technical man-
ual.
Figure 7-48. Repair Rib Layup and Tool
3 Prepare the Repair Rib Tool. If a
tool is not available, fabricate a tool
from a wood block as shown in fig-
ure 7-48. Use an identical undam-
aged spare part to obtain dimen-
sions for fabricating tool.
a Lightly sand the surface
of the tool to remove any
protrusions. Wipe sanded
area with a clean, dry wiping
cloth to remove sanding
residue.
b Tape a layer of release film
over the layup tool. The
release film should be several
inches larger than the largest
ply.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
7-79
TM 1-1500-204-23-11
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
4 Prepare liquid adhesive as
described in paragraph 6-17. Refer
to the system specific technical
manual for the amount of resin to
use for each square foot of cloth.
5 Impregnate woven carbon cloth per
paragraph 6-16.
6 Using the cutting template manu-
factured above, cut impregnated
plies as described in paragraph
6-16.
Failure to observe the correct number of repair
plies, the correct repair ply orientation, the
correct repair ply overlap and removal of all
pieces of vacuum bagging film will reduce the
strength of the repair and may result in the
loss of structural integrity.
7 Layup the plies using the Flat Ply
Collation Technique described in
paragraph 6-16.
8 Apply the layup to the DVD tool and
perform debulking using the debulk
cycle per system specific techni-
cal manual. Refer to the system
specific technical manual for the
type and number of bleeder plies
required.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
9 Form the DVD layup to the repair
rib tool, vacuum bag the lay-up to
the tool, and pre-cure the laminate
according the system specific tech-
nical manual and paragraph 6-18
and paragraph 6-19.
10 Following cure, disassemble vac-
uum bag and carefully remove rib.
7-80
11 Perform NDI of rib according to the
system specific technical manual
and paragraph 5-2.
12 Using a 90 degree router motor and
a diamond coated cutting wheel,
trim repair rib length to ensure the
required overlap is achieved. Save
excess material for the rib spacer.
(h) Fabricate Splice Plates.
1 Splice plates shall be at least 3
inches in width to ensure a mini-
mum overlap exists for splice plate
to parent skin bond and splice plate
to skin spacer bond.
2 From pre-cured patch material, cut
two laminate pieces to the shape
illustrated in figure 7-47, View B.
Use a 90 degree router motor and
diamond coated cutting wheel.
3 Drill three 1⁄8 inch diameter holes
in both splice plates for temporary
fastener installation. Centerline of
holes shall be 0.75 inch from edge
of splice plate ( figure 7-47, View
B).
4 Remove peel ply from splice plates.
(i) Fabricate Rib Spacers. From the
excess repair rib material saved above,
cut two laminate pieces same width as
the parent rib and as long as necessary
to ensure a good fit up with the parent
rib. Use a 90 degree router motor and
diamond coated cutting wheel.
(j) Fabricate Skin Spacers. From
pre-cured patch material, cut two lam-
inate pieces to the shape illustrated in
figure 7-47, View E.
(k) Allow pieces to be 1⁄4 inch larger than
the part. Use a 90 degree router motor
and diamond coated cutting wheel. Do
not taper edge.
(l) Drill Holes in the Parent Skin.
1 Lay splice plate on upper moldline
(UML) skin and mark the skin for
drilling.
2 Mate drill 1⁄8 inch diameter holes
into parent skin per paragraph 6-8.

3 Repeat steps 1 and 2 for lower
moldline (LML) surface.
(m) Prepare Temporary Fasteners.
DO NOT allow release liquid to come into
contact with repair or repair details. Disbonds
may result in loss of structural integrity.
1 Apply release liquid to temporary
fasteners in areas that will be in
contact with the splice plate during
adhesive cure.
2 Cure applied release liquid per
manufacturer’s instructions.
(n) Ensure Proper Fit-Up. Use temporary
fasteners to fasten together the parent
skin and splice plate.
(o) Mark Splice Plate for Alignment.
1 While clamped-up, use a marker
to mark the splice plate where the
splice plate extends past the par-
ent skin drawing the lines pointing
toward the drilled holes.
2 While clamped-up, apply flash
breaker tape to the part of the
splice plate which extends past the
parent skin. Trim off any excess
tape.
(p) Repeat step (m) through (o) for LML sur-
face.
(q) Prepare mating surfaces of splice
plates and UML and LML inner surfaces
for bonding by lightly hand sanding
with 150-180 grit abrasive paper as
described in paragraph 6-7. Handle
prepared surfaces wearing powder free
latex gloves until patch bonding is com-
plete. If splice plates are not to be
bonded immediately, cover them and
the repair area with clean barrier mate-
rial and secure with tape to prevent
contamination.
(r) Bond Splice Plate to UML Inner Surface
(see figure 7-47, View B).
TM 1-1500-204-23-11
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
1 Prepare adhesive as described in
paragraph 6-17.
NOTE
Use scrim cloth if required by the system
specific technical manual.
2 Apply a thin layer of adhesive on
the UML inner surface using a
spatula and adhesive comb (where
practical) per paragraph 7-6.
3 Apply a thin layer of adhesive on
the splice plate in the area that
mates with UML skin. Use a spat-
ula and adhesive comb per para-
graph 7-6.
4 Align the drilled holes of the splice
plate with the drilled holes in the
parent skin. Fasten with temporary
fasteners.
5 Remove excess squeeze out.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
6 Allow adhesive to set at room tem-
perature for a minimum of 8 hours.
As an alternate, the adhesive/filler
may be set using a heat lamp with
the cure cycle from the system
specific technical manual. Operate
heat lamps per paragraph 6-19h.
7-81
TM 1-1500-204-23-11
7 Remove temporary fasteners.
8 Repeat steps 1 through 7 for LML
surface.
(s) Prepare parent rib inner rib surface,
repair rib and rib spacers for bonding by
lightly hand sanding with 150-180 grit
abrasive paper as described in para-
graph 6-7. Handle prepared surfaces
wearing powder free latex gloves until
patch bonding is complete. If repair rib
and rib spacers are not to be bonded
immediately, cover them and the repair
area with clean barrier material and
secure with preservation tape to pre-
vent contamination.
(t) Bond Together the Parent Rib, Repair
Rib and Rib Spacer (see figure 7-47,
View C and View D).
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
1 Prepare of adhesive as described
in paragraph 6-17 .
NOTE
Use scrim cloth if required by the system
specific technical manual.
2 Apply a thin layer of adhesive on
repair rib and parent rib mating sur-
faces, using a spatula and adhe-
sive comb per paragraph 7-6.
3 Insert the repair rib into the parent
rib and align with edge of part.
7-82
4 Fasten with clamps (see figure
7-47, View C). See paragraph 6-19j
for use of clamps.
5 Apply a thin layer of adhesive on
the rib spacer and repair rib mating
surface, using a spatula and adhe-
sive comb per paragraph 7-6.
6 Lay rib spacer on UML surface of
repair rib.
7 Fasten with clamps (see figure
7-47, View D). See paragraph 6-19j
for use of clamps.
8 Remove excess squeeze out.
9 Repeat 5 through 8 for LML surface
of repair rib.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
10 Allow adhesive to set at room tem-
perature for a minimum of 8 hours.
As an alternate, the adhesive/filler
may be set using a heat lamp using
the cure cycle from the system
specific technical manual. Operate
heat lamps per paragraph 6-19h.
11 Remove clamps.
(u) Prepare Skin Spacer and Mating Sur-
faces for Bond. Remove peel ply from
spacer surface and tape from splice
plate. Prepare spacer and mating sur-
faces (splice plates and rib spacers)
for bonding by sanding with 150-180
grit abrasive paper as described in
paragraph 6-7. Handle prepared sur-
faces wearing powder free latex gloves
until patch bonding is complete. If skin
spacer is not to be bonded immediately,
cover it and the repair area with clean
barrier material and secure with preser-
vation tape to prevent contamination.
(v) Bond Skin Spacer to UML Surfaces
(see figure 7-47, View E).

Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
1 Prepare of adhesive as described
in paragraph 6-17.
NOTE
Use scrim cloth if required by the system
specific technical manual.
2 Apply tape to outer side of skin
spacer to facilitate anchoring to
parent skin.
3 Apply a thin layer of adhesive in
patch bond area on UML surface of
part using a spatula and adhesive
comb, per paragraph 7-6. Extend
the adhesive 1⁄4 inch past the patch
bond periphery.
4 Apply a thin layer of adhesive in
patch bond area on UML surface of
part using a spatula and adhesive
comb, per paragraph 7-6. Extend
the adhesive 1⁄4 inch past the patch
bond periphery.
5 Lay the skin spacer on top of rib
spacer and splice plate, flush with
the parent skin. Anchor with tape.
6 Tape release film over skin spacer.
7 Apply pressure with caul plate and
shot bags as illustrated in figure
7-47, View E. Allow adhesive to set
at room temperature for a minimum
of 8 hours.
8 Remove caul plate and shot bags.
TM 1-1500-204-23-11
9 Remove tape and squeeze out.
(w) Prepare a mixture of chopped fibers and
paste adhesive per paragraph 6-17,
with mrF = 14. Fill in trailing edge with
mixture.
(x) Repeat steps (v)1 through (v)8 for LML
surface.
(y) Machine edges of skin spacer flush with
part according to paragraph 6-8. (See
figure 7-47, View F).
(z) Install a vacuum bag over the patch
bond area per paragraph 6-18 except
omit heat blanket and caul plate. Apply
a minimum of 20 inches of mercury
without audible leaks. If this cannot
be achieved, remove vacuum bag and
repair leaks by applying additional paste
adhesive to skin spacer/part surface
gap. Repeat leak check as required.
(aa) Dry the repair area to remove subsur-
face moisture per paragraph 6-6. Use
a heat blanket and vacuum bag as
described in paragraph 6-18.
(ab) Cut UML and LML patches from the
patch material specified in the system
specific technical manual according to
paragraph 6-8. Patch periphery should
extend onto part UML/LML surface a
constant distance beyond original dam-
age cleanup edge to provide required
patch overlap.
(ac) Remove peel ply from both sides of
patch if required. Use care to not inad-
vertently remove fibers from patch dur-
ing peel ply removal.
(ad) Taper edge of patches using a 90
degree router motor and an 80 grit
sanding disk to the dimensions shown
in figure 7-10.
(ae) Prepare patches and mating surface
of skin spacers for bonding by lightly
hand sanding with 150-180 grit abra-
sive paper as described in paragraph
6-7. Handle prepared surfaces wearing
powder free latex gloves until patch
bonding is complete. If patches are not
to be bonded immediately, cover them
and the repair area with clean barrier
material and secure with tape to prevent
contamination.
7-83
TM 1-1500-204-23-11
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
1 Prepare adhesive as described in
paragraph 6-17.
NOTE
Use scrim cloth if required by the system
specific technical manual.
2 Apply tape to outer side of patch to
facilitate anchoring to parent skin.
3 Apply a thin layer of adhesive in
patch bond area on UML surface of
part using a spatula and adhesive
comb, per paragraph 7-6. Extend
the adhesive 1⁄4 inch past the patch
bond periphery.
4 Apply a thin layer of adhesive on
bond surface of patch using a spat-
ula and adhesive comb, per para-
graph 7-6.
Part to patch alignment must be main-
tained within ±1 degree. Fabricated com-
posite patches are orientation sensitive from
a strength standpoint. In-correct alignment
of part and patch during layup will result in
reduced strength and loss of structural integrity
may occur.
5 Apply bond side of patch contain-
ing adhesive onto part UML surface
containing adhesive. Ensure patch
is aligned on part, even with the
part dimensions (see figure 7-47,
View G). Anchor with tape.
7-84
6 Repeat steps 1 through 5 for LML
surface.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
(af) Bond Patches to UML and LML Sur-
faces (see figure 7-47, View G).
1 Layup vacuum bag and heat blan-
ket as described in paragraph 6-18.
2 Cure UML and LML patch bond
adhesive as described in para-
graph 6-19 using the appropriate
cure cycle from the system specific
technical manual.
3 Disassemble the vacuum bag and
the heat blanket.
4 Remove tape. Sand adhesive
squeeze out flush with edge of part.
(ag) NDI Patch Bonds.
1 Visually inspect adhesive squeeze
out at patch edge as described in
paragraph 5-2. (See figure 6-45).
2 Perform NDI of patch to skin and
patch to filler bond areas to verify
bondline integrity.
(ah) If applicable, repair outer lightning mesh
according to paragraph 7-12 and the
system specific technical manual.
(ai) Refinish.
DO NOT sand into laminate near patch edge
when sanding adhesive squeeze out.
1 Sand the area smooth with 180 grit
abrasive paper. Vacuum sanding
dust from repair area. Wipe with
clean, dry wiping cloth to remove
sanding residue.
2 Apply finish system in accordance
with paragraph 7-13b or the system
specific technical manual.

7-10. FASTENER HOLE REPAIR. The following pro-
cedures are used to repair damaged fastener holes in
load-bearing structures. Materials and repair details
are described in system specific technical manuals.
If specific repair materials are not identified, match
the repair to the existing structure (i.e., carbon repair
on carbon structures).
a. Fastener Repair. This procedure is used to
remedy small punctures or incorrectly located fastener
holes in a composite laminate. This repair procedure
is not necessarily applicable to a particular weapon
system. The applicability of this repair depends
upon additional factors such as loading conditions
and laminate thickness. Consult the system specific
technical manual or engineering for further guidance.
Refer to figure 7-49 for the Process Flow Diagram
for Fastener Repair.
Figure 7-49. Process Flow Diagram for Fastener
Repair
(1) Facilities, Equipment and Materials. The
following equipment and materials are required: Vac-
uum Cleaner, HEPA Filter, Fastener Installation Equip-
ment, Drill Motor, 2000 RPM, Drill Guide, Drill Bit, Sil-
icon Carbide Abrasive Paper, Solvent, Cotton Tipped
Applicator, Fastener (See System Specific Technical
Manual).
(2) Fastener Repair Procedure.
Distance of repair fastener from adjacent
fasteners and substructure shall be a minimum
of two times the diameter of the repair fastener.
(a) Remove dirt, grease and aircraft fluids
from repair area as described in para-
graph 6-5.
(b) Lightly abrade the surface area around
the entrance (and exit if possible) of the
puncture or fastener hole with 150 to
TM 1-1500-204-23-11
180 grit sandpaper, see paragraph 6-3
for paint removal steps. Abrade 1 inch
beyond the hole.
(c) Dry the repair area to remove subsur-
face moisture per paragraph 6-5.
(d) Determine the hole size. For non-round
holes, determine the maximum width of
the damage.
Installation of an aluminum fastener is pro-
hibited in carbon fiber laminates.
(e) Select a repair fastener according to
the system specific technical manual.
The repair fastener diameter should be
slightly larger than the damaged/mislo-
cated hole.
(f) Ream the damaged/mislocated hole
true and round for the diameter of the
repair fastener.
(g) Vacuum to remove sanding and ream-
ing residue.
(h) Using cotton-tipped applicators and
solvent, clean the reamed hole and
abraded part surface(s). Thoroughly
clean these areas with repeated wiping
until no residue is left on the applica-
tors. Allow the solvent to evaporate for
30 minutes.
(i) Install repair fastener according to para-
graph 3-4g.
b. Countersink Repair. This procedure is limited
to oversized, elongated, or damaged fastener hole
countersink areas only. Oversized, elongated, or
damaged countersinks that involve the fastener hole
in addition to the countersink area must be repaired
using one of the methods provided in paragraphs
7-10d,7-10e, 7-10g, or 7-10h. This repair procedure
is not necessarily applicable to a particular weapon
system. The applicability of this repair depends
upon additional factors such as loading conditions
and laminate thickness. Consult the system specific
technical manual or engineering for further guidance.
Refer to figure 7-50 for the Process Flow Diagram
for Countersink Repair.
7-85
TM 1-1500-204-23-11
Figure 7-50. Process Flow Diagram for
Countersink Repair
(1) Facilities, Equipment and Materials. The
following equipment and materials are required: Vac-
uum Cleaner, HEPA Filter, Weights, Shot Bags,
Clamps, Silicon Carbide Abrasive Paper, Wiping Cloth,
Adhesive, Liquid (See System Specific Technical Man-
ual), Release Film, Fabric (See System Specific Tech-
nical Manual), Aluminum Sheet Stock, 0.063 inches or
thicker (Local Procurement), Release Liquid, Cotton
Tipped Applicator, Solvent.
(2) Countersink Repair Procedure.
(a) Remove dirt, grease and aircraft fluids
from repair area as described in para-
graph 6-5.
(b) Define Damage. Visually inspect dam-
aged fastener hole countersink area to
ensure damage does not extend into
fastener hole.
(c) Prepare Surfaces For Filler Application.
1 Lightly sand countersink area using
180 grit abrasive paper to remove
sealant/paint and other foreign
debris, see paragraph 6-3 for paint
removal steps. Vacuum area to
remove sanding residue.
2 Clean fastener hole and counter-
sink area using a cotton tipped
applicator, wiping cloth and solvent.
Thoroughly clean the area with
repeated wiping until no residue is
left on the cotton tipped applica-
tor or the wiping cloth. Allow the
solvent to evaporate a minimum of
30 minutes, see paragraph 6-7 for
surface preparation steps.
3 Obtain the fastener used in the fas-
tener hole being repaired. Coat the
entire fastener with liquid release
agent. Apply a second coat, wait-
ing 15 minutes after each applica-
tion to ensure solvent in release
7-86
agent completely evaporates. Cure
per manufacturer’s instructions.
To prevent damage to part, ensure fastener
has been coated with release agent prior to
installation in fastener hole.
DO NOT allow release liquid to come into
contact with repair of repair details. Disbonds
may result in loss of structural integrity.
4 Insert the release agent coated
fastener into the hole containing
the damaged countersink until the
head is approximately 0.25 to 0.375
inch above surface of skin, see
paragraph for paint removal steps..
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
(d) Prepare a small quantity (25 grams) of
adhesive/chopped carbon fiber mixture
per paragraph 6-17, with mrF=5 (5 parts
by weight of chopped fiber).
(e) Apply Filler.
1 Apply filler to the countersink area
under the fastener head. Apply
sufficient material so that squeeze
out will occur when the fastener is
seated in position, see paragraph.
2 Apply filler to the countersink area
under the fastener head. Apply
sufficient material so that squeeze
out will occur when the fastener is
seated in position.

Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
(f) Set Filler.
1 Apply release film, a metal caul
plate and contact pressure to the
repair using either an external
weight or clamp.
2 Allow filler to set at room temper-
ature for 8 hours before removing
weights or clamps. If clamps were
used, the adhesive/filler may be set
using a heat lamp. Use the cure
cycle in the system specific techni-
cal manual to set the adhesive/filler.
Operate heat lamps per paragraph
6-19h.
3 Remove caul plate and release
film. Very carefully remove
installed fastener so as not to
cause damage.
(g) Refinish.
1 Sand the area smooth with 180 grit
abrasive paper. Vacuum sanding
dust from repair area. Wipe with
clean, dry wiping cloth to remove
sanding residue.
2 Apply finish system in accordance
with paragraph 7-13b or the sys-
tem specific technical manual. Use
care not to apply finish system in
fastener hole or countersink area.
c. Fill And Drill Repair. This repair is applicable
to damaged, misdrilled or elongated fastener holes.
It is limited to lightly loaded fastener holes used on
non-structural access covers and doors. For repairs
to load bearing fastener holes, use the potting, fabric
repair, swagged grommet or captive bushing method
per paragraphs 7-10d, 7-10e, 7-10f, or 7-10h. This
method uses a two-part resin filled with chopped
fibers to restore damaged fastener holes and part
surfaces. It is used to repair over-sized countersinks
and gouged surfaces which are caused by fastener
wear around the head and/or fastener removal. This
method is intended only for damage that does not
TM 1-1500-204-23-11
extend through the full thickness of the laminate.
This repair procedure is not necessarily applicable
to a particular weapon system. The applicability of
this repair depends upon additional factors such as
loading conditions and laminate thickness. Consult
the system specific technical manual or engineering
for further guidance. Refer to figure 7-51 for the
Process Flow Diagram for Fill and Drill Fastener Hole
Repair.
Figure 7-51. Process Flow Diagram for Fill and
Drill Fastener Hole Repair
(1) Facilities, Equipment and Materials. The
following equipment and materials are required: Vac-
uum Cleaner, HEPA Filter, Marking Pen, Weights, Shot
Bags, Clamps, Drill Motor, 2000 RPM, Drill Guide,
Drill Bit, Countersink Cutter, Piloted, Microstop Cage,
Silicon Carbide Abrasive Paper, Wiping Cloth, Spat-
ula, Adhesive, Liquid (See System Specific Technical
Manual), Release Film, Fabric (See System Spe-
cific Technical Manual), Aluminum Sheet Stock, 0.063
inches or thicker (Local Procurement), Cotton Tipped
Applicator, Solvent, Flash breaker Tape, Mylar.
(2) Fill and Drill Repair Procedure.
(a) Remove dirt, grease and aircraft fluids
from repair area as described in para-
graph 6-5.
DO NOT use oil or oil based materials
as NDI couplants on advanced composite
components. Use only water or water based
materials. Disbonds may result and loss of
structural integrity may occur.
(b) Inspect damaged fastener hole for
delaminations using NDI according to
paragraph 5-2 and the system specific
technical manual. If delaminations are
present, first repair the delaminations
per paragraph 7-10f.
7-87
TM 1-1500-204-23-11
(c) Remove NDI couplant by wiping with
clean, water moistened wiping cloth.
(d) Fabricate Mylar Template.
1 Establish the centerline of the fas-
tener hole using reference points
and lines marked on the part as
shown in figure 7-52, using a per-
manent ink marking pen. Ensure
the reference points are far enough
away from the fastener hole to not
be affected by the repair process.
Figure 7-52. Template Fabrication
2 Transfer the hole centerline and
the reference points to a piece of
Mylar. Use this Mylar as a guide in
redrilling the fastener hole follow-
ing filling.
(e) Prepare Fastener Hole For Filler Appli-
cation.
1 Lightly sand countersink area using
180 grit abrasive paper to remove
sealant, paint and other debris.
Vacuum area to remove sanding
residue. See paragraph 6-3 for
paint removal steps.
2 Dry the repair area to remove sub-
surface moisture using per para-
graph 6-6.
3 Clean fastener hole and counter-
sink area using a cotton tipped
applicator, wiping cloth and solvent.
Thoroughly clean the area with
repeated wiping until no residue is
7-88
left on the cotton tipped applicator
or the wiping cloth. Allow the sol-
vent to evaporate for a minimum of
30 minutes. See paragraph 6-7 for
surface preparation steps.
4 Seal the backside of the fastener
hole by securing release film and
an aluminum backup plate with
overlapped layers of flash breaker
tape as shown in figure 7-53.
Figure 7-53. Fastener Hole Sealing
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
5 Prepare a small quantity (30
grams) of adhesive/chopped fiber
mixture per paragraph 6-17 with
mrF = 5 (5 parts by weight of
chopped fiber). Ensure fiber is
chopped to 1/4 inch or smaller.
(f) Apply Filler.
1 Carefully apply the adhesive/fiber
mixture into the fastener hole and
fill to the top. Apply mixture in lay-
ered amounts to avoid air entrap-
ment.
2 Fair mixture with a spatula and
wipe off excess with clean, dry,
wiping cloth.

Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
NOTE
An optional method could be performed which
involves placing a vacuum cup over the
resin filled damaged area before curing. The
vacuum will remove any trapped air remaining
in the potting compound. When the air has
been removed, remove the cup and complete
the repair. Figure 3-25 includes a diagram of
a vacuum cup assembly.
Some potting compounds shrink during cure.
If using a mixture that is likely to shrink, build
compound slightly above the part surface.
(g) Set Filler.
1 Apply release film, a metal caul
plate and contact pressure to the
repair using either an external
weight, clamps or a vacuum bag.
2 Cure the repair using the cure cycle
from the system specific technical
manual and paragraph o. If an ele-
vated temperature cure is required,
use a heat lamp, heat blanket or
other heating equipment. Place a
thermocouple next to the repair on
the same side as the heat source.
If room temperature cure is used,
remove release film, caul plate, and
contact pressure after a minimum
of 8 hours. Allow to dwell at room
temperature for a minimum of 5
days.
(h) Redrill/Countersink Hole.
NOTE
If the resin is cured at room temperature,DO
NOT smooth or drill the hole for at least 24
hours after the resin sets.
TM 1-1500-204-23-11
1 Lightly sand any squeezed out filler
flush with part surface using 180
grit abrasive paper.
2 Using the template fabricated
above, carefully locate a drill guide
containing the correct drill bushing
for the hole to be redrilled. Secure
the drill guide to the part with a
clamp.
3 Redrill and countersink the
repaired fastener hole per para-
graph 6-8. If countersinking is
required, use a countersink micro
stop to prevent countersinking too
deep.
(i) Refinish.
1 Sand the area smooth with 180 grit
abrasive paper. Vacuum sanding
dust from repair area. Wipe with
clean, dry wiping cloth to remove
sanding residue.
2 Apply finish system in accordance
with paragraph 7-13b or the sys-
tem specific technical manual. Use
care not to apply finish system in
fastener hole or countersink area.
d. Potting Method. This repair is applicable to
repair misdrilled, oblong, and/or angled holes in addi-
tion to oversized countersinks and gouged surfaces.
This method uses a wet layup fabric plus a resin
filled with chopped fibers to restore damaged fastener
holes and part surfaces. This method is used to repair
minor damage to fastener holes that extends through
the full thickness of the laminate. The potting method
should not be used if the laminate surrounding the
damaged fastener holes is delaminated or damaged
in other ways. Refer to figure 7-54 for the Process
Flow Diagram for Potting Fastener Hole Repair.
A typical potted repair is shown in figure 7-55. This
repair procedure is not necessarily applicable to a
particular weapon system. The applicability of this
repair depends upon additional factors such as loading
conditions and laminate thickness. Consult the system
specific technical manual or engineering for further
guidance.
7-89
TM 1-1500-204-23-11
Figure 7-54. Process Flow Diagram for Potting
Fastener Hole Repair
Figure 7-55. Potted Fastener Hole Repair
(1) Facilities, Equipment and Material. The
following equipment and materials are required: Vac-
uum Cleaner, HEPA Filter, Marking Pen, Weights, Shot
Bags, Clamps, Drill Motor, 2000 RPM, Drill Guide,
Drill Bit, Countersink Cutter, Piloted, Microstop Cage,
Silicon Carbide Abrasive Paper, Wiping Cloth, Spat-
ula, Adhesive, Liquid (See System Specific Technical
Manual), Vacuum Bag Repair Materials Kit, Fabric
(See System Specific Technical Manual), Aluminum
Sheet Stock, 0.063 inches or thicker (Local Pro-
curement), Cotton Tipped Applicator, Solvent, Flash
breaker Tape, Mylar.
(2) Potting Fastener Hole Repair Procedure.
(a) Remove dirt, grease and aircraft fluids
from repair area as described in para-
graph 6-5.
DO NOT use oil or oil based materials
as NDI couplants on advanced composite
7-90
components. Use only water or water based
materials. Disbonds may result and loss of
structural integrity may occur.
(b) Inspect damaged fastener hole for
delaminations using NDI according to
paragraph 5-2 and the system specific
technical manual. If delaminations are
present, first repair the delaminations
per paragraph 7-10f.
(c) Remove NDI couplant by wiping with
clean, water moistened wiping cloth.
(d) Fabricate Mylar Template.
1 Establish the centerline of the fas-
tener hole using reference points
and lines marked on the part as
shown in figure 7-52, using a per-
manent ink marking pen. Ensure
the reference points are far enough
away from the fastener hole to not
be affected by the repair process.

2 Transfer the hole centerline and
the reference points to a piece of
Mylar. Use this Mylar as a guide in
redrilling the fastener hole follow-
ing filling.
(e) Prepare Fastener Hole For Filler Appli-
cation.
1 Lightly sand countersink area using
180 grit abrasive paper to remove
sealant, paint and other debris.
Vacuum area to remove sanding
residue. See paragraph 6-3 for
paint removal steps.
2 Dry the repair area to remove sub-
surface moisture using per para-
graph 6-6.
3 Clean fastener hole and counter-
sink area using a cotton tipped
applicator, wiping cloth and solvent.
Thoroughly clean the area with
repeated wiping until no residue is
left on the cotton tipped applicator
or the wiping cloth. Allow the sol-
vent to evaporate for a minimum of
30 minutes. See paragraph 6-7 for
surface preparation steps.
NOTE
For lightly loaded or secondary structure,
only one ply may be necessary. Refer to
the system specific technical manual for the
required number of plies.
(f) Prepare plies of repair fabric according
to paragraph 6-16 to overlay the repair.
Typically two or more overlay plies are
used on each side of a potted repair on
load-bearing structures.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Failure to observe the correct number of repair
plies, the correct repair ply orientation, the
correct repair ply overlap and removal of all
pieces of vacuum bagging film will reduce the
strength of the repair and may result in the
loss of structural integrity.
TM 1-1500-204-23-11
(g) Impregnate the repair plies with laminat-
ing resin. Apply two of the repair plies to
the exit side of the fastener hole. Orient
the repair plies per the system specific
technical manual in the same direction
as the original outer parent ply.
(h) Prepare a small quantity (30 grams)
of adhesive/chopped fiber mixture per
paragraph 6-17 with mrF = 5 (5 parts by
weight of chopped fiber). Ensure fiber
is chopped to 1/4 inch or smaller.
(i) Apply Filler.
1 Carefully apply the adhesive/fiber
mixture into the fastener hole and
fill to the top. Apply mixture in lay-
ered amounts to avoid air entrap-
ment.
2 Fair mixture with a spatula and
wipe off excess with clean, dry,
wiping cloth.
NOTE
Some potting compounds shrink during cure.
If using a mixture that is likely to shrink, build
compound slightly above the part surface.
(j) Apply the remaining repair plies,
impregnated in step (g), to the entrance
side of the fastener hole. Orient the
repair plies per the system specific
technical manual in the same direction
as the original outer parent ply. Work
out any air bubbles from both the upper
and lower plies.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 ºF, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select a heat blanket (if required)
and all necessary vacuum bag materials prior
to mixing resin.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
7-91
TM 1-1500-204-23-11
(k) Cure repair
1 Apply release film, metal caul
plates and contact pressure over
the repair area using either an
external weight, clamps or a vac-
uum bag. These plates should
extend 1 to 2 inches beyond the
repair area and will ensure even
pressure is applied to the repair.
2 Cure the repair using the cure cycle
from the system specific techni-
cal manual and paragraph 6-19.
If an elevated temperature cure is
required, use a heat lamp, heat
blanket or other heating equipment.
Place a thermocouple next to the
repair on the same side as the heat
source. If room temperature cure
is used, remove release film, caul
plate and contact pressure after a
minimum of 8 hours. Allow to dwell
at room temperature for a minimum
of 5 days.
(l) Redrill/Countersink Hole.
NOTE
If the resin is cured at room temperature, do
NOT smooth or drill the hole for at least 24
hours after the resin sets.
1 Lightly sand any squeezed out filler
flush with part surface using 180
grit abrasive paper.
2 Using the template fabricated
above, carefully locate a drill guide
containing the correct drill bushing
for the hole to be redrilled. Secure
the drill guide to the part with a
clamp.
3 Redrill and countersink the
repaired fastener hole per para-
graph 6-8. If countersinking is
required, use a countersink micro
stop to prevent countersinking too
deep.
(m) Refinish.
1 Sand the area smooth with 180 grit
abrasive paper. Vacuum sanding
dust from repair area. Wipe with
clean, dry wiping cloth to remove
sanding residue.
7-92
2 Apply finish system in accordance
with paragraph 7-13b or the sys-
tem specific technical manual. Use
care not to apply finish system in
fastener hole or countersink area.
e. Fabric Layup Repair. This repair is applicable
to repair damaged fastener holes when the surrounding
laminate is delaminated and/or damaged in other ways.
This repair procedure is not necessarily applicable to
a particular weapon system. The applicability of this
repair depends upon additional factors such as loading
conditions and laminate thickness. Consult the system
specific technical manual or engineering for further
guidance. Refer to figure 7-56 for the Process Flow
Diagram for Fabric Layup Fastener Hole Repair.
Figure 7-56. Process Flow Diagram Fabric Layup
Repair
(1) Facilities, Equipment and Materials. The
following equipment and materials are required: Vac-
uum Cleaner, HEPA Filter, Marking Pen, Weights, Shot
Bags, Clamps, Drill Motor, 2000 RPM, Drill Guide,
Drill Bit, 90 Degree Router Motor, 20,000 RPM, Sand-
ing Disks, 80 Grit, 1.0 Inch Diameter, Sanding Disk
Holder, Countersink Cutter, Piloted, Microstop Cage,
Silicon Carbide Abrasive Paper, Wiping Cloth, Spat-
ula, Adhesive, Liquid (See System Specific Technical
Manual), Vacuum Bag Repair Materials Kit, Fabric
(See System Specific Technical Manual), Aluminum
Sheet Stock, 0.063 inches or thicker (Local Pro-
curement), Cotton Tipped Applicator, Solvent, Flash
breaker Tape, Mylar.
(2) Fabric Layup Repair Procedure.
(a) Remove dirt, grease and aircraft fluids
from repair area as described in para-
graph 6-5.
(b) Inspect damaged fastener hole for
delaminations using NDI according to
paragraph 5-2 and the system specific
technical manual. If delaminations are

present, first repair the delaminations
per paragraph 7-10f.
DO NOT use oil or oil based materials
as NDI couplants on advanced composite
components. Use only water or water based
materials. Disbonds may result and loss of
structural integrity may occur.
(c) Remove NDI couplant by wiping with
clean, water moistened wiping cloth.
(d) Fabricate Mylar Template.
1 Establish the centerline of the fas-
tener hole using reference points
Figure 7-57. Fabric Layup Fastener Hole Repair
(f) Lightly abrade the surface area around
the entrance and exit sides of the fas-
tener hole with 180-grit sandpaper.
Abrade 1 inch beyond the cleanup area.
Vacuum the area to remove sanding
residue. See paragraph 6-3 for paint
removal steps.
(g) Dry the repair area to remove subsur-
face moisture using per paragraph 6-6.
(h) Clean fastener hole and countersink
area using a cotton tipped applicator,
wiping cloth and solvent. Thoroughly
clean the area with repeated wiping until
no residue is left on the cotton tipped
applicator or the wiping cloth. Allow
the solvent to evaporate for a minimum
of 30 minutes. See paragraph 6-7 for
surface preparation steps.
TM 1-1500-204-23-11
and lines marked on the part as
shown in figure 7-47, using a per-
manent ink marking pen. Ensure
the reference points are far enough
away from the fastener hole to not
be affected by the repair process.
2 Transfer the hole centerline and
the reference points to a piece of
Mylar. Use this Mylar as a guide in
redrilling the fastener hole follow-
ing filling.
(e) Taper sand the entrance side of the fas-
tener hole, typically 120 to 150 degrees
C/L of the fastener hole, as shown in fig-
ure 7-57. Vacuum the area to remove
sanding residue.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 ºF, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select a heat blanket (if required)
7-93
TM 1-1500-204-23-11
and all necessary vacuum bag materials prior
to mixing resin.
(i) Prepare a small quantity (30 grams) of
liquid adhesive per paragraph 6-17.
(j) Calculate the number of filler patch plies
required per system specific technical
manual.
(k) Prepare plies of repair fabric to fill the
fastener hole and overlay the repair
according to paragraph 6-16.
Failure to observe the correct number of repair
plies, the correct repair ply orientation, the
correct repair ply overlap and removal of all
pieces of vacuum bagging film will reduce the
strength of the repair and may result in the
loss of structural integrity.
NOTE
Do not use unidirectional material.
(l) Stack the repair plies into the tapered
fastener hole cleanout until it is filled.
Consult system specific technical man-
ual to determine if ply orientation for fas-
tener hole repair is required.
(m) Apply overlay plies to the upper and
lower repair surfaces as shown in fig-
ure 7-57. Orient the repair plies per the
system specific technical manual in the
same direction as the original outer par-
ent plies.
(n) Layup the vacuum bag and heat blanket
as described in paragraph 6-18. Place
metal caul plates on both sides of the
repair. These plates should extend 1
to 2 inches beyond the repair area and
will ensure even pressure is applied to
the repair. Refer to the system specific
technical manual for the porous release
film, bleeder material and the number of
bleeder plies.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
7-94
(o) Cure the repair using the cure cycle
from the system specific technical man-
ual and paragraph 6-19. If an elevated
temperature cure is required, use a
heat lamp, heat blanket or other heating
equipment. Place a thermocouple next
to the repair on the same side as the
heat source. If room temperature cure
is used, remove release film, caul plate,
and vacuum bag after a minimum of 8
hours. Allow to dwell at room tempera-
ture for a minimum of 5 days.
(p) Redrill/Countersink Hole.
NOTE
If the resin is cured at room temperature, DO
NOT smooth or drill the hole for at least 24
hours after the resin sets.
1 Lightly sand any squeezed out filler
flush with part surface using 180
grit abrasive paper.
2 Using the template fabricated
above, carefully locate a drill guide
containing the correct drill bushing
for the hole to be redrilled. Secure
the drill guide to the part with a
clamp.
3 Redrill and countersink the
repaired fastener hole per para-
graph 6-8. If countersinking is
required, use a countersink micro
stop to prevent countersinking too
deep.
(q) Refinish.
1 Sand the area smooth with 180 grit
abrasive paper. Vacuum sanding
dust from repair area. Wipe with
clean, dry wiping cloth to remove
sanding residue.
2 Apply finish system in accordance
with paragraph 7-13b or the sys-
tem specific technical manual. Use
care not to apply finish system in
fastener hole or countersink area.
f. Fastener Hole Delamination Repair. This repair
is applicable to fastener holes with delaminations
exposed to the edge of the hole only and uses the
vacuum injection technique. Refer to figure 7-58 for the
Process Flow Diagram for Fastener Hole Delamination
Repair (Vacuum Injection).

Figure 7-58. Process Flow Diagram for Fastener
Hole Delamination Repair (Vacuum Injection)
For fastener holes with delaminations open to the
edge of the part, follow steps in 7-8(g). This method
Figure 7-59. Vacuum Injection Fastener Hole Repair
(1) Facilities, Equipment and Materials. The
following equipment and materials are required:
Heat Lamp, Temperature/Vacuum Controller, Vacuum
Cleaner, HEPA Filter, Vacuum Cup and Lid, Torque
Wrench, Bolt, Nut & Washers (Local Availability),
Marking Pen, Silicon Carbide Abrasive Paper, Pres-
sure Sensitive Tape, Wiping Cloth, Spatula, Adhesive,
Liquid (See System Specific Technical Manual), Vac-
uum Bag Repair Materials Kit, Aluminum Sheet Stock,
0.063 inches or thicker (Local Procurement), Release
Liquid, Cotton Tipped Applicator, Solvent, Mylar.
(2) Fastener Hole Delamination Repair
Procedure.
(a) Remove dirt, grease and aircraft fluids
from repair area as described in para-
graph 6-5.
TM 1-1500-204-23-11
is used when little or no airflow is possible, such as
delaminations around fastener holes. The delaminated
area is heated to the minimum viscosity temperature
of the adhesive, and then adhesive is added to a
vacuum chamber which has been placed over the
delaminated area. The adhesive is maintained at
this minimum viscosity temperature under vacuum to
allow outgassing of air and/or volatiles, then vented
to atmosphere to force the resin into the delaminated
area. The vacuum chamber is then removed and
a fastener or clamp is installed to provide positive
pressure for curing the adhesive. NDI is performed on
the delaminated area when the repair is complete to
ensure successful injection. See figure 7-59 for details.
This repair procedure is not necessarily applicable to
a particular weapon system. The applicability of this
repair depends upon additional factors such as loading
conditions and laminate thickness. Consult the system
specific technical manual or engineering for further
guidance.
DO NOT use oil or oil based materials
as NDI couplants on advanced composite
components. Use only water or water based
materials. Disbonds may result and loss of
structural integrity may occur.
(b) Inspect damaged fastener holes using
NDI to determine extent of delamina-
tion according to paragraph 5-2 and the
system specific technical manual. Mark
the perimeter of the delamination on the
part surface and on a Mylar template
7-95
TM 1-1500-204-23-11
using a marking pen. Ensure delami-
nation meets the criteria of paragraph
7–10f above.
(c) Remove NDI couplant by wiping with
clean, water moistened wiping cloth.
(d) Obtain/Prepare Bolt, Nut and Washers.
DO NOT allow release liquid to come into
contact with repair or repairs details. Disbonds
may result in loss of structural integrity.
Table 7-5. Clamp-Up Bolts and Torque Values 1
HOLE DIAMETER (IN) BOLT SIZE
3/16 #8-36
1/4 #10-32
5/16 1/4-28
3/8 5/16-24
2 Coat bolt, nut, washers and back-
ing plate with liquid release agent.
Apply a second coat, waiting 15
minutes after each application to
ensure solvent in release agent
completely evaporates. Cure per
manufacturer’s instructions.
(e) Prepare Surfaces For Adhesive Appli-
cation.
1 Lightly sand around fastener hole in
the area where the vacuum cup will
be applied and in the countersink
area using 180 grit abrasive paper
to remove sealant, paint and other
debris. Vacuum area to remove
sanding residue. See paragraph
6-3 for paint removal steps.
2 Clean fastener hole and counter-
sink area using a cotton tipped
applicator, wiping cloth and solvent.
Thoroughly clean the area with
repeated wiping until no residue is
left on the cotton tipped applicator
or the wiping cloth. Allow the sol-
vent to evaporate for a minimum of
30 minutes.
7-96
1 Obtain the required bolt, nut and
washers given in table 7-5. Washer
outer diameter shall be of sufficient
size to extend a minimum of 0.060
inch beyond the area of delamina-
tion as determined by NDI. Select
bolt grip length to ensure no more
than three washers per side are
used.
TORQUE VALUES (IN-LBS)
10
20
50
70
3 Seal the backside of the fastener
hole by securing an aluminum
plate with vacuum bag sealant.
Apply vacuum bag material over
the aluminum plate and secure to
backside of part using vacuum bag
sealant as shown in figure 7-59.
Plug adjacent holes that may pro-
vide a leak path for the vacuum
system with vacuum bag sealant.
See paragraph 6-7 for surface
preparation steps.
(f) Install Vacuum Cup/Perform Leak Test.
1 Obtain a vacuum cup and lid. If
one is not available, fabricate one
perfigure 3-25.
2 Apply vacuum cup, with lid installed
on part surface over the affected
fastener hole using vacuum bag
sealant as shown in figure 7-59.
3 Apply 25-30 inches of mercury vac-
uum to cup. Ensure a minimum
of 25 inches of mercury is attained
without any audible leaks. Reseal
as required to eliminate leaks and
obtain the required vacuum.

