CESSWA AIRCRAFT COMPANY 4 MAINTENANCE MANUAL DAMAGE CLASSIFICATION 1, General AL B. Damage as considered in this manual, is any cross-sectional area change or permanent distortion of a structural member. Use good judgment in determining the type of damage to flat stock structural material, The terms dent, crease, abrasion, gouge, nick, scratch, crack and corrosion referred to elsewhere in the manual, are defined’ below as a guide for this determination, particularly with respect to the external skin of the airplane. (1) Dent - A dent is normally a damage area which is depressed with respect to its normal contour. There is no cross-sectional area change in the material. Area boundaries are smooth. Its form is generally the result of contact with a relatively smoothly con- toured object. NOTE: A dent-like form of damage to skin in nonpanel areas (or thick skin in panel areas) may be the result of the peen- ing action of a smoothly contoured object contacting it. Consider that such damage results in a local cross- sectional area change, if the inner surface of skin shows no contour change. (2) Crease - A damage area which is depressed or folded back upon itself in such a manner that its boundaries are sharp or well defined lines or ridges. Consider it to be the equivalent of a crack. (3) Abrasion - An abrasion is a damage area of any size which results in a cross-sectional area change due to scuffing, rubbing, scrap ing or other surface erosion. It is usually rough and irregular. (4) Gouge - A gouge is a damage area of any size, which results ina cross-sectional area change. It is usually caused by contact with a relatively sharp object which produces a continuous, sharp or smooth channel-like groove in the material. (5) Nick - A nick is a local gouge with sharp edges. Consider a series of nicks, in a line pattern to be the equivalent of a gouge. (6) Scratch - A scratch is a line of damage of any depth in the material and results in a cross-sectional area change. It is usually caused by contact with a very sharp object. 51-10-01 Page 1 Oct 1/82CESSWA AIRCRAFT COMPANY MAINTENANCE MANUAL (7) Crack - A crack is a partial fracture or complete break in the material with the most significant cross-sectional area change. In appearance, it is usually an irregular line and is normally the result of fatigue failure. (8) Corrosion - Corrosion, due to a complex electro-chemical action, is a damage area of any size and depth which results in a cross- sectional area change. Depth of such pitting damage mst be determined by a clean up operation. Damage of this type may occur on surfaces of structural elements. Use good judgment in the determination of significant cross-sectional area changes by proper visual measurement of both depth and length of any type tor combinations) of damage. Repairable Damage - Typical. CAUTION: EXERCISE CARE WHEN OPERATING POWER TOOLS TO PREVENT DAMAGE TO STRUCTURAL SURFACES BY OVERHEATING OR SCUFFING. NOTE: All replaceable structural components, which are considered suitable for field replacement are listed in the airplane parts catalog. (1) Any skin damage such as scratches, rivet set marks, cuts, pits ‘and abrasions no greater than 15 percent of the skin thickness can be repaired by blending and polishing. Refer to Chapter 51-40-04 Polishing Repairs. (2) Corrosion requires rework to determine its depth of penetration into the structural menber prior to determining the repair tech- nique. Refer to Chapter 11 for Chemical Cleaners. (3) Any skin damage, such as scratches, rivet set marks, cuts, pits, and abrasions greater than 15 percent of the skin thickness and any skin cracks can be repaired by patching. Refer to Chapter 51-40-04 for Typical Repairs. Damage Requiring Replacement of Part. (1) Where damage repair is impractical, the entire part should be replaced. 51-10-01 Page 2 Oct 1/82F CESSNA AIRCRAFT COMPANY 402 MAINTENANCE MANUAL Assembly Procedure for Dissimilar Metals Contact. (1) Dissimilar Metal Contact with Magnesium. (a) (b) Interior Application. 1) 2) 3) Contacts between magnesium alloy and other dissimilar metals which do not reach a service temperature in excess of 300°F shall be insulated by four (4) coats of non-chromate primer on each contacting faying surface or one (1) coat of epoxy primer on the magnesium part. and three (3) coats of non-chromate or one (1) coat of epoxy primer on the contacting faying surface. In addition to the paint insulation, the magnesiun part shall be insulated with a pressure sensitive tape (Number 473, Minnesota Mining and Manufacturing Co.) or Type 1, Class 8 sealant. Magnesium dissimilar metal joints which reach a temper- ature (300-500°F) shall be insulated by two (2) coats of heat-resistant enamel on the magnesium part and two (2) coats of heat-resistant enamel on the contacting faying surface and separated by tape, Mystik 7010 Mystik Tape Inc.) or silicone glass cloth tape P-211 Permacel Tape Co.) or sealant Q93-006-6 (Dow Corning Corporation). Magnesium dissimilar metal joints which reach a service temperature in excess of 500°F shall receive two (2) coats of silicone enamel on both the magnesium part and the contacting faying surface. The painted faying surface shall be separated by silicone glass cloth tape P-211 (Permacel Tape Co.). Exterior application. 1) Exterior magnesium dissimilar metal joints which do not reach a service temperature in excess of 320°F shall be sealed with Type 1, Class B sealant. 51-10-01 Page 3 Oct 1/822) CESSNA AIRCRAFT COMPANY 402 MAINTENANCE MANUAL Exterior magnesium dissimilar metal joints which reach a service temperature in excess of 320°F shall be sealed with Q93-006-6 sealant (Dow Corning Corpora- tion). Where the use of sealant on the contacting faying surface is not feasible, such as a part which must be assembled by sliding it into another part, use tape Mystik 7010 (Mystik Tape Co.) or silicone glass cloth tape P-211 (Permacel Tape Co.) to insulate the fay surface. The mold line butt joint shall be sealed with Q93-006-6 sealant. The tape applied to the fay surface shall not protrude into the mold butt joint and interfere with the sealant