NOTE
Position the heat lamp(s) such that the thermo-
couples are not in the shadow of the vacuum
cup.
(g) Heat Repair Area.
1 Perform a heat survey of the repair
area per paragraph 6-18g. Adjust
the position and number of heat
lamps to obtain a part temperature
of 125 ±5 ºF. After successfully
completing the heat survey, pro-
ceed with the repair.
2 Heat the repair area to a tem-
perature of 125 ±5 °F using heat
lamp(s) as described in paragraph
6-19h. Monitor the temperature
of the repair area using thermo-
couples. To prevent early gelation
of the adhesive, ensure the repair
area temperature does not exceed
130 ºF. Maintain 125 ±5 °F part
temperature throughout the injec-
tion procedure.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
(h) Prepare a small quantity (30 grams) of
liquid adhesive per paragraph 6-17.
(i) Perform Vacuum Injection.
1 Remove lid from vacuum cup using
care not to affect the cup to part
seal.
2 Pour the prepared adhesive into
the fastener hole until filled. Pour
remaining adhesive into cup.
TM 1-1500-204-23-11
3 Replace the lid and reseal with vac-
uum bag sealant.
4 Apply 25-30 inches of mercury
vacuum and hold until no more air
bubbles escape or until 8-10 min-
utes pass, whichever occurs first.
Monitor the adhesive continuously
during the 8-10 minute period by
looking through the lid. If excessive
foaming of the adhesive occurs,
control the foaming by alternately
disconnecting and reapplying the
vacuum hose to the cup, but do
not vent the cup to atmospheric
pressure. In no case exceed 10
minutes.
5 After the 8-10 minute vacuum
dwell, disconnect vacuum hose
and vent the cup to atmospheric
pressure by activating the vacuum
connector plunger. Leave the cup
vented to atmosphere for 5 min-
utes.
6 Reconnect the vacuum hose and
apply 25-30 inches of mercury vac-
uum. Hold for 5 minutes. Monitor
the adhesive and control foaming
per step 4 above.
7 After the second vacuum dwell,
disconnect the vacuum hose and
vent cup to atmospheric pressure
by activating the vacuum connec-
tor plunger. Remove the vacuum
cup, backup plate, bagging film
and sealant tape.
8 Clean up excess adhesive on part
surface using clean, dry wiping
cloth. Do not wipe inside fastener
hole.
DO NOT exceed the torque values listed in
table 7-5 or damage to part may result.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
(j) Cure Adhesive.
7-97
TM 1-1500-204-23-11
1 Install release agent coated bolt,
washers and nut as shown in figure
7-60. Remove any adhesive from
bolt threads with clean, dry, wiping
cloth prior to installing nut.
Figure 7-60. Application of Clamp-Up Pressure
2 Torque the nut and bolt to the appli-
cable torque value listed in table
7-5 using a torque wrench to obtain
the required clamp-up pressure.
3 Room Temperature Cure Cycle.
a Allow to dwell with nut and bolt
in place for 8 hours.
b Remove bolt, nut and washer.
c Allow to dwell at room
temperature for a minimum of
5 days.
4 Elevated Temperature Cure Cycle.
a Allow to dwell with nut and
bolt in place for 8 hours. As an
alternate, the adhesive/filler
may be set using a heat lamp.
Use the cure cycle from the
system specific technical
manual. Operate heat lamps
per paragraph 6-19h.
b Remove bolt, nut and washer.
Layup the vacuum bag and
heat blanket as described in
paragraph 6-18.
7-98
c Cure the adhesive as specified
in the system specific technical
manual.
d After the adhesive has cured,
debag.
(k) Clean Up/Redrill Hole If Required.
1 Lightly sand any residual adhesive
left on part surfaces using 180 grit
abrasive paper. Vacuum sanding
residue from part surface.
2 Visually inspect fastener hole for
residual adhesive. Redrill hole if
required.
(l) Inspect repaired fastener hole to verify
delamination was successfully injected.
(m) Refinish.
1 Sand the area smooth with 180
grit abrasive paper. Vacuum the
sanding dust from the repair area.
Wipe with clean, dry wiping cloth to
remove sanding residue.
2 Apply finish system in accordance
with paragraph 7-13b or the sys-
tem specific technical manual. Use
care not to apply finish system in
fastener hole or countersink area.
g. Swagged Grommet Repair. This repair is appli-
cable to damaged, misdrilled or elongated fastener
holes in advanced composite panels such as remov-
able access covers. This repair is limited to a maxi-
mum cleaned up damage of 0.030 inch on the hole
radius. Damage which exceeds this limit may be
repaired using the method provided in paragraph
7-10h. This repair procedure is not necessarily appli-
cable to a particular weapon system. The applicability
of this repair depends upon additional factors such as
loading conditions and laminate thickness. Consult the
system specific technical manual or engineering for
further guidance. Refer to figure 7-61 for the Process
Flow Diagram for Fastener Hole Repair: Swagged
Grommet.

(d) Measure the panel thickness for deter-
(e) Countersink OML side of cover as
(f)
Figure 7-61. Process Flow Diagram for Fastener
Hole Repair: Swagged Grommet
(1) Facilities, Equipment and Materials. The
following equipment and materials are required: Vac-
uum Cleaner, HEPA Filter, Drill Motor, 2000 RPM,
Drill Guide, Alignment Pin, Dagger Drill Bits, Over-
hose Assembly, Marking Pen, 90 Degree Router Motor,
20,000 RPM, Sanding Disks, 80 Grit, 1.0 Inch Diame-
ter, Sanding Disk Holder, Microstop Cage, Countersink
Cutter, Piloted, Counterbore Cutter, Removable Pilot,
Grommet Installation Tool (Local Availability), Wiping
cloth, Solvent, Silicon Carbide Abrasive Paper, Cotton
Tipped Applicator, Adhesive, Paste (See System Spe-
cific Technical Manual), Double Sided Adhesive Tape,
Pressure Sensitive, Grommet (Local Manufacture).
(2) Swagged Grommet Repair Procedure.
(a) Remove dirt, grease and aircraft fluids
from repair area as described in para-
graph 6-5.
(g) Prepare surfaces for bonding. Clean
(b) Visually inspect and measure hole dam-
age. The damage must be no more than
0.030 inch maximum on the radius.
(c) Remove Damage.
1 Locate original hole centerline
using the drill guide and alignment
pin. Secure drill guide in place.
2 While maintaining the original hole
centerline increase the hole diame-
ter 0.0625 inch using a dagger drill.
TM 1-1500-204-23-11
mining the proper grommet length.
described in paragraph 6-8 using a
countersink cutter and micro stop cage.
Spotface IML Surface.
1 Place a countersink cutter with the
same pilot diameter as the fastener
hole being repaired into a micro
stop cage. Center the countersink
pilot in the hole on the IML surface
of the cover.
2 With a marking pen or pencil, trace
around the perimeter of the micro
stop cage.
3 Remove the countersink cutter
from the micro stop cage.
4 Remove pilot from the counterbore
cutter. Place counterbore cutter
into the micro stop cage.
5 Center the micro stop cage over the
hole with its perimeter aligned with
the circle marked in step 2 above.
To stabilize the counterbore dur-
ing cutting, place double sided tape
over the marked circle. Carefully
place micro stop cage onto the tape
maintaining alignment.
6 Spotface IML side of cover to
a depth of 0.020 +0.005/-0.000
inches with counterbore cutter and
micro stop cage.
bonding surfaces of grommet and fas-
tener hole using a cotton-tipped appli-
cator, wiping cloth and solvent. Thor-
oughly clean the area with repeated
wiping until no residue is left on the
cotton tipped applicator or the wiping
cloth. Handle the grommet and part
from this point forward wearing powder
free latex gloves to prevent contamina-
tion of bonding surfaces.
7-99
TM 1-1500-204-23-11

Reduced strength will result if the incorrect

mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.

Pressure must be applied to adhesive within

the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.

(h) Prepare a small amount of adhesive (25

grams) as described in paragraph 6-17
and apply adhesive to the grommet and
fastener hole mating surfaces.

(i) Install and flare grommet into coun-

tersink (see figure 7-62) with grommet
installation tool. See system specific
technical manual for any torque require-
ments.

Figure 7-62. Swagged Grommet Install

7-100

(j) Leave grommet installation tool in place
and allow adhesive to set at room tem-
perature for 8 hours. Following removal
of installation tool, allow adhesive to set
at room temperature for an additional 16
hours before performing grinding oper-
ation.
(k) Grind excess grommet material flush
with OML surface using a router motor
and 80 grit abrasive disk. Use care not
to sand into laminate surface or over-
heat the laminate during grinding.
(l) If required, ream and/or countersink
the grommet to comply with applicable
system specific technical manual hole
diameter.
(m) Refinish.
1 Sand the area smooth with 180
grit abrasive paper. Vacuum the
sanding dust from the repair area.
Wipe with clean, dry wiping cloth to
remove sanding residue.
2 Apply finish system in accordance
with paragraph 7-13b or the system
specific technical manual.
h. Captive Bushing Repair. This repair is applica-
ble to damaged or elongated fastener holes in struc-
tural composite panels such as removable access
covers. This repair is limited to a maximum damage
of 0.060 inch on the radius. Damage which exceeds
this limit requires engineering disposition. This repair
procedure is not necessarily applicable to a partic-
ular weapon system. The applicability of this repair
depends upon additional factors such as loading con-
ditions and laminate thickness. Consult the system
specific technical manual or engineering for further
guidance. Refer to figure 7-63 for the Process Flow
Diagram for Captive Bushing Repair.
TM 1-1500-204-23-11
Figure 7-63. Process Flow Diagram Captive
Bushing Repair
(1) Facilities, Equipment and Materials. The
following equipment and materials are required:
Piloted Reamer, Solid Carbide, 0.381 Inch Diameter,
Piloted Reamer, Solid Carbide, 0.4435 Inch Diameter,
Vacuum Cleaner, HEPA Filter, Drill Guide, Drill Motor,
2000 RPM, 90 Degree Router Motor, 20,000 RPM,
Overhose Assembly, Carborundum Wheel, Arbor, Drill
Chuck, Sanding Disk Holder, Sanding Disks, 80 Grit,
1.0 Inch Diameter, Countersink Cutter, Piloted, Car-
bide Inserts, Countersink Cutter Pin, Microstop Cage,
Counterbore Cutter, Removable Pilot, Bearing Press
(Common Support Equipment), Adhesive, Paste (See
System Specific Technical Manual), Cotton Tipped
Applicator, Solvent, Dry Ice (Local Availability), Flange
and Countersink Bushings 4 (1⁄4 Inch), Flange and
Countersink Bushings 5 (5/16 Inch), Spatula, Silicon
Carbide Abrasive Paper, Wiping cloth, and Release
Liquid.
(2) Captive Bushing Repair Procedure.
(a) Remove dirt, grease and aircraft fluids
from repair area as described in para-
graph 6-5.
(b) Visually inspect and measure the hole
damage. The damage must be no more
than 0.060 inch maximum on the radius.
(c) Using a reamer, increase the hole diam-
eter by 0.131 inches. Ensure that the
original hole centerline is maintained.
(d) Countersink moldline side of cover or
panel to accept countersink bushing
using the appropriately sized counter-
sink cutter and micro stop cage.
7-101
TM 1-1500-204-23-11

(e) Prepare Countersink Bushing. Two 1 Temporarily install countersink

flange and countersink bushings are bushing and scribe outer diameter
listed. For other fasteners hole sizes, of bushing flush with inner moldline
flange and countersink bushings may surface of panel. See figure 7-65,
be fabricated per figure 7-64. View A.

2 Remove bushing and rough cut

length to scribe line (flush with IML
surface) with router motor and car-
borundum wheel. Grind bushing
to exact length using router motor
and 80 grit abrasive disk.

Figure 7-64. Captive Bushing Repair Components

7-102

Figure 7-65. Captive Bushing Repair Flange and Countersink Bushing Installation
(f) Spotface IML Surface.
1 Place a countersink cutter with the
same pilot diameter as the fastener
hole being repaired into a micro
stop cage. Center the countersink
pilot in the hole on the IML surface
of the cover.
2 With a marking pen or pencil, trace
around the perimeter of the micro
stop cage.
3 Remove the countersink cutter
from the micro stop cage.
4 Remove the pilot from the counter-
bore cutter. Place counterbore cut-
ter into the micro stop cage.
5 Center the micro stop cage over the
hole with its perimeter aligned with
the circle marked in step 2 above.
6 Spotface inner moldline side of
cover to a 0.020 +0.005/-0.000
depth with counterbore cutter and
micro stop cage.
(g) Prepare Flange Bushing.
1 Determine length of flush bushing
to allow proper seating of counter-
sink bushing.
2 Rough cut bushing to approximate
length using router motor and car-
borundum wheel. See figure 7-65,
View B. Grind flange bushing to
exact length using router motor and
80 grit abrasive disk.
(h) Prepare Surfaces for Bonding.
TM 1-1500-204-23-11
1 Clean bonding surfaces of bush-
ings and fastener hole using a cot-
ton-tipped applicator, wiping cloth
and solvent. Thoroughly clean the
area with repeated wiping until no
residue is left on the cotton tipped
applicator or the wiping cloth. See
paragraph 6-7 for surface prepara-
tion steps. Handle bushings and
part from this point forward wearing
powder free latex gloves to prevent
contamination of bonding surfaces.
DO NOT allow release liquid to come into
contact with repair of repair details. Disbonds
may result in loss of structural integrity.
2 Obtain a bolt, washer and nut
which will be used to clamp-up
and retain bushings during cure.
Coat the bolt, washer and nut with
liquid release agent. Apply a sec-
ond coat, waiting 15 minutes after
each application to ensure solvent
in release agent completely evap-
orates. Cure per manufacturer’s
instructions.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
7-103
TM 1-1500-204-23-11
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
(i) Prepare Adhesive. Prepare a small
amount (25 grams) of adhesive per
paragraph 6-17.
(j) Apply adhesive to flange bushing and
countersink bushing bonding surfaces
and fastener hole bonding surfaces as
shown in fFigure 7-66.
Figure 7-66. Installation View of Captive Bushing
Repair
(k) Install Bushings.
1 Install flange bushing into hole.
2 Press countersink bushing into
flange bushing. To aid in installa-
tion, countersink bushing may be
frozen in a mixture of dry ice and
solvent. A bearing press may also
be utilized to facilitate installation.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
(l) Cure Adhesive.
1 Clamp assembly together with
slave bolt, washer and nut. Ensure
7-104
bushings are seated flush with
moldline surfaces. See figure 7-65,
View C.
2 Room Temperature Cure Cycle.
a Allow to dwell with nut, bolt
and washer in place for 8
hours.
b Remove bolt, nut and washer.
Allow to dwell at room
temperature for a minimum of
5 days before proceeding to
step (m) below.
3 Elevated Temperature Cure Cycle.
a Allow to dwell with nut, bolt
and washer in place for 8
hours. As an alternate, the
adhesive may be set using
a heat lamp. Use the cure
cycle from the system specific
technical manual. Operate
heat lamps per paragraph
6-19h.
b Remove bolt, nut and washer.
Layup the vacuum bag and
heat blanket as described in
paragraph 6-18.
c Cure the adhesive as specified
in the system specific technical
manual and paragraph 6-19.
d After cure, debag.
(m) If required, ream bushing to comply with
applicable system specific technical
manual hole diameter.
(n) Refinish.
1 Sand squeezed out adhesive flush
with moldline surfaces with 180
grit abrasive paper. Inner moldline
end of flush bushing to be flush to
0.010 and subflush with surface of
shoulder bushing as shown in fig-
ure 7-65, View D. Vacuum sanding
dust from repair area. Wipe with
clean, dry wiping cloth to remove
sanding residue.
2 Apply finish system in accordance
with paragraph 7-12b or the sys-
tem specific technical manual. Use

care not to apply finish system in
fastener hole or countersink area.
7-11. DOUBLE VACUUM DEBULK PROCESS. The
DVD wet layup process is similar to the standard wet
layup process in that it is performed by the repair
technician to prepare patches for a part, and can be
utilized for contoured areas and substructure detail
manufacture. Unlike the standard wet layup process,
it provides a technique for removing entrapped air
that causes porosity in wet layup laminates. The DVD
process also provides better control of resin content
and better fiber wetting. These characteristics of the
DVD process result in increased mechanical properties
for the laminate. As a result, DVD wet layup laminates
are not limited to lightly-loaded structures.
a. DVD Wet Layup Process. In this technique a
rigid box is placed over the vacuum bag (inner
vacuum bag) containing the wet layup laminate and
heat blanket. The outer vacuum bag is placed over
the box and vacuum applied. This second vacuum
bag and rigid box relieve the compaction pressure
on the laminate induced by the initial vacuum bag,
while maintaining vacuum on the inner bag. With
vacuum applied to both bags, the laminate is heated
to the debulk temperature and held for a specified
time. This allows gases to be removed without being
trapped by the compressing (inner) vacuum bag. Next,
compaction of the laminate is accomplished by venting
the outer vacuum bag to the atmosphere so that only
the inner vacuum is applied to the repair patch.
Following debulking and compaction, the laminate is
removed from the debulking tool and formed to a
tool or part surface. A vacuum bag is then applied
over the laminate (and heat blanket if applicable) and
vacuum applied. Heat is then applied to cure the
laminate using an oven or heat blanket. The resin
used in this technique must have a fairly long pot
life due to the use of heat and the time required
to perform the process. Laminating resins need to
have a minimum of a 4-hour pot life and 200 ºF cure
temperature. These requirements are necessary to
allow for the debulking and compacting cycle times and
temperatures. Unique process procedures need to be
developed for each resin system used by either the
resin manufacturer or system specific authority. Two
fabrics are typically used for repair, 8 harness satin
weave and plain weave. These fabrics vary in weight
and thickness (see paragraph 4-3, figure 4-6 and figure
4-9). Since these fabrics differ, different amounts of
resin per square foot are required to impregnate the
fabrics. Also, the number of bleeder plies is specific to
the fabric type in order to obtain the correct resin ratio
and laminate thickness. Another process variation is
the compaction time. The compaction time is the
period after venting of the outer box, when only one
vacuum is applied to the laminate. An 8 harness fabric
TM 1-1500-204-23-11
requires less compaction time than the plain weave
fabric. After the dry cloth has been impregnated with
resin, the plies cut, and the plies flat ply collated,
it is debulked using a double vacuum bag debulking
tool (see figure 3-6). If the tool is not available, a
rigid box can be manufactured locally according to
figure 3-7 and paragraph 7-11c. This repair procedure
is not necessarily applicable to a particular weapon
system. Refer to the system specific technical manual
for instructions on the fiber, resin, number of bleeder
plies, and processing parameters. The applicability of
this repair depends upon additional factors such as
loading conditions and laminate thickness. Consult
the system specific technical manual or engineering
for further guidance.
(1) Facilities, Equipment and Materials. The
following equipment and materials are required: Tem-
perature/vacuum controller, Double vacuum debulk
tool or locally manufactured rigid box, Scribe, Base
Plate. This plate will be used below during the
layup of the DVD Tool Schematic (See figure 3-6).
It should be made from at least 0.5 inch thick alu-
minum. (Local procurement), Heat Blanket, Vacuum
Bag Repair Materials Kit, Fabric (See System Spe-
cific Technical Manual), Adhesive, Liquid (See System
Specific Technical Manual), Aluminum Sheet Stock,
0.063 inches or thicker (Local Procurement), Marker,
Flash breaker Tape, Mylar, Squeegee.
(2) Material Preparation.
(a) Fabricate templates for each ply of the
patch using Mylar film. Mark the ply
orientation, ply number, and orientation
marks on each template to facilitate
layup. See paragraph 5-6.
(b) Cut two sheets of porous release film so
they extend 1 inch past each edge of the
largest ply of the patch.
(c) Cut the required number and type of
fiberglass plies to be used as bleeder
plies per table 7-6; cut them so they
extend 1 inch past the largest ply of the
patch.
(d) Cut a single piece of the required repair
fabric, large enough to fit all the repair
plies.
(e) Cut one ply of non-porous release film
so it is at least 1/2 inch past the edge
of the porous release film. Perforate the
non-porous release film with a scribe on
approximately 2 inch centers.
7-105
TM 1-1500-204-23-11
(f) Cut one ply of non-porous release film
large enough to cover the aluminum
caul sheet.
(g) Cut a piece of breather material large
enough to cover the caul sheet and
reach the vacuum source.
(h) Cut a piece of bagging film at least 2
inches past the edge of the caul sheet
and the vacuum source.
(3) Tool Preparation.
Use only flash breaker tape under the vacuum
bag to prevent contamination of laminate.
(a) Place at least four layers of breather
material that are the same size as
the caul sheet to act as insulation on
the base plate. If the double-vacuum
debulk tool is being used, this step can
be skipped as the insulation is already
incorporated into the tool.
(b) Place the heat blanket on top of the
insulation. The heat blanket selected
must be large enough to maintain a
patch edge to heat blanket edge dis-
tance of at least 1 inch (see figure 3-7).
(c) Cut an aluminum sheet the same size
as the heat blanket and center on top
of the heat blanket. Tape to base plate
with a few pieces of tape. Cover the
aluminum caul sheet with non-porous
release film and tape in place.
(d) Place the caul sheet on the heat blan-
ket.
(e) Tape one piece of porous release film
on the center of the non-porous release
film covered caul sheet.
(f) Use at least three thermocouples to
monitor heat blanket temperature. All
thermocouples must be taped to within
0.5 inch of the perimeter of the porous
release film and electrically insulated
from the caul sheet using flash breaker
tape. Connect thermocouples to the
7-106
temperature/vacuum controller and
check for proper operation before plac-
ing next to patch. Refer to paragraph
6-19f for operation of the controller.
Thermocouple readings should approx-
imate the ambient air temperature. If
the thermocouple reading does not,
replace thermocouple.
(g) Mark the warp orientation and center
lines on the non-porous release film out-
side the porous release film with a per-
manent marker. Extend the center lines
outside the repair ply stacking area to
assist in the alignment of each ply as the
patch is being fabricated.
(h) Place a bead of vacuum bag sealant
tape around the perimeter of the base
plate within the tape boundary line. Do
not remove the backing paper from the
vacuum bag sealant tape.
(4) DVD Wet Layup Procedure.
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Impregnating cloth must be completed within
40 minutes of mixing resin. Double vacuum
bag debulking must begin within 75 minutes
of mixing resin. An unsatisfactory repair
will result if the resin gels before adequate
pressure is applied. Select heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
Wear protective gloves when laying up and
handling repair plies to prevent contamination
of adhesive or repair plies.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
 TM 1-1500-204-23-11

(if required) and all necessary vacuum bag
materials prior to mixing resin.
NOTE
Mixing resin and cloth impregnation should be
done in a controlled environment per Chapter
2.
If a heat survey is required, perform according
to paragraph 6-18g before beginning this
process.
When a wet layup patch is to be formed
to a contoured shape, final processing of
the patch must be started within 10 minutes
after completion of the double-vacuum debulk
process. Preparation of contoured surfaces
for curing patch on tool or on aircraft must be
completed prior to completion of DVD process
per this procedure.
During this procedure, refer to figure 3-6 for
Double Vacuum Bag Debulking Tool Schematic
and figure 3-7 for Rigid Box Configuration.
(a) Using table 7-6 and/or 6-17, calculate
the amount of resin required to impreg-
nate the fabric.

Table 7-6. DVD Parameters

Bleeder Plies
Cloth Resin Resin Ratio Debulk Compaction Cure
(1)
Grams
Temp Time Temp Time Ramp Temp
Adhesive/ sq
Vacuum Vacuum Time Vacuum
ft Fabric
Carbon Fiber, Fiberglass
3 to 5 ºF/min
8 Harness 120 1 bleeder 110 to 120 ºF 110 to 120 ºF15
245 (±15)º F
Satin 3k Tows EA9390 25 to 29 for every 60 to 65 minutes to 20 minutes
150 minutes
Areal Weight 2 plies of ≥20 in Hg ≥20 in Hg
≥20 in Hg
373 g/m2 laminate
Carbon Fiber Fiberglass
125 (±5) ºF 60 125 (±5) ºF 30 3 ºF/min 215
Plain Weave 120 1 bleeder
min ≤ 16 plies 90 min ≤16 plies (+10/-15)º F
3k Tows EA9390 21 to 23 for every
min > 16 plies 60 min > 16 120 minutes
Areal Weight 4 plies of
≥20 in Hg plies ≥20 in Hg ≥25 in Hg
193 g/m2 laminate
Fiberglass
110 to 120 3 to 5 ºF/min
120 1 bleeder 110 to 120 ºF
Fiberglass ºF 15 to 20 245 (±15)º F
EA9390 18 to 20 for every 60 to 65 minutes
7781 minutes ≥20 150 minutes
2 plies of ≥20 in Hg
in Hg ≥20 in Hg
laminate

NOTE

1. Do not round up. For example, if the bleeder ply schedule is one bleeder for every four plies of
laminate, a seven ply laminate would get one bleeder, an eight ply laminate would get two bleeders.
2. Refer to the system specific technical manual for DVD processing parameters. If no processing
parameters are provided use this table.

(b) Mix the required amount of resin using Do not apply a thin layer of adhesive
the mix ratio specified in the system onto the vacuum bag film taped to the
specific technical manual or by the resin flat surface.
manufacturer.
(d) Using the ply templates, mark and cut
(c) Impregnate repair plies per table 7-6 the individual plies without disturbing
and paragraph 6-16. Using a squeegee, the vacuum bagging film or the repair
thoroughly wet-out the fabric taking care ply per paragraph 6-16.
not to force resin from the fabric edges.

7-107
TM 1-1500-204-23-11
Failure to observe the correct number of repair
plies, the correct repair ply orientation, the
correct repair ply overlap and removal of all
pieces of vacuum bagging film will reduce the
strength of the repair and may result in the
loss of structural integrity.
(e) Verify the layup sequence by stacking
the patch plies in numerical sequence
prior to layup.
NOTE
Ensure the vacuum bagging film is removed
from both sides of each ply during the layup
process. Save all removed pieces of vacuum
bagging film until verified.
(f) Layup the plies using the Flat Ply Colla-
tion Technique described in paragraph
6-16.
1 Starting with the first ply of the
patch, stack the plies in the center
of the porous release film placed
on the caul sheet, while maintain-
ing the correct orientation for each
ply in relationship to the orienta-
tion marked on the caul sheet.
Ensure the vacuum bagging film is
removed from both sides of each
ply during the layup process.
2 Verify no vacuum bagging film was
left in the patch by counting the
number of pieces of vacuum bag-
ging film. There must be twice as
many pieces of vacuum bagging
film as there are plies in the fabri-
cated patch. If all pieces of vacuum
bagging film can be accounted for,
proceed to step (g); otherwise, fol-
low the procedure in step 3.
A patch with one or more pieces of vacuum
bagging film accidentally left in during layup
and cure is unacceptable and must be dis-
carded. A new patch must be fabricated.
Prior to separating any repair stack, the warp
orientation of the patch must be identified
and maintained during all operations used to
separate and join the layers of the stack.
7-108
3 Locate the embedded piece of
vacuum bagging film by gently sep-
arating the plies of the patch at
one location (for a square patch,
perform this operation in one cor-
ner). Carefully separate the plies
and remove the embedded vac-
uum bagging film without distorting
or wrinkling the pieces of the patch.
Replace the removed portion of
the patch in its proper orientation
and smooth out the surface of the
patch.
(g) Place the wet layup laminate on the
porous release film.
(h) Place the other layer of porous release
film over the laminate taking care to
align the edges of the porous release
film with the edges of the porous release
film on the bottom of the patch. Tape in
place.
(i) Cover stacking sequence with the
proper number of bleeder plies taking
care to align the edges with the porous
release film.
(j) Cut a layer of release film at least 0.5
inch larger than the laminate. Place
over the stacking sequence. Tape in
place.
(k) Manually perforate the release film with
pin holes on 4 inch centers.
(l) Place and trap seal tape the perfo-
rated non-porous release film over the
bleeder plies.
(m) Place a bead of vacuum bag sealant
around the perimeter of the base plate
for sealing inner bag. Ensure sealant is
applied at a distance of at least 2 inches
beyond the perimeter of the rigid box.
See figure 3-6.
NOTE
If using the double vacuum tool, verify the
breather material covers the sharp edges of
the vacuum groove and the inner bag port
fitting to prevent cutting the inner bag.
(n) Cover the base plate and layup with two
plies of breather to within 1/2 inch of the
vacuum bag sealant on the base plate.
(o) Connect heat blanket to controller.

(p) Place vacuum connector base and vac-
uum gage base on pads located on top
of breather plies. Remove the back-
ing paper from the vacuum bag sealant
tape and place inner vacuum bag mate-
rial over the layup and press into vac-
uum bag sealant to seal the bag. Make
small slits in the bagging film over the
two bases and install vacuum connec-
tor and vacuum gage.
(q) Connect the vacuum source to the inner
bag. (A dedicated vacuum pump is
recommended to ensure vacuum level
integrity.) Apply a minimum of 20 inches
of mercury vacuum.
(r) Make sure there are no wrinkles in the
vacuum bag over the laminate. Wrin-
kles will leave markoff on the laminate.
To ensure the integrity of the repair, it is
critical to complete the inner bag leak check
procedure.
(s) Disconnect vacuum source and take
initial reading on inner vacuum bag
gage to check for leaks. Wait 5 minutes
and take final reading on inner vacuum
bag gage. The vacuum level must not
drop more than 5 inches of mercury
over a five minute interval. Repair or
replace bag until bag can meet leak
check requirements.
(t) If a leak is found, work the bag into the
sealant tape and look for tears/punc-
tures. If necessary, replace the bag
until the leak rate meets the specified
requirement.
(u) Reapply vacuum to the bag after the
leak check has been completed.
NOTE
If using the double vacuum tool, before closing
the outer box, verify the O-ring seal and mating
surfaces are clean and the O-ring is properly
retained inside the outer box groove.
(v) Center the rigid box over the laminate.
(w) If necessary, place a bead of vacuum
bag sealant just outside of the perime-
ter of the rigid box on top of the inner
vacuum bag material.
TM 1-1500-204-23-11
(x) Cover the entire rigid box with two layers
of breather cloth.
(y) Place vacuum connector base and vac-
uum gage base on pads located on top
of breather plies. Place outer vacuum
bag material over the breather on the
rigid box and press into vacuum bag
sealant to seal the bag. Make small slits
in the bagging film over the two bases
and install vacuum connector and vac-
uum gage.
(z) Apply vacuum to the outer box as fol-
lows:
1 Remove vacuum source to inner
bag ensuring a minimum of 25
inches of mercury vacuum is
retained in the inner bag.
2 Apply vacuum to the outer box.
3 When the vacuum level in the outer
box is within 1 inch Hg of the inner
bag, reapply vacuum to the inner
bag.
(aa) Smooth wrinkles in the outer bag as air
is evacuated. Ensure a minimum of 20
inches of mercury vacuum is obtained
on the outer bag vacuum gage without
audible leaks. If a minimum of 20 inches
of mercury cannot be obtained on the
outer vacuum bag and/or audible leaks
cannot be eliminated, repair or replace
outer bag using new bagging materials.
(ab) Debulk the patch per system specific
technical manual, engineering guideline
or table 7-6.
1 With vacuum applied to both bags,
heat laminate to the required
debulk temperature at a rate of 3-5
°F per minute. Ensure a vacuum of
20 inches of mercury minimum is
maintained in both bags.
2 Upon the coldest thermocouple
reaching the minimum debulk tem-
perature, begin a timed soak. Con-
tinuously monitor and record all
thermocouples to ensure the tem-
perature range is maintained dur-
ing the soak period.
7-109
TM 1-1500-204-23-11
If the inner vacuum is lost during the switch
from the debulk cycle to the compaction cycle,
the patch integrity is compromised and should
be scrapped.
(ac) After the timed soak, compact the patch
by releasing the vacuum pressure in the
outer bag while maintaining pressure in
the inner bag for the applicable time.
Ensure a vacuum of 20 inches of mer-
cury minimum is in the inner bag.
1 Check inner bag for leaks by
removing the vacuum source. The
vacuum level must not drop more
than 5 in Hg over a 5 minute time
period.
2 Reapply vacuum to the bag after
the leak check has been com-
pleted.
3 Maintain the compaction cycle per
the system specific technical man-
ual or table 7-6.
(ad) Turn off heat blanket and vent the vac-
uum from the inner bag.
(ae) Remove outer box and inner bag from
base plate. Remove breathers, release
film and bleeders from the laminate as
7-110
soon as possible after debulk cycle has
been completed. Do not remove the
porous release film from the patch.
(af) Remove the patch from the caul sheet
keeping the patch and porous release
film intact to prevent separation of the
plies and introducing air into the patch.
(ag) After completing the debulk cycle, the
laminate should be vacuum bagged as
soon as possible and the cure cycle ini-
tiated within 30 minutes.
(5) Cure Cycle. There are two methods
described in this paragraph, Method 1: pre-curing
a laminate and Method 2: cocuring a part. If the
laminate is to be cocured, proceed to Method 2.
(a) Method 1. This method uses a heat blan-
ket to pre-cure the laminate for subsequent secondary
bonding (see figure 7-67). As an alternate and if the
layup tool/part will fit in an oven, an oven may be
used instead of the heat blanket for curing the lam-
inate. If an oven is used, omit copper sheet and
heat blanket from the layup and place thermocouples
near the edge of the laminate. Operate the oven
per paragraph 6-6. Patch may be pre-cured on the
part or a tool and later bonded to the part. Cure
according to the cure cycle specified in the system
specific technical manual or table 7-6.
 TM 1-1500-204-23-11

Figure 7-67. DVD Precure Stacking Sequence

7-111
TM 1-1500-204-23-11
1 Apply non-porous release film on
the layup tool/part surface. Ensure
release film is 1 inch larger than the
largest ply of the laminate. If a heat
blanket is used, release film should
extend one inch beyond edge of heat
blanket. Tape in place.
2 Apply the debulked laminate to the
release film at the required location
on the layup tool/part. Heat lamp(s)
operating at 110 ±10 °F may be used
to assist in forming the laminate to the
layup tool/part.
3 Position at least two monitoring ther-
mocouples around the perimeter of
the laminate and tape in place. (Do
not place the thermocouples on the
laminate stack).
4 Connect the thermocouples to a tem-
perature measuring device/vacuum
controller.
5 Place a layer of non-porous release
film over the laminate the same size
as in step 1 above.
NOTE
Refer to paragraph 6-18 for vacuum bag and
heat blanket installation.
6 Cover the layup with a 0.020 inch
thick aluminum or copper sheet.
7 Cover with a heat blanket and tape in
place.
8 Place a control thermocouple on top
of the heat blanket over the center of
the repair.
9 Cover with 2 layers of breather cloth.
7-112
10 Seal the assembly in a vacuum bag.
Apply full vacuum (≥20 inches of mer-
cury) to the bag.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
11 Heat at 3-5 °F per minute to the tem-
perature and time from the system
specific technical manual or table 7-6.
12 Hold at the temperature for the time
from the system specific technical
manual or table 7-6. Begin timing
when coldest thermocouple reaches
the minimum temperature tolerance.
Maintain a minimum of 20 inches of
mercury vacuum on the vacuum bag.
13 Cool to 140 °F while maintaining a
minimum of 20 inches of mercury. Do
not exceed a cool down rate of 5 °F
per minute.
14 Release vacuum and debag part.
15 Perform NDI of laminate as described
in paragraph 5-2 and the system spe-
cific technical manual.
b. Method 2: Cocuring to Part. This method is
used to simultaneously cure the laminate and the
adhesive to the part surface. See figure 7-68. Patch
may be cocured to the part needing repair, in which
case a layer of paste adhesive (as specified in the
system specific technical data) should be used. Cure
according to the cure cycle specified in the system
specific technical manual or table 7-6.

Figure 7-68. DVD Cocure Stacking Sequence (Typical)
Do not attempt to consolidate the patch by
placing the double bag box on aircraft or
components as it may induce damage to the
structure. Consolidate the patch in the box
prior to placing it on the component.
(1) Prepare the surface of the aircraft or compo-
nent for bonding per paragraph 6-7.
NOTE
Apply the scrim cloth if required in the system
specific technical manual.
TM 1-1500-204-23-11
(2) Cut a piece of scrim cloth 0.25 inch larger
than the largest ply of the laminate.
(3) Cut one piece of porous release film approx-
imately 3 inches larger than the largest ply of
the laminate.
(4) Cut one piece of non-porous release film
approximately 4 inches larger than the
largest ply of the laminate. Manually pin
hole perforate on 4 inch centers.
7-113
TM 1-1500-204-23-11
Reduced strength will result if the incorrect
mix ratio is used, if an excessive amount
of air is introduced into the adhesive during
mixing, or if mixing is inadequate and may
result in loss of structural integrity.
Pressure must be applied to adhesive within
the pot life of the resin. For ambient temper-
atures in excess of 90 °F, decrease this time
by 50%. An unsatisfactory repair will result
if the resin gels before adequate pressure is
applied and may result in loss of structural
integrity. Select and prepare a heat blanket
(if required) and all necessary vacuum bag
materials prior to mixing resin.
(5) Prepare paste adhesive per paragraph 6-7.
Apply to part and laminate bonding surfaces
using an adhesive comb per paragraph 7-6.
Failure to observe the correct number of repair
plies, the correct repair ply orientation, the
correct repair ply overlap and removal of all
pieces of vacuum bagging film will reduce the
strength of the repair and may result in the
loss of structural integrity.
(6) Apply the laminate containing adhesive to
the part surface containing the adhesive and
scrim cloth. Tape patch in place using flash
breaker tape.
(7) Cover the layup with the piece of porous
release film prepared in step (3). Tape in
place.
(8) Position at least two monitoring thermocou-
ples at the edge of the laminate and tape in
place. (Do not place the thermocouples on
the laminate stack).
(9) Cover the layup with the manually perforated
release film prepared in paragraph 7-11a2.
Tape in place.
7-114
(10) Cover the layup with 4 plies of Style 120
glass breather cloth cut at least 1 inch larger
than the heat blanket that will be used.
(11) Obtain a heat blanket at least two inches
larger than the largest ply of the laminate.
Center over the layup and tape in place.
(12) Cover with 2 layers of breather cloth.
(13) Seal the assembly in a vacuum bag. Apply
a minimum of 20 inches of mercury vacuum
to the bag.
Failure to properly cure adhesive in accor-
dance with the specified cure cycle will result in
reduced repair strength may not be detectable
by visual or nondestructive inspection. This
may result in loss of structural integrity.
(14) Heat at 3–5 °F per minute to to the tempera-
ture and time from the system specific tech-
nical manual or table 7-6.
(15) Hold at the temperature for the time from
the system specific technical manual or table
7-6. Begin timing when coldest thermocou-
ple reaches the minimum temperature toler-
ance. Maintain a minimum of 20 inches of
mercury vacuum on the vacuum bag.
(16) Cool laminate to below 140 °F with a max-
imum cool down rate of 5 °F/minute while
maintaining a minimum of 20 inches of mer-
cury vacuum on the vacuum bag.
(17) Release vacuum bag and debag part.
(18) Perform NDI of laminate and laminate to part
bondline as described in paragraph 5-2 and
the system specific technical manual.
c. Locally Manufactured DVD Tool. A locally
manufactured DVD tool can be constructed from
wooden 2 x 4s and 1 inch thick plywood, see figures
3-6 and 7-69. The inner vacuum bag must extend
past the wooden box and the outer vacuum bag to
allow connection of the vacuum port and hoses.

Figure 7-69. Double Vacuum Debulk Locally Manufactured Tool
(1) Outer Box Construction.
(a) Locate and drill 1/4 inch air holes on
each side.
(b) Cover with two layers of breather cloth.
(c) Cover with vacuum bagging film; be
sure to use plenty of film and pleat it as
necessary.
(2) Process. The process is the same as with
the production DVD tool except you do not have
valves to turn the vacuum source on and off. If
your vacuum probes have airtight valves, you may
disconnect the vacuum hose; if not, you may need
to clamp the vacuum hose shut.
TM 1-1500-204-23-11
7-12. LIGHTNING STRIKE REPAIR. Since compos-
ite parts are nonconductive, a fine wire mesh is used
to provide an electrical path through exterior com-
ponents in case the aircraft is struck by lightning.
Exterior composite parts without lightning mesh can
fail catastrophically due to lightning if this mesh is
not in place. Lightning mesh also provides an elec-
trical ground plane for electronic equipment such as
avionics or antennas. The mesh is typically on the
OML of the part, however IML application may be
necessary depending on the part design. Copper foil
is typically used for carbon laminates and aluminum
is used on fiber-glass laminates. Since repairing the
laminate requires extensive removal of lightning mesh,
the mesh must also be repaired. In certain cases
the lightning mesh may be included as the outer-
most ply in the repair and cocured with the repair.
7-115
TM 1-1500-204-23-11
In other instances it is a secondarily bonded layer
after the repair patch has already been cured. This
repair procedure is not necessarily applicable to a
particular weapon system. The applicability of this
repair depends upon additional factors such as load-
ing conditions and laminate thickness. Consult the
system specific technical manual or engineering for
further guidance. Refer to figure 7-70 for the Process
Flow Diagram for Lightning Strike.
Figure 7-70. Process Flow Diagram for Lightning
Strike.
a. Facilities, Equipment and Materials. The fol-
lowing equipment and materials are required: Vacuum
Cleaner, HEPA Filter, Temperature/Vacuum Controller,
Heat Blanket, Ohm Meter, Dual Action Sander or 90
degree die-grinder and sanding mandrel, Scissors,
Vacuum Bag Repair Materials Kit, Flash breaker Tape,
Silicon Carbide Abrasive Paper, Sanding Pad, Wiping
cloth, Solvent, Peel Ply, Release Film, Spatula, Adhe-
sive, Liquid (See System Specific Technical Manual),
Wire Mesh (See System Specific Technical Manual).
b. Lightning Strike Procedure.
DO NOT use aluminum lightning mesh on
carbon fiber composite structure.
NOTE
Processed parts shall be handled using clean
powder free latex gloves.
(1) Using 240 or finer grit abrasive paper, lightly
hand sand a 1 inch overlap area enough
7-116
to expose the foil. The overlap area is the
area surrounding the repair area extending
out to 1 inch from the repair. A dual action
sander with 320 or finer grit abrasive paper
may be used as an alternate to hand sand-
ing. The expanded foil is considered to be
exposed when an electrical resistance mea-
surement of less than 10 milliohms can be
achieved by lightly pressing the probe tips
of a milliohm meter on the sanded overlap
area. The probe tips should be at least 1 inch
apart. The reading should be achieved in
several places on the sanded overlap area.
The electrical measurements are for the pur-
pose of assisting in the sanding process only
and verification is not required at this point.
The expanded foil is extremely thin. Sanding
down into the foil will cause damage to the
expanded foils and will result in high resistance
measurements. Damage caused by over
sanding is not visible to the eye and may
occur without actually sanding through the foil.
Failure to follow these procedures will result
in faulty Electromagnetic Interference (EMI)
shielding/lightning strike protection. In order
to prevent damage, hand sand or use 320
grit abrasive paper on the dual action sander
and make electrical resistance measurements
frequently during sanding in order to evaluate
the sanding progress. Stop sanding when the
surface is measuring less than 10 milliohms
as described above.
(2) Using a fine sanding pad, lightly abrade the
surface surrounding the repair area for an
additional 1 inch in all possible directions.
This is referred to as the extended repair
area. The repair areas together with the
extended repair area make up the entire
repair area.
(3) Vacuum sanding dust from repair area.
Do not expose the expanded foil in the
extended repair area.
(4) Clean the entire repair area with solvent
using a clean dry wiping cloth according to
paragraph 6-5. Wipe dry with a second cloth
prior to the evaporation of the solvent. Wait
30 minutes for solvent to evaporate. Mask
off around extended repair area with flash

breaker tape. Cover repair area with clean
bagging film.
(5) Cut a piece of dry expanded foil to size of
entire repair area and solvent wipe. To get a
smoother surface in areas of complex cur-
vature, the foil patch may consist of sev-
eral overlapping pieces providing each piece
makes contact with the overlap area.
(6) Mix adhesive per paragraph 6-17.
(7) Remove bagging film from repair area and
apply a thin coat of adhesive to the entire
repair area surface.
(8) Place the repair foil on the repair area and
apply a thin coat of adhesive to the top sur-
face of the foil.
(9) Cut a piece of peel ply to extend past the
repair area and place on the extended repair
area.
(10) Carefully remove excess resin from under-
neath the replacement expanded foil.
(11) Cut a piece of non-porous release film to the
size of the repair area. Place on repair area.
(12) Cut a piece of breather cloth to extend past
the extended repair area and place on repair.
(13) Cover with nylon bagging film.
If insufficient pressure is applied, the electrical
measurements will be high.
(14) Apply pressure to the repair using a vacuum
bag according to paragraph 6-18.
(15) Cure according to paragraph 6-19 and the
system specific technical manual.
(16) Debag the repair area.
(17) If necessary, lightly hand sand the entire
repair area using 240 or finer grit abrasive
paper to remove any surface imperfections
caused by resin squeeze out. Vacuum sand-
ing dust from repair area. Wipe with clean,
dry wiping cloth to remove sanding residue.
Do not expose expanded foil when sanding.
TM 1-1500-204-23-11
(18) Using the milliohm meter, take electrical
resistance measurements between the
replacement expanded foil at the center
of the repair and the adjacent embedded
foil. Refer to the system specific technical
manual for resistance requirements. If not
specified, the maximum resistance shall be
25 milliohms for copper foil. The replace-
ment foil and adjacent foil may have to
be exposed by sanding in order to make
the measurements. Use the same sand-
ing precautions as called out above. After
the measurement is made, cover over the
exposed foil areas with a light coat of adhe-
sive. Mix according to paragraph 6-17 and
cure according to paragraph 6-19 and the
system specific technical manual.
(19) Apply finish system in accordance with para-
graph 7-13b or the system specific technical
manual.
7-13. POST CURE PROCEDURES. The following
are the post cure procedure to be performed.
a. Visually Inspect.
(1) Disassemble (if required) and trim laminate
to specified dimensions (if applicable).
(2) Visually inspect surface of laminate for resin
starved areas or voids and fill with additional
adhesive as necessary. If there are any
rough edges or excess resin flow, sand them
smooth.
(3) Coin tap or ultrasonically inspect the repair
according to paragraph 5-2 or the system
specific technical manual to insure adequate
consolidation.
(4) Trim and sand area for painting according to
the system specific technical manual.
Protect areas not to be refinished with covers
to prevent damage. Do not allow paint, corro-
sion removers, solvents, or corrosion resistant
coating to contact transparent plastic panels,
bonded joints, reinforced plastic surfaces, or
rubber seals.
b. Paint. Trim and sand area for painting according
to the system specific technical manual or TM 55-1500-
345-23. Coat with MIL-PRF-23377 primer and finish
with MIL-DTL-53039 or MIL-DTL-64159 CARC paint.
MIL-DTL-53072 provides additional guidance.
7-117/(7-118 blank)
 TM 1-1500-204-23-11
APPENDIX A
REFERENCES

A-A-3174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercial Item Description, Plastic Sheet Polyolefin

A-A-55063 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercial Item Description, Apron, Utility, Impermeable, Rubber
Coated Fabric (General Purpose)
A-A-58092 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercial Item Description, Tape, Antiseize, Polytetrafluorethylene Air
Force Advanced Composite Repair Facility Guide
AC145-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Stations for Composite and Bonded Aircraft Structure
AR 385-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Army Safety Program
AR 385-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Color Code Markings and Signs
AR 385-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protective Clothing and Equipment
AR 11-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Army Respiratory Protection Program
ASTM D 6507 – 11 . . . . . . . . . . . . . . . . . . . . Standard Practices for Fiber Reinforcement Orientation Codes for Com-
posite Materials
ASTM E 230 . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Measurement Thermocouple
ASTM E 1309 – 00 . . . . . . . . . . . . . . . . . . . . Standard Guide for Identification of Fiber-Reinforced Polymer-Matrix
Composite Materials in Databases
CCC-C-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cloth, Cleaning, Nonwoven Fabric
CMH-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Composite Materials Handbook
ISO 14644 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleanrooms and Associated Controlled Environments
MIL-DTL-53039 . . . . . . . . . . . . . . . . . . . . . . . Detail Specification: Coating, Aliphatic Polyurethane, Single Compo-
nent, Chemical Agent Resistant
MIL-DTL-53072 . . . . . . . . . . . . . . . . . . . . . . . CARC Painting
MIL-DTL-64159 . . . . . . . . . . . . . . . . . . . . . . . Detail Specification Coating, Water Dispersible Aliphatic Polyurethane,
Chemical Agent Resistant
MIL-HDBK-337 . . . . . . . . . . . . . . . . . . . . . . . . Adhesive Bonded Aerospace Structure Repair
MIL-HDBK-1028/5 . . . . . . . . . . . . . . . . . . . . . Environmental Control – Design of Clean Rooms
MIL-PRF-131 . . . . . . . . . . . . . . . . . . . . . . . . . . Performance Specification, Barrier Materials, Water-vapor proof,
Grease-proof, Flexible, Heat-Sealable
MIL-PRF-23377 . . . . . . . . . . . . . . . . . . . . . . . Performance Specification: Primer Coatings: Epoxy, High-solids
MIL-PRF-81309 . . . . . . . . . . . . . . . . . . . . . . . Corrosion Preventive Compounds, Water Displacing, Ultra-Thin Film
MIL-STD-810 . . . . . . . . . . . . . . . . . . . . . . . . . . Department of Defense Test Method Standard for Environmental Engi-
neering Considerations and Laboratory Tests
NAVAIR 1-1A-21 . . . . . . . . . . . . . . . . . . . . . . . Organizational and Intermediate Maintenance General Composite
Repair1
NEHC-TM 91-6 . . . . . . . . . . . . . . . . . . . . . . . . Navy Environmental Health Center Technical Manual
NFP Standard 30 . . . . . . . . . . . . . . . . . . . . . . Flammable And Combustible Liquids Code
SAE AMS 3819 . . . . . . . . . . . . . . . . . . . . . . . . Cloths, Cleaning, For Aircraft Primary and Secondary Surfaces,

A-1
TM 1-1500-204-23-11
SAE AMS-T-22085 . . . . . . . . . . . . . . . . . . . . Tapes, Pressure-Sensitive, Adhesive, Preservation and Sealing
SAE ARP 4916 . . . . . . . . . . . . . . . . . . . . . . . . Aerospace Recommended Practice, Masking and Cleaning Of Epoxy
and Polyester Matrix Thermosetting Composite Materials
SAE ARP 4977 . . . . . . . . . . . . . . . . . . . . . . . . Aerospace Recommended Practice, Drying Of Thermosetting Compos-
ite Materials
SAE ARP 4991 Rev A . . . . . . . . . . . . . . . . . Aerospace Recommended Practice, Core Restoration of Thermosetting
Composite Components
SAE ARP 5089 . . . . . . . . . . . . . . . . . . . . . . . . Aerospace Recommended Practice, Composite Repair NDT/NDI Hand-
book
SAE ARP 5143 . . . . . . . . . . . . . . . . . . . . . . . . Aerospace Recommended Practice, Vacuum Bagging Of Thermosetting
Composite Repair, 7/2002
SAE ARP 5144 . . . . . . . . . . . . . . . . . . . . . . . . Aerospace Recommended Practice, Heat Application for Thermosetting
Res-in Curing
SAE ARP 5319 . . . . . . . . . . . . . . . . . . . . . . . . Aerospace Recommended Practice, Impregnation of Dry Fabric and Ply
Lay-Up
TM 1-1500-204-23-7 . . . . . . . . . . . . . . . . . . . Aviation Unit Maintenance (AVUM) and Aviation Intermediate Mainte-
nance (AVIM) Manual for General Aircraft Maintenance (Nondestructive
Testing and Flaw Detection Procedures and Practices) Volume 7
TM 1-1500-204-23-10 . . . . . . . . . . . . . . . . . . Aviation Unit Maintenance (AVUM) and Aviation Intermediate Mainte-
nance (AVIM) Manual for General Aircraft Maintenance (Sheet Metal
Shop Practices) Volume 10
TM 1-1500-344-23 . . . . . . . . . . . . . . . . . . . . . Aircraft weapon systems Cleaning and Corrosion Control
TM 1-1500-335-23 . . . . . . . . . . . . . . . . . . . . . Nondestructive Inspection Methods, Basic Theory
TM 55-1500-345-23 . . . . . . . . . . . . . . . . . . . . Painting And Marking of Army Aircraft
TB 385-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Procedures for Maintenance of Electrical/Electronics Equipment
TM 385-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions for Maintenance of Electrical/Electronic Equipment
TO 1-1-690 . . . . . . . . . . . . . . . . . . . . . . . . . . . General Advanced Composite Repair Processes Manual

A-2
 TM 1-1500-204-23-11
APPENDIX B
TOOLS AND CONSUMABLE ITEMS

B-1. TOOLS

Table B-1. Tools

Item Cage
Description Part Number Notes
Number Code
Abrasive Disk 1" 180 grit 5345-01-270-7989 Merit #6103 power lock disc.
Aluminum oxide. Attachment
method: Snap on plastic. Use
with rubber arbor purchases
separately.
Air Hose Hansen Connector 4720-00-956-5313 SG280001EA/
Apex Holder 5130-00-337-9125 (3/8" Drive) 1/4" hex shank Order
thru GSA
Bandsaw Blade, Tungsten Carbide 3455-01-046-8836 162" long, .375 wide.
coated, no teeth
Coiled Air Hose 4720-00-451-1008 .250 inside diameter, 300" long
Compass w/ Pencil Attachment 6675-00-641-3207
Comp. Balancing Digital Scale 6670-01-384-3640 Floor scale, 1000 lb capacity.
(LG) Equipment item on allowance
standard 783 (sheet metal
and plastics shops). See the
allowance standard for additional
scales
Core Slicer Router Bit 3455-01-087-2242
Core Knife, 4 1/4” Blade 5110-00-595-8403
3460-00-170-7886 3" X .035 thick, with .375 hole in
the middle. Aluminum oxide, 60
Grit
3460-00-528-3100 3" X .125 thick, with .375 hole in
the middle. Aluminum oxide, 60
Grit
Cut-off wheel
3460-01-102-8534 3" X .062 thick, with .375 hole in
the middle. Aluminum oxide, 54
Grit
3460-00-172-5291 3" X .062 thick, with .375 hole in
the middle. Aluminum oxide. 36
Grit
Die Grinder, 90 degree head 5130-00-827-0895 Order thru GSA. Pneumatic,
(Dotco) 12,000 rpm, .250 collet.
Die Grinder, 90º, ≥20,000 RPM, 5130-01-351-2065
Rear Exhaust
Chuck Wrenches W/ Grinder
Router Bit, 1/4” Diamond Abrasive

B-1
TM 1-1500-204-23-11

Table B-1. Tools — Continued

Item Cage
Description Part Number Notes
Number Code
Router Bit, 1/4” Split Helix
Sanding Mandrel, 3/4”
Sanding Mandrel, 2” 5210-00-234-5223
3/4” Sanding Disks, 180 Grit
Sanding Disks, 2”, 180 Grit
Abrasive Disks, 2” Scotchbrite
(medium soft)
Drill Bit, 1/8” Brad Point Carbide
Hole Saw, 1” Diameter Kevlar®
(w/ 1/8” Pilot)
Hole Saw, 1” Diameter Diamond
Abrasive (w/ 1/8” Pilot)
Drill Bits, Carbide: #30, #21, #10, *
Countersink, Carbide, 100º,,
Replaceable Pilot Type
(AT455CTE-4)
Countersink, 100º, Kevlar®
Cutting, Replaceable Pilot Type
(AT455SK)
Countersink Pilots, 1/8”, 5/32”, 3460-01-292-4755
3/16”, 1/4” (AT484-57-59-61-65) 3460-01-292-4756
3460-01-292-4757
3460-01-292-4758
Countersink Cage (AT442HS)
Mandrel, 1” Sanding Drum
Sanding Drums, 1”x 1”, 180 Grit
Thermometer, Digital Type 6685-01-292-7873 When ordering by NSN, may get
J/K(Fluke 51) other brands.
Dial Calipers 5210-01-010-4522
or
5210-01-458-1327
Micrometer Local Availability
Dividers, Machinists, 6” 5210-00-263-0376
Double Vacuum Debulk Tool(DVD) 4920-01-470-1453
Drill Motor, 3/8” Chuck, Reversible,
Keyless Chuck (AT805KC or
IR7811KC)
Fractional Drill Gauge 5210-00-273-9865 Order thru GSA. Used to
determine size of drill bits
between 1/16 and 1/2 inch
HEPA Vacuum (portable) 7910-01-192-2495 Order thru GSA

B-2
 TM 1-1500-204-23-11

Table B-1. Tools — Continued

Item Cage
Description Part Number Notes
Number Code
Dust Collection System, HEPA 4SE01754/7910-01-306-4144
Filter Vacuum Cleaner Hako Minuteman/16893
Heat Lamp, Infrared, 115V, 250 6240-00-712-3090
Watt
Inspection Mirror 5120-01-335-1572
Letter Drill Gauge 5210-00-203-7657
Magnifying Glass (2X, 2" Dia) 6650-00-252-6250
Magnifying Glass 6650-00-252-6249
Number Drill Gauge 5210-00-221-1893 Order thru GSA. Used to
determine size of drill bits
between #1 and #60. Order thru
GSA
Oil (Vacuum Pump) 9150-00-273-8663 MIL-L-83767. to view the spec,
visit vml. Viscosity=90
Orbital Sander 5130-00-606-9694
Pressure Regulator R01-200-RGLA
C.A. Norgren/43990
Pinking Shears 5110-00-162-2202
Putty Knife, 11/2” Wide Blade 5120-00-221-1536
Router (23,000 RPM) 5130-00-618-4445 Air Driven, 3/4 HP, 1/4" collet,
20,000 RPM Order thru GSA
Ruler, 6” Steel 5210-00-234-5223
Ruler, 12” Steel 5210-00-234-5224
Scale, Triple Beam Balance 6670-00-494-3604 2600 gram capacity. 0.1 g
increments
Screwdriver, Ratcheting, Magnetic 5120-01-432-5179
(SSDMR4B) *
Sealant Gun, SEMCO Model 250 5130-00-341-1931 SEMCO/92108
Sealant Gun, Metallic Retainer 5120-00-693-8069 SEMCO/92108/220256
Barrel, 2 1/2 Oz
Sealant Gun, Cartridge, 2 1/2 Oz 5120-00-670-3295 SEMCO/92108/220323/
Disposable
Sealant Gun, SEMCO Nozzle, 2.5 5120-00-167-0150 SEMCO/92108 Model 252
Inches Long
Sealant Gun, SEMCO Nozzle, 4 5120-00-042-6577 SEMCO/92108 Model 420
Inches Long
Sealant Gun, SEMCO Nozzle, 6 5120-00-167-0152 SEMCO/92108 Model 620
Inches Long
Shears 5110-00-293-0089 Straight cut hand held metal
sheer, (tin snips)

B-3
TM 1-1500-204-23-11

Table B-1. Tools — Continued

Item Cage
Description Part Number Notes
Number Code
Scissors, Padded Handle 5110-00-161-6909
Scissors, 9” Fiskars 5110-01-278-4823
Squeegee, Adhesive Spreader, 5120-00-628-5569
Plastic
Tap Hammer
Thermocouple Welder (ATACS 3432-01-150-5391
4025)
Utility Knife (Craftsman) 5110-00-268-3883 Order thru GSA
Stanley Knife 5110-00-892-5071
Stanley Knife Blades 5110-00-293-2865
Weights, Shot Bag Local Availability
X-Acto Knife 5110-00-595-8400 Order thru GSA
Surgical Razor 6516-00-926-2089
C-Clamp, 4 Inch 5120-00-180-0908
Torque Wrench, 0-75 Inch-Lbs Local Availability
Microstop Cage Local Availability
Composite Repair Kit 4920-01-556-2562

B-2. DRILL MOTOR AND DRILL BITS

Table B-2. Drill Motor and Drill Bits

Item Cage
Number Description Part Number Code Notes
Drill Bit, Carbide, Straight Flute 2.0 ST1257B-261-2.0 Quality Carbide-threaded Tool
inches long, 1/4-inch diameter,
Drill Bit, Carbide, Straight Flute 6.0 ST1257B-1285-6.0 Quality Carbide Tool
inches long, No. 30
Drill Bit, Dagger, Carbide Starlite Industries (Part of F-18
0.2510-inch diameter, 35-degree kit)
point, 6.0 inches long

B-3. HOT BONDER MATERIALS

B-4
 TM 1-1500-204-23-11
Table B-3. Hot Bonder Materials

Item
Num- Cage
ber Description Part Number Code Notes
Hot Bonder, Single Zone 4920-01-462-4658 Heatcon HCS9000A (or
equivalent):
Hot Bonder, Dual Zone 4920-01-445-4529 Wichitech HB2 (or equivalent):
Heat Blankets, 1 ea. 8”, 12”, 18”
Round or Square
Thermocouples, “J” Type, 20 ea 9505-01-472-6824
Vacuum Fittings, 12 male, 6 female 4730-01-299-0752
Vacuum Ports, (Vac Valve 401), 4 4820-01-192-5828
ea
Vacuum Manifold (1 input 2
output), 2 ea.
Vacuum Gauge, Liquid Filled
Tape Dispenser 7520-00-285-1772
Digital Scale
Vacuum Pump 4310-00-131-9183 This is a master NSN. It’s an
equipment item. It’s listed
on Allowance Standard 783
(sheet metal and plastic shops).
See also 4610-00-212-6265,
4310-01-086-1168,
4310-01-112-6712
Vacuum Attachment, Compressed
Air Driven

B-4. CONSUMABLE MATERIALS

Table B-4. Consumable Materials

Item
Num- Cage
ber Description Part Number Code Notes
Shim-In-A-Can, Stainless, .009”
Thick
7920-01-180-0556 Meets CCC-C-46 Type 1 Class
7 requirements. Suitable for
solvent wiping prior to bonding.
Cloth, Cleaning
7920-01-180-0557 Meets CCC-C-46 Type 1 Class
7 requirements. Suitable for
solvent wiping prior to bonding
Rymplecloth 7920-01-004-7847 Purified cloth for solvent wipe
prior to bonding
Rymple cloth 301

B-5
TM 1-1500-204-23-11

Table B-4. Consumable Materials — Continued

Item
Num- Cage
ber Description Part Number Code Notes
6850-01-487-2859
6850-01-487-2861
Sonatra Wipes
6850-01-488-7711
6850-01-488-7707
Adhesive Spreader P.A.-13M Co/76381
Adhesive Comb SK340-00192 Local Manufacture per figure
7-22
Acid Brushes 7920-00-514-2417 3’ X 20’ roll. .003 thick. Not
suitable for food
Aluminum Foil 0.004" 9535-00-752-9061 For sealing bags for storing
pre-preg and film adhesive
3540-01-465-7631 For sealing bags for storing
Bag Sealer, Heat Sealer pre-preg and film adhesive
3540-00-975-4255
Jaw Type Heat Sealer
Baking Soda 100lb 6810-00-290-5574 Sodium bicarbonate, technical
Copper Sheet 9535-00-232-0355 .012 thick, used to help dissipate
heat evenly when using heat
blankets
Cotton Tip applicator 7350-00-290-0586 Short, squat type
Cup, Mixing, 16 ounce, wax free 7350-00-641-4520
Cups, Mixing, wax free 7350-00-641-4518 12 oz. capacity. 1200 per case
Cups, Paper, Disposable 7350-00-641-4516 Use only if authorized by the
system specific tech manual.
5, 1 gallon containers. See
www.orelube.com for more info
Cutting Fluid, Boelube 9150-01-518-9018 Search Fedlog. Use Part Num-
bers MIL-C-9084 and AMS-C-
9084. To download the Mil
spec, visit http://stinet.dtic.m-
il/str/dodiss4_fields.html. To
Purchase the AMS spec, visit
http://aerospace.sae.org/
Fiberglass Cloth
Paper, Kraft 8135-00-160-7764 For protecting parts from
contamination during storage
Peel Ply Airtech Release Ply G
Pencil, Aircraft Marking, Red MIL-P-83953
Pencil, aircraft marking, yellow MIL-P-83953

B-6
 TM 1-1500-204-23-11

Table B-4. Consumable Materials — Continued

Item
Num- Cage
ber Description Part Number Code Notes
Pencil, Silver Used for marking damage on
composite parts. Not for marking
on dry fabric or pre-preg. Berol #
753 or Sanford Verithin # 02460.
Do a search online or go to local
office or art supply store
Marking Pen, Extra Fine Point, 0.4 Sharpie, Sanford Corp./ 86874
mm Line Width, Permanent Ink
Sharpie Pen, Fine Point
Berol™ Pencil, Black
Berol™ Pencil, Black
Pin Connector (J-type Male) 5935-01-256-1841
Scotch Bright Pad 7920-00-753-5242 Scotchbrite 96
Stirring Stick 7340-00-753-5565 Probably too thin for our use
(kaw). Order thru GSA. 5 1/4
long. .187 wide, .036 thick
Tape, High Temp Nylon, 400 °F 7510-01-202-2195 3M#855, 1" wide, .003" thick,
max 400F max, Non-silicone
adhesive allows use on many
parts where subsequent painting
or bonding is necessary.
Template Material 9330-01-358-7521 .020 thick. Clear.
Template material, Acetate 9330-00-290-6755 .040 thick
Template material, Mylar 9330-01-223-6127 .005 thick, clear. Good for
marking lay-ups and fiber
direction
Wooden Spatula 6515-00-324-5505
6515-00-324-5500 6" X .750" X .062"
Tongue Depressors
6515-00-324-5500
5 cc Industrial Syringe 6515-00-754-0406 SEMCO/92108
18 Gauge Needle 6515-00-656-0477 SEMCO/92108
20 Gauge Needle 6515-00-349-3400 SEMCO/92108

B-5. VACUUM BAGGING

B-7
TM 1-1500-204-23-11
Table B-5. Vacuum Bagging Materials

Item
Num- Cage
ber Description Part Number Code Notes
Porous Teflon Sheet (Armalon or 8305-01-100-9061
eq.)
1581 Style Fiberglass Cloth 5999-01-184-3935
Perforated Teflon (Airtech 9330-01-381-4622
A4000-RP or eq.)
Solid Release Film (Airtech A4000 9330-01-196-5436
or eq.)
4 oz. Breather (Airtech Airweave 9330-01-381-9005
N4 or eq.)
Bagging Film (Airtech WL7400 or 9330-01-408-5068
eq.)
Vacuum Bag Sealant Tape 9320-01-182-9220 (Schnee-Morehead 9151)
PVC Film, 0.020" 8135-00-050-7698 L-P-375 Type 1 Class 1. Temp
limit 0F to 130F. To view the
spec, visit vms
Bagging Film 9330-01-119-9657 .002 thick. Nylon. Blue. 450F
max. Can be heat seamed.
Product can be Vac-Pac HS6262
from Richmond Aircraft or
Wrightlon 8400 from Airtech
Bagging Film, Nylon, 450F 9330-01-119-9657 Part numbers are WRIGHTLON
8400 and VAC-PAC HS-6262.
Max temp = 450F. Good for
epoxy. Avoid phenolic resins.
.002" thick
Cloth, breather, 9390-01-366-6326 Non-woven Polyester, .125 thick,
4.4 oz/yd2. Max temp 400F
Duckseal 8030-00-281-2337 Similar to tacky tape. Can
be re-used. Less expensive.
Harder to get a good seal and a
good vacuum
Nylon Film High Temp Green 9330-00-302-7957 Part numbers include HS8171,
WRIGHTLON 7400, and VACPK
H.S. 8171 6/66. Temp limit =
400F. Good for epoxy. Do not
use with phenolic resins
Polyethylene Film, general purpose 8135-00-579-6489 L-P-378 Type 1 Class 1, Grade
A finish 1. visqueen. Clear.
To view the spec, visit vms,
thickness = .006"
Release Film, FEP 9330-01-225-9550 Fluorocarbon Release Film,
Max temp 500F. Non-perforated.
.001" thick. Red, violet, or white

B-8

Table B-5. Vacuum Bagging Materials — Continued
Item
Num-
ber Description
Tacky Tape
Tape, Flash breaker 1
Tape, Flash breaker 2, 1"
Tape, Flash breaker 2, 2"
Tape, Flash breaker 5, 1"
Tape, Flash breaker 5, 2"
Teflon Coated FiberglassCloth
0.0003", FEP
Vacuum Bag Repair Materials Kit
Vacuum bag kit (Kit, fiberglass)
B-6. PERSONAL PROTECTIVE EQUIPMENT
TM 1-1500-204-23-11
Cage
Part Number Code Notes
9320-01-182-9220 425 °F max cure. Pink. Made
by Schnee-Morehead part
#SM9151. 12 month shelf life
8030-01-183-1721 Gray or tan. Up to 350 °F cure
7510-01-108-0174 1" wide, light blue, 400 °F max
temp, .002 thick. 1 year shelf
life. Polyester
7510-01-408-9946 Order thru GSA, Blue, .003 thick.
400 °F max temp. 1" wide. Flash
breaker 2 is slightly thicker and
thus stronger than Flash breaker
1. both are available in 1" or 2"
widths.
7510-01-480-4366 Order thru GSA, Blue, .003 thick.
400 °F max temp. 2" wide. Flash
breaker 2 is slightly thicker and
thus stronger than Flash breaker
1. both are available in 1" or 2"
widths.
8040-01-390-7587 Order thru GSA, Blue, .006
thick. 400 °F max temp. 1" wide.
Flashbreaker 5 is thicker and
stronger than Flash breaker 1
and 2.
7510-01-408-9948 Order thru GSA, Blue, .006 thick.
400 °F max temp. 1" wide. Flash
breaker 5 is thicker and stroner
than Flash breaker 1 and 2.
8040-01-390-7589 Order thru GSA, Blue, .006 thick.
400F max temp. 2" wide. Flash
breaker 5 is thicker and stronger
than Flash breaker 1 and 2.
5970-01-258-2504 250 yard roll. Part numbers
PRFP3 and TEMPRGLAS3TLL
4920-01-501-0059
4130-01-471-6416
B-9
TM 1-1500-204-23-11
Table B-6. Personal Protective Equipment

Item Description Part Number Cage Notes

Num- Code
ber
Coveralls disposable. Large/XLGE 8415-01-445-6568 Hooded, with booties
Coveralls disposable. 8415-01-445-6565 Hooded, with booties
Small/medium
Gloves, white cotton, medium 8405-01-138-2495
Gloves, white cotton, small 8405-01-138-2494
Gloves, White Cotton 8415-00-268-8353
Lab Coats, Large 8415-00-823-7613 Knee length. Button Front.
Cotton or poly/cotton blend
Lab Coats, Medium 8415-00-823-7612 Knee length. Button Front.
Cotton or poly/cotton blend
Lab Coats, Small 8415-00-823-7611 Knee length. Button Front.
Cotton or poly/cotton blend
Lab Coats, Xlge 8415-00-823-7614 Knee length. Button Front.
Cotton or poly/cotton blend
Rubber Apron 8415-00-634-5023 Order thru GSA
Plastic gloves 6515-01-150-2978
Latex surgeons gloves 6515-01-149-8842
Latex Gloves 6516-01-149-8842
Leather and leather palmed gloves 8415-00-268-8350
Face Shield MIL-STD-1202

B-10
 TM 1-1500-204-23-11
GLOSSARY
The contents of this glossary were derived from many sources. Several terms may not have been used in this
document but were included to assist composite material maintenance and design personnel in understanding
standard composite terminology.

A
A-SCAN A data presentation method for ultrasonic inspection. Data is displayed on a cath-
ode ray tube (CRT). Sound energy amplitude is plotted on the vertical axis and
distance (or time of flight) on the horizontal axis..
A-STAGE Early stage in the reaction of a thermosetting resin in which the resin is still soluble
and fusible. (See B-Stage and C-Stage.)
ACCELERATOR A material mixed with a resin to speed up the curing process between the resin and
hardener or catalyst.
ACTIVATOR Material or process used to prepare a surface for bonding.
ADHEREND An object bonded or to be bonded to another object by an adhesive. (See Sub-
strate.)
ADHESIVE A glue-like material used to produce a strong bond between two parts by surface
attachment. Adhesives take the form of films, foams, pastes, or liquids.
ADHESIVE OUT-TIME See OUT-TIME.
ADVANCED COMPOSITE A combination of high strength, high extensional stiffness fibers (boron, carbon,
MATERIALS aramid) embedded in a matrix material (epoxy, bismaleimide, polyimide).
AGING Effect on materials of environmental exposure for an interval of time.
AIRSTREAM STRIPPING Damage caused by air flow over a laminate subjected to penetration or edge dam-
age. Portions of the outer ply are lifted off and peeled back until fiber failure occurs.
AMBIENT DRYING Drying a material at room temperature, 75 °F recommended.
AMBIENT TEMPERATURE Temperature of the environment surrounding the object under consideration. Usu-
ally refers to room temperature.
ANGLE PLY Containing plies alternately oriented to any angle to the reference axis not including
0,90 plies.
ANGLE PLY LAMINATE Laminates composed of plies oriented at different angles (typically 0, ±45 and 90°)
to a stated reference direction.
ARAMID FIBER Generic name for a class of synthetic fibers made by the dry-jet wet spinning
process. Aramid fibers are characterized by toughness and impact resistance.
Laminates made using these fibers are notoriously difficult to machine and drill.
Kevlar® and Nomex® are examples of aramids.
AREAL WEIGHT The weight of fiber per unit area. This is often expressed as grams per square
meter.
AUTOCLAVE A vessel capable of providing heat and pressure for curing or consolidating
advanced composite laminates, composite bonded assemblies and metallic
bonded assemblies (i.e., a pressurized oven).

B
B-STAGE An intermediate stage in the curing of a thermosetting resin that is between
completely uncured (A-STAGE) and completely cured (C-STAGE). The resin in
this stage has been partially reacted and is normally a solid at room temperature.
The resin melts to a liquid state when heat is applied. Uncured film adhesive and
pre-preg materials are provided in this stage and completely cured.
B-SCAN An Ultrasonic Inspection (UT) method used to determine the depth of a defect.
BCM Beyond capability of maintenance. A part that is BCM is sent to the next higher
level of maintenance for repair.
BALANCED LAMINATE A composite laminate in which each positive angle ply is balanced by a negative
angle ply, with respect to a reference axis.
BINDER A bonding resin used to hold strands together in a mat or during manufacture of a
molded object. This is not a matrix resin.

Glossary-1
TM 1-1500-204-23-11
BISMALEIMIDE A thermosetting polyimide resin system with an intermediate service temperature
of 400 to 450 °F. They are used as both adhesives and matrix materials.
BLEEDING The removal of resin from composite pre-preg or wet layup into bleeder plies during
the cure process. Resin bleeding is used to remove volatiles, to facilitate ply to ply
bonding and to remove excess resin from the laminate.
BLEEDER CLOTH A material, usually fiberglass cloth, used in the manufacture of composite parts to
absorb excess resin and to allow gases to escape during the curing process. The
bleeder cloth is separated from the part after cure and is not part of the composite.
BLEEDER PLIES Several layers of bleeder cloth. The amount of resin removed from the laminate is
a function of the number and type of bleeder plies used. Bleeder plies are removed
from the laminate after cure and discarded.
BLEEDOUT Excess resin that migrates to the bleeder cloth during the resin cure.
BLISTERING A bubble like swelling on the surface of a laminate usually the result of thermal
damage.
BLOWING AGENT A heat activated nitrogen-releasing material used in foaming adhesives to cause
expansion.
BLOWN CORE Honeycomb core that has experienced skin to core disbonds and/or node bond
failures. The usual cause is the pressure buildup resulting from the presence of
moisture in the assembly during an elevated temperature cure cycle.
BOND The attachment of one surface to another through the use of an adhesive as a
gluing agent. (See Joint.)
BOND STRENGTH The load carrying capacity of two materials attached through the use of an adhe-
sive.
BONDLINE The adhesive interface between two materials attached through the use of an adhe-
sive or the stress required to separate a layer of material from the adherend to which
it is bonded.
BORON FIBER A strong, high extensional stiffness fiber produced by chemical vapor deposition of
elemental boron onto a small diameter tungsten wire. Primarily used for its stiffness
and compressive strength.
BREATHER CLOTH A layer of coarse woven fiberglass cloth or polyester mat used in vacuum bagging
to allow bag venting or breathing by providing separation between the vacuum bag
and the part.
BRIDGING (1) An unsupported area on a part being vacuum bagged that can result in bag
failure when pressure is applied.
(2) A condition than can exist in a composite layup where inadequate pressure is
applied during cure resulting in voids.
BROADGOODS A term loosely applied to pre-preg material greater than 12 inches in width, usually
furnished by suppliers in continuous rolls. The term is currently used to designate
both unidirectional tape and woven fabric pre-pregs. (See Fabric.)
BUCKLING A mode of compression deformation similar to stepping on and flattening a bever-
age can.
BUNDLE (See Tow.)

C
C-SCAN A data presentation method for ultrasonic inspection which provides a plan view
of the part scanned using an X and Y coordinate system. A hard copy of the data
presented can be provided.
C-STAGE The final stage of the curing of a thermosetting resin in which the material has
become infusible and insoluble in common solvents. Fully cured thermosets are in
this stage. (See A-Stage and B-Stage.)
CARBON FIBER A strong, high extensional stiffness fiber produced by the carbonization of a syn-
thetic material similar to rug yarn. When compared to graphite fibers, carbon fibers
are carbonized at a lower temperature, have less elemental carbon present follow-
ing carbonization (80-95% versus 99% for graphite) and have a lower extensional
stiffness. The terms carbon and graphite have been used interchangeably but the
fibers used on aircraft are technically carbon.

Glossary-2
 TM 1-1500-204-23-11
CARBONIZATION The process of pyrolyzation in an inert environment at high temperatures. Carbon
fibers are pyrolyzed at temperatures near 3000 °F and graphite fibers at tempera-
tures in excess of 3000 °F. Most non-carbon elements are driven off in the process.
CARRIER Backing material on film adhesive or pre-preg. To facilitate ease of handling; is part
of the cured repair.
CATALYST A substance that changes the rate of a chemical reaction without itself undergoing
permanent change in its composition.
CAUL PLATES Smooth metallic or plastic plates used in a composite layup or on a repair part
to distribute pressure and/or heat and to provide a smooth surface on the finished
laminate. The caul plates are not part of the finished repair; they are removed when
the vacuum bag is removed.
COBONDING The process of curing different materials in a single step. An example would be
curing a laminate while bonding that laminate to honeycomb core. During repair, the
cocure process may be used to simultaneously cure the repair patch and adhesive
to ensure a good patch to part fit is achieved.
COCURE The process of curing different materials in a single step. An example would be
curing a laminate while bonding that laminate to honeycomb core. During repair, the
cocure process may be used to simultaneously cure the repair patch and adhesive
to ensure a good patch to part fit is achieved.
COEFFICIENT OF The fractional change in length of a material with each degree of change in temper-
THERMAL EXPANSION ature. Composite materials generally have low CTEs when compared to metallic
materials.
COIN TAP The technique of lightly tapping the surface of a bonded part in the area of a sus-
pected defect. Applicable for detecting disbonds and delaminations in bonded hon-
eycomb sandwich assemblies with thin face sheets but not effective for finding
defects in thick laminates.
CONSOLIDATION The process of compacting composite material through elimination of trapped air.
DEBULKING
CONSTITUENT An element of a larger grouping. In advanced composites, the principal constituents
are the fibers and the matrix.
CONTAMINANT A foreign substance introduced into a bondline, laminate, or core material during
the layup process that degrades the strength of the part.
CONTACT ANGLE When a drop of liquid is placed on a surface, it will either retract into a ball, like a
drop of mercury, or spread out like water on a clean, high-energy surface. Contact
angle is the angle made between surface and a tangent to surface of drop at the
point of contact. A major purpose of surface treatments prior to adhesive bonding
is to ensure good wetting of bonding faces when adhesive is applied.
CORE The central member of a sandwich construction to which the faces of the sandwich
are bonded.
CORE CRUSH A collapse, depression or compression of the core.
CORE DEPRESSION A dent or gouge in the core.
CORE, HONEYCOMB Thin sheet of metallic foil or pressured or woven non-metallic impregnated or coated
with a specified resin, bonded at node points with an adhesive or compatible resin,
and expanded or formed into specific cell sizes and shapes. It is used as a core
in sandwich structure and provides a strong, lightweight assembly with exceptional
stiffness.
CORE PEGGING Joining two pieces of core by crush splicing them together with a third piece of core.
CORE SEPARATION A partial or complete breaking of the core node bond.
CORE SPLICING The structural joining of segments of core.
CRAZING The formation of minute surface cracks in the matrix material seen as a whitish
discoloration of the laminate.
CROSS-LINKING The joining of molecular chains in a thermoset material into a three dimensional
rigid structure. The joining occurs via chemical reaction with a curing agent during
the cure process.
CROSS-PLY Containing plies oriented at right angles (0,90) with respect to the principal fibber
direction.

Glossary-3
TM 1-1500-204-23-11
CRUSH SPLICING Joining or pegging core segments by overlapping each segment at least two cells,
then driving them together.
CURE The chemical process during which a thermosetting resin is irreversibly changed
from a weak flexible material into a strong rigid material usually involving heat and
pressure. Both polymerization and cross-linking occur during this process.
CURE CYCLE The total time heat and pressure are applied during the curing process.
CURE TEMPERATURE The temperature at which a resin-impregnated reinforcement or adhesive is cured.
CURING AGENT (1) The chemical compound in a thermosetting resin that links molecular chains
during the cure process.
(2) Part B in a two part adhesive system which combines with the base resin to
produce a cured material. (See Hardener.)

D
DAM Blockage area created to prevent uncontrolled resin loss.
DEBOND An adhesive failure in a joint area between two separate details resulting from
improper fit of the details, failure of the adhesive bondline or contamination of one
of the faying surfaces (e.g., separation between a face sheet and a core).
DEBULK A process to remove air and compact the layup prior to curing by the application of
vacuum bag or autoclave pressure.
DEFLECTION TEMPERA- Temperature at which a standard test bar deflects a specific amount under a stated
TURE load. Under Load (DTUL)
DEFORMATION Any change of form or shape produced in a body by a stress or force.
DEGAS Removal of air and volatiles from a laminate or patch bond during the cure cycle.
Air and volatiles not removed during the cure process result in voids.
DEGRADATION An undesirable change in the material properties.
DELAMINATION The separation of the layers or plies in a laminate. It may occur during fabrication
or sometime during the service life of the part. Most frequently caused by impact
forces. This term is often confused with the term disbond.
DESICCANT A substance which absorbs moisture. A color changing version (calcium sulfate
containing cobalt chloride) can be used as a moisture detector during the drying
process.
DILUENT An ingredient usually added to an adhesive to reduce the concentration of bonding
materials. A diluting agent, any liquid or solid, which when added to another liquid
or solid, reduces quantity per unit volume of base material in the total volume. A
reactive diluent may also take part in the curing action and is primarily used to
reduce viscosity.
DISBOND Lack of adhesion between members in a bonded joint or part. It can occur during
part fabrication or sometime during the service life of the part. It may be caused by
improper fit of bonded details, contamination of the adhesive or bonded details dur-
ing the layup process, failure of the adhesive bondline due to cure cycle stresses,
handling damage, or corrosion of metallic bonded members. (See Debond.)
DOUBLER A local area built up for added reinforcement.
DOUBLE VACUUM DEBULK A wet layup process technique that removes the entrapped air that causes porosity
in standard wet layup laminates.
DRAPE Ability of a fabric (or pre-impregnated material) to conform to an irregular shape.
DWELL The period of time that a process, such as the application of temperature and pres-
sure, is held constant. (See Soak.)

E
E-GLASS Electrical glass. E-glass is cheaper than S-glass but is not as strong.
ECCENTRICITY The amount by which two load paths in a bonded or bolted joint are not coincident.
EDGEBAND The solid laminate area around the core edge (i.e., core closure).
ENVIRONMENTAL Usually referred to as the controlled conditions of storage (e.g., cold storage).
STORAGE

Glossary-4
 TM 1-1500-204-23-11
EIGHT (8) HARNESS SATIN A weave pattern in which the fill fiber tows proceed over 7 warp fiber tows before
WEAVE passing under a warp fiber tow. This weave pattern is used for fabrication and repair
of complex contours and substructure details.
EMBOSSED/STAGED Film adhesive subjected to a short duration low temperature heat cycle during which
ADHESIVE a honeycomb core pattern is imprinted on the adhesive surface. The pattern pro-
vides a leak path for volatiles extraction during the initial stages of the cure cycle.
The staging process also removes residual solvent from the adhesive.
ENVELOPE BAG A vacuum bag that completely surrounds the part. Used for drying honeycomb
sandwich parts and when an oven or autoclave is used as the primary heat source
for curing repairs.
EPOXY A thermosetting resin made by reaction of epoxy groups. They are used for adhe-
sives and are the most commonly used matrix materials for structures manufactured
from ACM. Most epoxies have an upper service temperature limit of 250 °F.
EXOTHERM The liberation of heat during the curing of a thermosetting resin.
EXOTHERMIC REACTION A reaction obtained when mixing certain substances together, characterized by evo-
lution of heat. A reaction that gives off heat when certain substances are mixed
together. The mixing of two parts of an epoxy resin system produces an exothermic
reaction. Exotherm can exceed curing temperature, if uncontrolled, and damage
the repair.
EXTENSIONAL STIFFNESS A measurement of the ability of a material to resist elongation (or extension) when
a load is applied.

F
FACE SHEETS Composite or metal skins that sandwich a core material.
FAIRING A member or structure, the primary function of which is to streamline the flow of a
fluid by producing a smooth outline and to reduce drag, as in aircraft frames and
boat hulls. The process of shaping a curved surface to be free of unwanted bumps
and wiggles resulting in a smooth continuous curvature.
FAYING SURFACE Surface of an object that is bonded to another object.
FEP Type of Teflon film used as a parting agent (nonadhesive). Used during the repair
process but not part of the finished repair.
FIBER TOW An untwisted bundle of strands or filaments.
FIBER A strand of material with length as its one major dimension. It is used as the prin-
cipal load carrying member in a composite laminate.
FIBER DIRECTION/ The orientation or alignment of fibers within a laminate with respect to a stated
ORIENTATION reference direction.
FIBERGLASS Glass in fibrous form used in the fabrication of composites. E-Glass has a high
electrical resistance. S-Glass is a very high strength fiberglass.
FILAMENT Fibers characterized by extreme length and thinness, such that there are no ends
within a part except at a discontinuity. Filaments can be formed into yarn without
twist or with a very low twist. (See Yarn.)
FILAMENT WINDING An automated process in which continuous filament yarn or tape is treated with
resin and wound in a pattern onto a removable mandrel.
FILL Yarn oriented at right angles to the warp in a woven fabric. Also referred to as weft.
FILLER A substance added to an adhesive to improve or alter its working properties, per-
manence, viscosity, strength or other qualities such as electrical proper-ties and
color.
FILLER PLY Partial plies, usually located on sandwich edge bands that provide the desired edge
band thickness.
FILM ADHESIVE One part adhesive systems cast into thin sheets during adhesive manufacture. The
sheet is supported by a scrim cloth carrier material or is unsupported by reinforce-
ment.
FILL DIRECTION The direction of the fiber tows in a woven laminate that are oriented at right angles
to the warp tows.

Glossary-5
TM 1-1500-204-23-11
FILLET BOND The adhesive bond between facesheets and honeycomb core material in a honey-
comb sandwich assembly.
FLASH Excess resin material that forms at the parting line of a mold or die or is extruded
from a closed mold.
FLAT PLY COLLATION To collect or arrange plies of composite material during the layup process in the
proper sequence and orientation on a flat surface.
FLOW The movement of an uncured resin under heat and pressure. The amount of flow of
an uncured resin is a measure of the degree of aging the material has experienced.
It can be an indicator of how usable the material is for performing repairs.
FOAM A material, such as a plastic, that contains encapsulated gas bubbles referred to
as cells.
FOAM, OPEN CELL The cells are broken and interconnected which allows for the passage of air and
fluids through the foam. Open cell foam is typically soft with low strength and den-
sities from 0.5 to 0.75 lb/ ft³.
FOAM, CLOSED CELL The cells are intact and not interconnected. Closed cell foam is harder with a higher
strength than open cell foam and densities typically ranging from 2 to 3 lb/ ft³.
FOAM, SYNTACTIC A cellular plastic that is produced by incorporating preformed cells (hollow spheres
or microballoons) into a resin matrix.
FOAM-IN-PLACE Deposition of foam in a liquid state into a mold or cavity.
FOAMING ADHESIVE An epoxy film adhesive containing a blowing agent. It is used as a strong, light-
weight core splice material.
FREEZER A thermally insulated cabinet that maintains a temperature below zero degree
Fahrenheit.

G
GEL The point during the cure of a thermoset material when the viscosity increases to
the point where flow is no longer possible.
GEL COAT A resin applied to the surface of a mold before layup that becomes an integral part
of the finished laminate, usually to improve surface appearance.
GEL POINT The point at which the adhesive transitions from a fluid to a semi-solid (gel) state
takes place. Once in the gelled state, the adhesive molecules have networked;
any further manipulation of the adhesive will break down the net-work of molecules
and weaken the adhesive bond.. The stage at which a liq-uid begins to exhibit
pseudoelastic properties. This stage may be conveniently observed from inflection
point on a viscosity time plot.
GEL TIME The interval of time required from the introduction of the curing agent or accelerator
until the resin sets. As temperature rises, the gel time typically gets shorter. Also
referred to as set time.
GRAPHITE FIBER Carbon based fiber with a higher extensional stiffness and higher percentage of
elemental carbon than the carbon fiber (see CARBON FIBER). Graphite filaments
are made by graphitizing tows or bundles of organic precursor filaments, the most
predominant of which today are made from Polyacrylonitrile (PAN), although rayon
and pitch are used to some extent. These filaments are designated herein as high-
strength and high-modulus fibers.
GLASS CLOTH Conventionally woven glass fabric consisting of fiberglass fibers.
GLASS TRANSITION The temperature at which a cured thermoset material softens from a glassy state
TEMPERATURE to a rubbery state. The effect is completely reversible. ACM experience a consid-
erable loss in strength and stiffness at temperatures above their Tg.

H
HAND LAYUP The process of placing successive plies of reinforcing material or resin-impregnated
reinforcement on a mold or part by hand.
HARDENER A material added to a polymeric material to promote or control the curing action by
becoming an integral part of the cured resin.

Glossary-6
 TM 1-1500-204-23-11
HELICAL WINDING In filament-wound items, a winding in which a filament band advances along a heli-
cal path, not necessarily at a constant angle except in case of a cylinder.
HOMOGENEOUS Uniform composition throughout.
HYBRID LAMINATE A laminate containing two or more types of reinforcements such as car-bon/boron
or fiberglass/carbon.

I
IMPACT ENERGY The energy resulting from dropped tools, equipment, or other objects striking an
object. This energy may cause dents and/or delamination damage to composite
laminates depending upon the amount of energy imparted to the laminate. The
energy is measured in foot-pounds. Note: A two pound object dropped from six
feet imparts twelve foot-pounds of impact energy on the part surface.
IMPREGNATED A reinforcement material (fabric, tape, etc.) saturated with resin.
REINFORCEMENT
INCHES OF MERCURY A common unit of measure of the amount of vacuum obtained by a vacuum pump.
VACUUM One inch of mercury equals approximately 0.5 pounds per square inch of vacuum
pressure. At sea level, the maximum vaccum you can draw is 29 inches of mercury;
this decreases as you go up in elevation.
INCLUSION A physical and mechanical discontinuity occurring within a material or part, usually
consisting of foreign material particles, chips, films, etc., of varying sizes which are
inadvertently left in the layup.
INNER MOLD LINE (IML) The inner surface of the part.
INSULATOR A material of low thermal or electrical conductivity (e.g., wood, glass).
INTERFACE The boundary between the individual, physically distinguishable constituents or
components of a composite.
INTERPLY At ply interfaces (between plies).
INTRALAMINA Existing or occurring entirely within a single ply without reference to any adjacent
laminae.
INTRAPLY Within a ply.
ISOTROPIC Having uniform properties in all directions.

J
JOINT For repair, the means by which a patch and structure are joined together to restore
load path continuity. This may be accomplished by either bonding or bolting the
patch and structure together.
JOINT, OVERLAP A joint made by placing one component partly over another and bonding/bolting the
overlapping portions together.
JOINT, STEP A joint made by cutting each layer or ply to produce a terraced shape.
JOINT, SCARF A co-linear joint made by cutting away similar angular segments of two adherends,
then bonding the adherends with the two cut faces fitting together (e.g., spliced
joint).

K
K-COR® The registered trade mark for the foam core produced by Albany International.
K-Cor® consists of interlacing carbon pins embedded in a foam core. The carbon
pins are pressed down during manufacturing and the core is adhesively bonded to
the face sheets.
KEVLAR® The registered trade mark for the aramid fiber produced by the E. I. DuPont de
Nemours and Company, Incorporated. See ARAMID FIBER.
KICKOVER Resin and adhesive systems which have hardened.

L
LAMINA A single layer in a laminate. The layer contains fibers and matrix material in either
unidirectional or woven form.

Glossary-7
TM 1-1500-204-23-11
LAMINAE Plural of lamina.
LAMINATE A structural member made by bonding together two or more layers (plies or lami-
nae) of material. Matrix material from each lamina is used as the bonding agent.
LAMINATION The process of laying up a laminate.
LAYUP The process of fabrication involving the placement of successive layers of materi-
als. (Note: Use of two or more different materials to build a laminate generally is
referred to as building a hybrid laminate).
LIQUID SHIM A liquid or paste material used in place of a metal shim to position components in
an assembly where dimensional alignment is critical. For example, epoxy adhesive
is introduced into gaps after assembly is placed in desired configuration.

M
MANDREL A form fixture or male mold used for the base in the production of a part by layup
or filament winding.
MASTER MODEL A pattern whose contours are the absolute and final contour definition of a part or
assembly. Tooling masters are most generally made from tooling plaster, but can
also be made of composite material.
MAT A fibrous material consisting of randomly oriented chopped filaments or swirled fil-
aments with a binder. Available in various lengths, widths, and weights.
MATCHED METAL A reinforced plastics manufacturing process in which matching male and female
MOLDING metal molds are used (similar to compression molding) to form the part with time,
pressure, and heat.
MATRIX The material that supports the fibers in ACM. Matrix materials used in advanced
composites on aircraft consist of epoxies, bismaleimides and poliomyelitis. (See
Resin.)
MATRIX CRACKS Resin cracks that exist at ply interfaces (interply) as well as between fibers within a
ply (intraply).
MICROCRACKING Microscopic cracks in the matrix material. Commonly caused by cooling down from
the cure temperature at too high a rate (in excess of 5 °F per minute).
MIX RATIO The ratio of part A to part B to be mixed in a two part adhesive system. Always
done by weight unless container specifies otherwise.
MOISTURE ABSORPTION The pickup of water vapor from the air by adhesives and composite materials in
either the cured or uncured state. Uncured materials pickup water vapor at a much
higher rate than cured materials.
MOLD The cavity or mandrel in or on which a material can be formed or shaped.
MOLD LINE The surface of a part that is controlled to a specified tolerance.
MOLDLINE (INNER AND The surface of a part. Inner moldline, or IML refers to the inner surface of a part.
OUTER) Outer moldline or OML refers to the outer surface of the part (usually the side
exposed to the airstream).
MOLDLINE PROTRUSION Stick-out above the surface of a part. This stick out may interfere with airflow over
the part surface or cause interference with interior mating surfaces or equipment.
MOLD RELEASE AGENT Chemical (lubricant) applied to the mold surfaces to prevent adhesion of the molded
article to the mold.
MONOLITHIC LAMINATES Originally derived from monolith, meaning a single block of stone. In composite ter-
minology, it means made from fiber and resin only, i.e., solid composite as opposed
to thin composite skins in a sandwich panel, which are bonded to a lightweight core
of honeycomb or other material.

N
NONDESTRUCTIVE A procedure for determining if defects are present in a material, part, or assembly
INSPECTION without permanently altering its physical or mechanical characteristics. Ultrasonic
and radiographic methods are commonly used on ACM.
NDI COUPLANT A material (usually a liquid) used during ultrasonic inspection as an interface to
eliminate air gaps between the part being inspected and the ultrasonic transducer.
NEAT RESIN A resin containing no reinforcement material, usually used in testing.

Glossary-8
 TM 1-1500-204-23-11
NESTING Turning every other ply of woven cloth during layup so that the fiber tows of one
ply lay in the valleys of the adjacent ply. This layup technique only applies to adja-
cent plies of the same orientation. No advantage is obtained when making repair
patches with varied ply orientations.
NODES The bonded areas along thin ribbons of material that form honeycomb core.
NOMEX ARAMID Paper form is used to make honeycomb. When burned it produces low smoke and
FIBER/PAPER flame.
NOTCH SENSITIVITY The extent to which a material’s susceptibility to fracture is increased by the pres-
ence of a discontinuity such as a crack, scratch or sudden change in shape or size.

O
OUT-TIME The cumulative amount of time a material, such as pre-preg or film adhesive,
is exposed to temperatures above its storage temperature. When the allowed
out-time is exceeded, the material must either be tested or discarded.
OUTER MOLD LINE The outer surface of the part.

P
PASTE ADHESIVE A two part adhesive systems consisting of a base resin and a curing agent. The
base resin contains some type of filler material as a modifier. These adhesives
require measuring and mixing of both parts before the chemical re-action which
results in curing takes place.
PEEL PLY Nylon or polyester woven cloth, usually perforated, applied to the outer surfaces
of a laminate during the layup process. The cloth becomes an integral part of the
laminate. It provides a textured wrinkle free surface and is subsequently peeled off
prior to bonding or painting to provide a clean, prepared surface.
PEEL PLY IMPRESSION Surface texture left on the thin resin rich outer surface of a laminate following
removal of peel ply.
PIN HOLES Small cavities that penetrate the surface of a cured part.
PICK An individual filling yarn, running width of woven fabric at right angles to warp, also
called fill, woof, and weft.
PITCH FIBERS Reinforcement fiber derived from petroleum or coal tar pitch.
PLAIN WEAVE A weave pattern in which the fill fiber tows alternately proceed over and under warp
fiber tows. This weave pattern is used primarily for flat parts.
PLY A single layer of tape or fabric. See LAMINA
PLY ORIENTATION The orientation or alignment of an individual ply within a laminate with respect to
a stated reference direction. Usually expressed as 0, +45, -45 or 90°, or a similar
variation.
POLAR WINDING A winding in which filament path passes tangent to polar opening at one end of
chamber and tangent to opposite side of polar opening at other end. A one-circuit
pattern is inherent in system.
POLYIMIDE (PI) A thermosetting polyimide resin system with a high service temperature (550 °F).
Polyimides are used as both adhesives and matrix materials.
POLYACRYLONITRILE Used as a base material or precursor in manufacture of certain carbon fibers.
(PAN)
POLYMER MATRIX The epoxy or polyurethane based resin system that binds the fibers and helps to
spread the load applied to the composite between each of the individual fibers and
also protects the fibers from damage caused by abrasion and impact.
POLYMERIZATION The chemical reaction during which small molecules are connected by chemical
bonds into large molecular chains.
POROSITY Small areas of trapped pockets of air or gas that occur in cured laminates and adhe-
sive bondlines.
POROUS RELEASE CLOTH Fiberglass cloth lightly coated with Teflon. The resulting cloth is porous allowing
resin and gas passage without bonding to the resin or part.

Glossary-9
TM 1-1500-204-23-11
POSITIVE PRESSURE The process by which a repair is cured under pressure without the use of vacuum.
CURE This pressure may be applied using mechanical means or by an autoclave with the
vacuum bag vented to atmosphere.
POST-CURE The application of additional heat to a thermosetting material to either complete
the cure or increase cross-linking of an already cured material. In certain resins,
complete cure and ultimate mechanical properties are attained only by exposure of
the cured resin to higher temperatures than those of curing.
POT LIFE The length of time a resin or adhesive system can be used after its individual com-
ponents are mixed. Higher ambient temperatures result in shorter pot lifes. See
also work life and gel-time.
POTTING COMPOUNDS One- or two-part pastes that may be trowelled or cast to fill holes, depressions, core
cells, and other voids.
PRE-PREG Thin sheets or rolls of either unidirectional fibers or woven fibers preimpregnated
with a B staged resin. It is the basic material used in the manufacture of ACM
laminates.
PRIMER A very thin coating of diluted adhesive in the liquid state applied and cured on metal-
lic surfaces to be bonded. They are used on metallic materials to promote adhesion,
provide corrosion resistance and protect pretreated de-tails to allow extended stor-
age. They are not required on surfaces manufactured from ACM.
PULSE-ECHO An ultrasonic test method in which ultrasound energy is sent and received by a
ULTRASONICS single search unit or transducer.
PYROLYSIS Decomposition of a material due to the application of heat.
PRECURE The full or partial setting of a resin or adhesive in a joint before the clamping oper-
ation is complete or pressure is applied.
PRECURSOR For carbon or graphite fiber, rayon, PAN or pitch fibers from which carbon graphite
fibers are derived.
PREFORM A preshaped fibrous reinforcement of mat or cloth formed to the desired shape on a
mandrel or mockup before being placed in or on a structure. pre-preg, preimpreg-
nated mat, fabric or nonwoven material or roving combined with resin.
PRIMARY STRUCTURE One critical to flight safety and is subjected to flight loads.
PULTRUSION A continuous process for manufacturing composites that have a constant cross-
sectional shape. Process consists of pulling fiber-reinforcing material through a
resin impregnation bath and through a shaping die, where resin is subsequently
cured.
PYROLYZATION Material degradation due excessive heat application. Material may look dis-col-
ored, blistered, charred or burned

Q
QUASI-ISOTROPIC A laminate with approximately the same strength and extensional stiffness in all
LAMINATE directions. The laminate is laid up symmetrically with an equal number of plies at
each 0, ±45, and 90° angle. These laminates are not orientation sensitive from a
strength or stiffness standpoint.

R
RAMP-UP AND RAMP- The rate that a part is heated or cooled (e.g., 5 °F per minute). Also applies to
DOWN pressurization. Used in cure cycle.
REFRIGERATOR An enclosed cabinet used to store materials at a temperature of 35 to 50 °F.
RELEASE AGENT A material, usually a liquid, applied to layup tools or other repair tools to prevent
resin from sticking to them.
RELEASE FILM A thin heat resistant film used to provide a nonstick surface.
RESIN A polymer material used in film adhesives, paste adhesives and matrix mate-rials
to support the fibers of a composite material. (See Matrix.)

Glossary-10
 TM 1-1500-204-23-11
RESIN CONTENT (1) The amount of matrix material present in pre-preg. Pre-preg materials typically
have higher resin contents than cured laminates. The excess resin is bled during
the cure process.
(2) The amount of matrix material present in a cured laminate. Uneven resin bleed-
ing can result in areas in the laminate that are either resin rich or resin starved.
RESIN BLEED See BLEEDING.
RESIN/FIBER DUST Nuisance dust composed of a mixture of resin and fiber formed from solid material
by crushing, grinding, drilling, etc., of nonmetallic composites.
RESIN LIQUID An organic polymeric liquid which becomes a solid when converted into its final
state for use. Various curing agents may be used. Some require heat for a specified
time; some cure at room temperature.
RESIN POCKET An apparent accumulation of excess resin in a small, localized section visible on
cut edges of molded surfaces, or internal to the structure and nonvisible. (See also
Resin Rich area.)
RESIN RICH An area within a laminate containing an excess of resin.
RESIN STARVED An area within a laminate containing an insufficient amount of resin.
RESIN SYSTEM A mixture of resin and ingredients such as catalyst, initiator, diluents, etc., required
for in-tended processing and final product.
RESIN TRANSFER A process whereby catalyzed thermosetting resin is transferred or injected into an
MOLDING enclosed mold in which fiber reinforcement has been placed.
RETICULATION The term applied to the process needed before using a film adhesive to bond skin
to core on large cell honeycomb materials, usually for acoustic panels. The film
adhesive is laid on the honeycomb and made to shrink back on to the cell ends by
careful heating with hot air using a temperature controlled hot air gun, so that the
perforations in the skin for acoustic attenuation are not blocked during skin to core
bonding in an autoclave. This process re-quires film adhesive without any carrier
fabric so that under the careful application of hot air the adhesive can shrink back
onto cell ends. The heat must be sufficient to cause shrink-back but not too much
so as to cause cure. The adhesive on cell ends must melt again and flow to give
good fillets between honeycomb and skin during final curing process. Also used
with very light weight spacecraft structures, as thinner, lighter adhesive films can
be used.
RHEOLOGY The study of the flow of materials, particularly plastic flow of solids and the flow of
non-Newtonian liquids. The science treating the deformation and flow of matter.
RIBBON DIRECTION In honeycomb core material, the direction of the continuous foil.
ROOM-TEMPERATURE Capable of being cured without applying heat to at least handling strength at tem-
CURING peratures of 68 to 86 °F.
ROUTER SET BACK The distance between the cutting surface of a router bit and the edge of the router
guide that interfaces with the router template.
RULE OF MIXTURES When two materials are mixed together, it is normally the case that the properties
of the mixture are an average of the properties of the constituents according to the
proportion of each in the mixture. This applies, for example, to particulate reinforced
composites and fillers in resins.
RUNAWAY REACTION A condition in which the heat liberated during the curing of a thermoset mate-rial is
not able to escape (usually due to an excessive amount of material being cured) and
accelerates the chemical reaction. This acceleration liberates more heat resulting
in further acceleration of the reaction until an uncontrolled reaction results. Extreme
heat and fire may result.

S
S-GLASS Structural Glass, (Silical, Alumina, Magnesia) used as fiber reinforcement,
designed to give high-tensile strength. More expensive than E-glass.
SANDWICH CONSTRUC- A structural panel consisting in its simplest form of two relatively thin sheets of struc-
TION tural material bonded to and separated by a relatively thick, lightweight core. (See
Core.)

Glossary-11
TM 1-1500-204-23-11
SANDWICH PANEL A panel consisting of two thin face sheets bonded to a thick, lightweight honeycomb
or foam core.
SATURATION An equilibrium condition in which the rate of absorption under prescribed conditions
becomes essentially zero.
SCARF A tapered repair surface analogous to countersinking a fastener hole.
SCARF JOINT A flush high load transfer joint obtained by tapering the laminate from the damage
cleanup hole to a prescribed outline dimension on the laminate surface.
SCARF RATIO The angle of a tapered joint notated by length over thickness or depth (L/D)
SCRIM CLOTH A nylon or polyester monofilament woven reinforcing cloth used to support uncured
film adhesives. It is also used for flow and bondline thickness control in both films
and pastes. Close knit weaves act as a corrosion barrier between bonded car-
bon/epoxy patches and aluminum honeycomb core.
SECONDARY BOND Bonding of precured composite skins or precured repair patches to a part using
adhesive.
SECONDARY STRUCTURE Structure subjected to its own inertial loads and not flight loads. For example, fair-
ings, cowlings, and covers.
SELVAGE The edge of a woven fabric finished off so as to prevent the yarns from unraveling.
SEPARATOR SHEET Thin release film used to prevent uncured film adhesive or pre-preg material from
adhering to itself when rolled.
SERVICE ENVIRONMENT The range of worst case operating temperature and moisture condition the part is
subjected to during its service life. Materials used for manufacture and repair must
be strong enough to resist loads applied to the part throughout this environment.
SERVICE TEMPERATURE The maximum temperature the material can withstand without loss of mechanical
proper-ties. For polymer matrix composites, this condition usually is determined for
moisture saturated materials.
SET A fixed or hardened resin state. Note: A set adhesive is not a cured adhesive. (See
Gel Time or Kickover.)
SHEAR The force on a joining material (adhesive or mechanical fastener) resulting from the
application of two parallel but opposite loads.
SHEAROGRAPHY Was developed for strain measurements. This process now provides a full-field
video strain gauge, in real time, over large areas. It is an enhanced form of holog-
raphy, which requires the part being inspected to be under stress. A laser is used
to illuminate the part while under stress. The output takes the form of an image
processed video display.
SHEET MOLDING A composite of fibers, usually a polyester resin, and pigments, fillers, and other
COMPOUND additives that have been compounded and processed into sheet form to facilitate
handling in the molding operation.
SHELF-LIFE The length of time an uncured material can be stored at a specified temperature
and remain suitable for its intended function. Film adhesive shelf life is based on
a storage temperature of 0 °F or below. Shelf-life for 2 part adhesive systems is
dependent upon storage temperature.
SOAK The phase during the cure of a thermoset material during which time the applica-
tion of temperature and/or pressure is held constant. The majority of the cure is
performed during this phase.
SOLVENT A liquid material used for cleaning. The material dissolves solids from contami-
nated surfaces. It must be wiped dry prior to evaporation to prevent spreading the
contamination over the entire surface. For bonded repairs to ACM, it is used to
remove aircraft grease and other fluids prior to beginning the repair, and to flush
contaminates from disbonds and delaminations.
SPLASH A Splash is an intermediate tool made using fiber-filled synthetic plaster material.
SPRAYED METAL MOLDS Molds made by spraying molten metal onto a master until a shell of predetermined
thickness is achieved. The shell is then removed and backed up with plaster,
cement, casting resin or other suitable material. Used primarily as a mold in the
sheet forming process.

Glossary-12
 TM 1-1500-204-23-11
SPRAY-UP Technique in which a spray gun is used as an application tool. In reinforced plastics,
for example, fibrous glass and resin can be simultaneously deposited in a mold.
In essence, roving is fed through a chopper and ejected into a resin stream that
is directed at the mold by either of two spray systems. In foamed plastics, fast
reacting urethane foams or epoxy foams are fed in liquid streams to the gun and
sprayed on the surface. On contact, the liquid starts to foam.
STACKING SEQUENCE The order in which successive plies of material are laid up in a composite laminate.
Application of plies in the incorrect sequence can result in warping of laminates and
premature failure when load is applied.
STAGING Heating a premixed resin system, such as in a pre-preg, until the chemical reaction
(curing) starts, but stopping the reaction before the gel point is reached. Staging is
often used to reduce resin flow in subsequent press-molding operations.
STEP JOINT A flush, high load transfer joint obtained by machining controlled length and con-
trolled depth steps in the laminate.
STIFFNESS The ability of a material or structure to resist applied loads (bending, torsion, ten-
sion, compression, shear) without encountering excessive deflection.
STIFFENER A structural reinforcing member. Specific types of stiffeners are hat, I, J, H, C,
sinewave, semisinewave, bead, and blade (or T) sections.
STRAND Multiple filaments or fibers drawn together into an approximately parallel arrange-
ment without twist. The strand can be used as a basis for construction of yarns by
twisting and plying. (See Tow.)
STRENGTH A measure of a material’s ability to resist applied loads (bending, torsion, tension,
compression, shear) without failing.
SUBSTRATE Material on which an adhesive is spread for any purpose, such as bonding or coat-
ing. A broader term than adherend. (See Adherend.)
SUPPORTED ADHESIVE An adhesive supplied in a sheet or in film form with an incorporated carrier that
FILM remains in the bond when the adhesive is supplied and used. Both mat and woven
fabrics are used for this purpose. (See Carrier.)
SURFACE TENSION The contractive force in the surface film of a liquid which tends to make the liquid
occupy the least possible volume. It is due to the tendency of the body of liquid
to attract the unbalanced surface molecules towards the interior. For example, a
drop of water placed on a countertop tends to form a circle shape rather than a
square, rectangle, or other shape. It is expressed in dynes per centimeter and
varies for different liquids, being very high for mercury and very low for ether. It
decreases with increasing temperature. Lyophilic colloids in solid form, such as
soap and gelatin solution, lower the surface tension of the medium appreciably,
while lyophobic colloids have practically no effect.
SURFACING MAT A thin mat of fine fibers used primarily to produce a smoother surface on an organic
matrix composite.
SYMMETRIC LAMINATE A composite laminate in which the ply orientation is mirrored about the laminate
midplane.
SYNTATIC FOAMS Compounds made by mixing hollow microspheres of glass, epoxy, phenolic, etc.,
into fluid resins (with additives and curing agents) to form a moldable, curable, light-
weight fluid mass; as opposed to foamed plastic, in which the cells are formed by
gas bubbles released in the liquid plastic by either chemical or mechanical action.

T
TAPE Material in which the filaments are laid in a single direction within a resin matrix.
TAPE LAYING A fabrication process in which pre-preg tape is laid side-by-side or over-lapped to
form a structure.
TAPE WRAPPED Fabric tape is heated and wrapped onto a rotating mandrel and subsequently cooled
to form the surface for the next tape layer application.
TACK The slight amount of stickiness exhibited by an uncured adhesive or pre-preg mate-
rial. This stickiness is used to facilitate the layup process as the materials tend to
form a weak bond with one another. Lack of tack can be an indicator that the mate-
rial has aged excessively.

Glossary-13
TM 1-1500-204-23-11
THERMAL DAMAGE Damage incurred by a cured adhesive or ACM from excessive heat application.
Typical dam-age may be the result of an aircraft fire or runaway heat blanket.
THERMAL EXPANSION The fractional change in length of a material for a unit change in temperature. Val-
ues for plastics range from 0.01 to 0.2 in/° C. Some fiber reinforcements have a
negative longitudinal thermal coefficient of expansion.
THERMAL SHOCK A process involving an extremely rapid change in temperature.
THERMOCOUPLE A simple two-wire probe that, when connected to a reading device, indicates the
temperature in the repair area. Thermocouples are used to monitor the amount of
heat applied when curing resin. Construction: two wires of dissimilar metals are
joined near the end and produce a minute electromotive force (current) that drives
a galvanometer potentiometer (reading device). The most common thermocouples
used in composite fabrication and repair is J-type (iron constantan).
THERMOPLASTIC A plastic capable of being reshaped or reformed after the material has been initially
processed or consolidated.
THERMOSET A plastic that cannot be reshaped or reformed after curing.
THERMOSETTING A class of resins produced by dissolving unsaturated, generally linear, alkyd resins
POLYESTERS in a vinyl-type active monomer such as styrene, methyl styrene or diallyl phthalate.
Cure is affected through vinyl polymerization using peroxide catalysts and promot-
ers or heat to accelerate the reaction. The two important commercial types are (1)
liquid resins that are cross-linked with styrene and used either as impregnates for
glass reinforcements in laminates, filament-wound structures, and other built-upon
constructions or as binders for chopped-fiber reinforcements in molding compounds
such as Sheet Molding Compound (SMC), Bulk Molding Compound (BMC), and
Thick Molding Compound (TMC); and liquid or solid resins cross-linked with other
esters in chopped-fiber and mineral-filled molding compounds; for example, alkyd
and diallyl phthalate.
THERMOSET MATERIAL A material that undergoes an irreversible chemical reaction resulting in a hard,
infusible solid.
THIXOTROPIC Concerning materials that are gel-like at rest, but fluid when agitated. Having high-
static shear strength and low-dynamic shear strength at the same time. To lose
viscosity under stress.
THREAD COUNT The number of yarns (threads) per inch or centimeter in either the lengthwise (warp)
or crosswise (fill or weft) direction of woven fabrics.
THROUGH-TRANSMISSION An ultrasonic test method in which ultrasound energy is sent by one transducer and
ULTRASONICS received by a second transducer.
TOOLING RESINS Resins that have applications as tooling aids, core boxes, prototypes, hammer
forms, stretch forms, foundry patterns, etc. Epoxy and silicone are common exam-
ples.
TOUGHNESS A property of a material for absorbing work. The actual work per unit volume or unit
mass of material that is required to rupture it. Toughness is proportional to the area
under the load-elongation curve from the origin to the breaking point.
TOW A loose, untwisted bundle of filaments (normally 3000 filaments per tow).
T-PEEL TEST This test requires flexible adherends whether they are metal, plastic, rubber or fab-
ric. The materials must bend through 90° and are therefore usually thin. The top
of the T consists of the two loaded arms and the vertical of the T, the remaining
bonded length. Usually used with elostomeric or rubbery adhesives. Only fairly
tough adhesives can be tested by this .
TRACER YARN A colored yarn or thread woven into a fabric in the fill direction on the fill side to
facilitate identification of warp and fill directions.
TWO-COMPONENT An adhesive supplied in two parts that are mixed before application. Such adhe-
ADHESIVE sives can often be cured at room temperature but elevated temperature curing
strengthens the ACM and gives it a higher Tg.

Glossary-14
 TM 1-1500-204-23-11
U
ULTIMATE LOAD LIMIT Load X Factor of Safety - In aircraft, the ultimate load factor of safety is usually 1.5.
The requirements also specify that these ultimate loads be carried by the structure
without failure.
ULTRAVIOLET(UV) Zone of invisible radiation beyond the violet end of the spectrum of visible radi-
ation. Since UV wavelengths are shorter than visible wavelengths, their photons
have more energy, enough to initiate some chemical reactions and to degrade most
plastics, particularly aramids.
ULTRAVIOLET (UV) Any chemical compound that, when mixed with a resin, selectively absorbs UV rays.
STABILIZER
UNBOND See DISBOND
UNDERCURE A condition following the cure cycle of a thermoset material where the mate-rial has
not fully cured. A significant reduction in strength can result.
UNIDIRECTIONAL A reinforced plastic laminate in which all of the fibers are oriented in the same direc-
MATERIAL tion.

V
VACUUM BAGGING The process of sealing a layup under an airtight flexible sheet of bag material. Air
is evacuated from the bag using a vacuum pump allowing atmospheric pressure to
be applied to the layup.
VACUUM BAG The plastic or rubber layer used to cover the part so that a vacuum can be drawn.
VAPOR DEGREASING A cleaning process that uses the hot vapors of a chlorinated solvent to re-move
soils, especially oil, grease, waxes, fingerprints, etc.
VEIL An ultra-thin mat similar to a surface mat, often composed of organic fibers, as well
as glass fibers.
VENT An opening permitting the release of vacuum during an autoclave cure.
VENTING In autoclave curing of a part or assembly, turning off the vacuum source and venting
the vacuum bag to the atmosphere. The pressure on the part is then the difference
between pressure in the autoclave and atmospheric pressure outside the autoclave.
VINYL ESTERS A class of thermosetting resins containing esters of acrylic and/or methacrylic acids,
many of which have been made from epoxy resin. Cure is accomplished as with
unsaturated polyes-ters by copolymerization with other vinyl monomers, such as
styrene.
VISCOSITY A measure of the ability of an uncured resin to resist flow. As the age of the resin
increases, ability to flow decreases and its viscosity increases.
VOIDS Spaces in a cured laminate or adhesive bondline that contain air or other trapped
gases instead of resin. Void areas are essentially incapable of transmitting struc-
tural loads and can result in a strength loss.
VOID CONTENT Volume percentage of voids, usually less than 1 percent in a properly cured com-
posite. The experimental determination is indirect, that is, calculated from the mea-
sured density of a cured laminate and the theoretical density of the starting material.
VOLATILES Materials in a resin system that readily change to a vapor during the initial stages
of a cure process.
VOLATILE CONTENT The percentage of volatiles that are present in a plastic or an impregnated rein-
forcement. Drying a specimen under specified conditions to determine the amount
driven off is a common pre-preg physical property test.

W
WARP The threads or fibers which run lengthwise in a fabric. A group of yarn in long
lengths and approximately parallel.
WARP FACE Surface of a fabric containing the majority of the warp yarns.

Glossary-15
TM 1-1500-204-23-11
WARP DIRECTION (1) The direction of the tows in dry woven cloth or woven pre-preg that run in the
lengthwise direction. In a woven cloth, the warp direction is parallel to the selvage
edge.
(2) The direction of the tows in a cured laminate that are oriented parallel to the
primary load direction.
WATER ABSORPTION The rate of the weight of water absorbed by a material to the weight of the dry
RATIO material.
WATER BREAK TEST In this test, water is applied to the prepared surface and should remain in a con-
tinuous film over the whole area for at least 30 seconds. If the water sep-arates
out into droplets, or the film is not continuous, then the part is not clean and the
cleaning operations have to be repeated until water remains in a continuous film
for 30 seconds.
WEDGE TEST Often known as the Boeing wedge test because of its origin. Two thin adherend
beams are bonded together with a short unbonded length at one end into which
a wedge is driven. It was developed as a simple method of evaluating metal sur-
face pretreatment particularly with reference to predicting the durability in service
of bonded aerospace structures. Composite adherends may be used. The initial
crack length is measured between the shoulder of the wedge and the crack tip. The
specimen is then exposed to a chosen environment and the crack growth followed
with time. A formula is given from which the adhesive or resin fracture energy can
be calculated from the crack length, specimen dimensions, and material proper-
ties. Be-cause fracture energy declines rapidly with increasing crack length, it is
important to plot fracture energy versus time and not just crack growth. Bondline
thickness will affect the results obtained. It is a simplified version of the double can-
tilever beam test.
WEFT The transverse threads or fibers in a woven fabric. Those fibers running perpen-
dicular to the warp. Also called fill, filling yarn or woof.
WET INSTALLATION A bolted joint in which sealant is applied to the head and shank of the fastener so
that after assembly, a seal is provided between the fastener and the elements being
joined.
WET LAYUP A repair material fabrication process in which dry woven cloth is hand impregnated
with a two part liquid adhesive. This process is used for fabrication of substructure
repair details and patches bonded to complex contoured areas. It is limited to lightly
loaded areas.
WET-OUT The condition of an impregnated roving or yarn wherein substantially all voids
between the fibers or filaments are filled with resin.
WETTING The spreading, and sometimes absorption, of a fluid on or into a surface.
WET WINDING In filament winding, the process of winding glass on a mandrel in which the strand
is impregnated with resin just before contact with the mandrel.
WIND ANGLE The angular measure in degrees between the direction parallel to the filaments
and an established reference. In filament-wound structures, it is the convention to
measure the wind angle with reference to the centerline through the polar bosses,
that is, the axis of rotation.
WINDING PATTERN The total number of individual circuits required for a winding path to begin repeat-
ing by laying down immediately adjacent to the initial circuit. A regularly recurring
pattern of the filament path after a certain number of mandrel revolutions, leading
eventually to the complete coverage of the mandrel.
WORKING LIFE The period of time during which a liquid resin or adhesive, after mixing with catalyst,
solvent or other compounding ingredients, remains usable. (See al-so Gel Time
and Pot Life.)
WOVEN PRE-PREG Dry woven cloth preimpregnated with a B-staged resin system.
WOVEN CLOTH Tows of fibers woven into cloth to form such fabric patterns as plain, harness satin
or twill weaves. Two typical cloth weave patterns provided for repair applications
are plain weave and eight harness satin weave. The cloth is provided dry without
resin present.
WOVEN ROVING A heavy, glass-fiber fabric made by weaving roving or yarn bundles.

Glossary-16
 TM 1-1500-204-23-11
WRINKLE A condition where one or more of the plies are permanently formed into a ridge,
depression or fold.

X
X-COR® The registered trade mark for the foam core produced by Albany International.
X-Cor® consists of interlacing carbon pins embedded in a foam core. The carbon
pins protrude from the core and interlock with the face sheets during part manufac-
ture.

Y
YARN A strand given a twist, or a combination of two or more such twisted strands plied
together.
YOUNG’S MODULUS The ratio of normal stress to corresponding strain for tensile or compressive
stresses less than the proportional limit of the material.

Z
ZERO BLEED A laminate fabrication procedure that does not allow loss of resin during cure. Also
describes pre-preg made with the amount of resin desired in the final part, such
that no resin has to be removed during cure.

Glossary-17
TM 1-1500-204-23-11
ACRONYMS
ACM Advanced Composite Materials
ACS American Chemical Society
AMCOM US Army Aviation and Missile Command
AMS Aerospace Materials Specifications
AR Army Regualtion
ASTM American Society for Testing and Materials International
B Boron
B/EP Boron Fiber Epoxy Composite
BCM Beyond the Capability of Maintenance
BMC Bulk Molding Compound
BMI Bismaleimide
CF Carbon Fiber
CRES Corrosion Resistant Steel
CRT Cathode Ray Tube
CTE Coefficient of Thermal Expansion
D Scarf Outline Dimension
DED Damage Engineering Disposition
DVD Double Vacuum Debulk
DIA Diameter
E Heat Blanket Edge Distance
e Fastener Edge Distance
EMI Electromagnetic Interference
FAA Federal Aviation Administration
FEP Fluorinated Ethylene Propylene
FOD Foreign Object Damage
FRP Fibrous Reinforced Plastic
GBS Grit Blast Silane
GL Glass Fiber
GR Graphite
GR/BMI Graphite Fiber Bismaleimide Composite
GR/EP Graphite Fiber Epoxy Composite
GRP Graphite Reinforced Plastic
h Damage Depth
HEPA High Efficiency Particulate Air
HS Harness Satin
HSS High Speed Steel
IML Inner Moldline
in/m Inches Per Minute
ISA International Society for Automation
ISO International Organization for Standardization
K Kevlar®
K/EP Kevlar® Epoxy Composite
L Lower Moldline
MAX Maximum
MERV Minimum Efficiency Reporting Value
MIL-HDBK Military Handbook
MIL-PRF Military Performance Specification
MIL-STD Military Standard

Glossary-18
 TM 1-1500-204-23-11
MIN Minute
MOI Maintenance Operating Instructions
mrA Mix Ratio of Part A
mrB Mix Ratio of Part B
mrF Mix Ratio of Filler Material
MSDS Material Safety Data Sheet
MSHA Mine Safety and Health Administration
NAVAIR U. S. Navy Naval Air Systems Command
NDI NonDestructive Inspection
NEC National Electric Code
NEHC Navy Environmental Health Center
NFPA National Fire Protection Association
NHMA Next Higher Maintenance Activity
NIOSH National Institute of Occupational Safety and Health
OEM Original Equipment Manufacturer
OI Operating Instructions
OML Outer Moldline
OSHA Occupational Safety and Health Administration
P Load
PAA Phosphoric-Acid Anodized
PCF Pounds per Cubic Foot
PEEK Polyether Ether Ketone
PI Polyimide
PMI Polymethacrylimide
PPE Personal Protective Equipment
psi Pounds per Square Inch
PVA Polyvinyl Alcohol
PW Plain Weave
r Damage Layout Radius
REV Revolutions
RPM Revolutions per Minute
SAE Society of Automotive Engineers International
SEC Seconds
SFPM Surface Feet per Minute
SMC Sheet Molding Compound
SRM Structural Repair Manual
T Length of Taper for Partial Thickness Damage
t Skin Thickness
TC Thermocouple
UHM Ultra High Modulus
UML Upper Moldline
UV Ultraviolet
w Woven

Glossary-19/(Glossary-20 blank)
 By Order of the Secretary of the Army:

RAYMOND T. ODIERNO
General, United States Army
Official: Chief of Staff

GERALD B. O’KEEFE
Administrative Assistant to the
Secretary of the Army
1319108

Distribution:
To be distributed in Electronic Media Only (EMO).
 These are the instructions for sending an electronic 2028
The following format must be used if submitting an electronic 2028. The subject line must be
exactly the same and all fields must be included; however only the following fields are
mandatory: 1, 3, 4, 5, 6, 7, 8, 9, 10, 13, 15, 16, 17, and 27.
From: “Whomever” whomever@wherever.army.mil
To: 2028@redstone.army.mil
Subject: DA Form 2028
1 From: Joe Smith
2 Unit: home
3 Address: 4300 Park
4 City: Hometown
5 St: MO
6 Zip: 77777
7 Date Sent: 19-OCT-93
8 Pub no: 55-2840-229-23
9 Pub Title: TM
10 Publication Date: 04-JUL-85
11 Change Number: 7
12 Submitter Rank: MSG
13 Submitter FName: Joe
14 Submitter MName: T
15 Submitter LName: Smith
16 Submitter Phone: 123-123-1234
17 Problem: 1
18 Page: 2
19 Paragraph: 3
20 Line: 4
21 NSN: 5
22 Reference: 6
23 Figure: 7
24 Table: 8
25 Item: 9
26 Total: 123

27 Text:
This is the text for the problem below line 27.
 Use Part II (reverse) for Repair Parts and DATE
Special Tool Lists (RPSTL) and Supply
RECOMMENDED CHANGES TO PUBLICATIONS AND
BLANK FORMS
Catalogs/ Supply Manuals (SC/SM) 8/30/02
For use of this form, see AR 25--30; the proponent agency is ODISC4.

TO: (Forward to proponent of publication or form)(Include ZIP Code) FROM: (Activity and location)(Include ZIP Code)
Commander, U.S. Army Aviation and Missile Command MSG, Jane Q. Doe
ATTN: AMSAM--MMA--NP 1234 Any Street
Redstone Arsenal, AL 35898 Nowhere Town, AL 34565
PART 1 - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE Organizational, Direct Support, And
TM 9-1005-433-24 16 Sep 2002 General Support Maintenance Manual for
Machine Gun, .50 Caliber M3P and M3P
Machine Gun Electrical Test Set Used On
Avenger Air Defense Weapon System
ITEM PAGE PARA- LINE FIGURE TABLE
NO. NO. GRAPH NO. * NO. NO. RECOMMENDED CHANGES AND REASON

1 WP0005 2 Test or Corrective Action column should identify a different WP number.

PG 3

L E
P
A M
E X
* Reference to line numbers within the paragraph or subparagraph.
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/ SIGNATURE
AUTOVON, PLUS EXTENSION

MSG, Jane Q. Doe, SFC 788-1234

DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPA V3.01
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
Commander, U.S. Army Aviation and Missile Command MSG, Jane Q. Doe 8/30/02
ATTN: AMSAM-MMA-NP 1234 Any Street
Redstone Arsenal, AL 35898 Nowhere Town, AL 34565

PART II - REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE

TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
ITEMS RECOMMENDED ACTION
NO. NO. NO. NUMBER NO. NO. NO.
SUPPORTED

L E
P
M
PART III - REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)

A
E X
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION
MSG, Jane Q. Doe, SFC 788-1234
USAPA V3.01
 Use PartII(reverse) for Repair Parts and DATE
Special Tool Lists (RPSTL) and Supply
RECOMMENDED CHANGES TO PUBLICATIONS AND Catalogs/ Supply Manuals (SC/SM)
BLANK FORMS
For use of this form, see AR 25--30; the proponent agency is ODISC4.

TO: (Forward to proponent of publication or form)(Include ZIP Code) FROM: (Activity and location)(Include ZIP Code)
Commander, U.S. Army Aviation and Missile Command ATTN:
AMSAM-MMA-NP Redstone Arsenal, AL 35898

PART 1 --ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE

ITEM PAGE PARA- LINE FIGURE TABLE

NO. NO. GRAPH NO. * NO. NO. RECOMMENDED CHANGES AND REASON

* Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/ SIGNATURE
AUTOVON, PLUS
EXTENSION

DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPA V3.01
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
Commander, U.S. Army Aviation and Missile Command
ATTN: AMSAM-MMA-NP Redstone Arsenal, AL
35898

PART II --REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE

TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
ITEMS RECOMMENDED ACTION
NO. NO. NO. NUMBER NO. NO. NO.
SUPPORTED

PART III --REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and blank forms.
Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE

PLUS EXTENSION

USAPA V3.01
 The Metric System and Equivalents
Linear Measure
1 centimeter = 10 millimeters = .39 inch
1 decimeter = 10 centimeters = 3.94 inches
1 meter = 10 decimeters = 39.37 inches
1 dekameter = 10 meters = 32.8 feet
1 hectometer = 10 dekameters = 328.08 feet
1 kilometer = 10 hectometers = 3,280.8 feet
Weights
1 centigram = 10 milligrams = .15 grain
1 decigram = 10 centigrams = 1.54 grains
1 gram = 10 decigram = .035 ounce
1 decagram = 10 grams = .35 ounce
1 hectogram = 10 decagrams = 3.52 ounces
1 kilogram = 10 hectograms = 2.2 pounds
1 quintal = 100 kilograms = 220.46 pounds
1 metric ton = 10 quintals = 1.1 short tons
Liquid Measure
1 centiliter = 10 milliters = .34 fl. ounce
1 deciliter = 10 centiliters = 3.38 fl. Ounces
1 liter = 10 deciliters = 33.81 fl. ounces
1 dekaliter = 10 liters = 2.64 gallons
1 hectoliter = 10 dekaliters = 26.42 gallons
1 kiloliter = 10 hectoliters = 264.18 gallons
Square Measure
1 sq. centimeter = 100 sq. millimeters = .155 sq. inch
1 sq. decimeter = 100 sq. centimeters = 15.5 sq. inches
1 sq. meter (centare) = 100 sq. decimeters = 10.76 sq. feet
1 sq. dekameter (are) = 100 sq. meters = 1,076.4 sq. feet
1 sq. hectometer (hectare) = 100 sq. dekameters = 2.47 acres
1 sq. kilometer = 100 sq. hectometers = .386 sq. mile

Cubic Measure
1 cu. centimeter = 1000 cu. millimeters = .06 cu. Inch
1 cu. decimeter = 1000 cu. centimeters = 61.02 cu. Inches
1 cu. meter = 1000 cu. decimeters = 35.31 cu. feet

Approximate Conversion Factors

To change To Multiply by To change To Multiply by
inches centimeters 2.540 ounce-inches Newton-meters .007062
feet meters .305 centimeters inches .394
yards meters .914 meters feet 3.280
miles kilometers 1.609 meters yards 1.094
square inches square centimeters 6.451 kilometers miles .621
square feet square meters .093 square centimeters square inches .155
square yards square meters .836 square meters square feet 10.764
square miles square kilometers 2.590 square meters square yards 1.196
acres square hectometers .405 square kilometers square miles .386
cubic feet cubic meters .028 square hectometers acres 2.471
cubic yards cubic meters .765 cubic meters cubic feet 35.315
fluid ounces milliliters 29,573 cubic meters cubic yards 1.308
pints liters .473 milliliters fluid ounces .034
quarts liters .946 liters pints 2.113
gallons liters 3.785 liters quarts 1.057
ounces grams 28.349 liters gallons .264
pounds kilograms .454 grams ounces .035
short tons metric tons .907 kilograms pounds 2.205
pound-feet Newton-meters 1.356 metric tons short tons 1.102
pound-inches Newton-meters .11296

Temparature (Exact)

°F Fahrenheit 5/9 (after Celsius °C

temperature subtracting 32) temperature
PIN: 087494-000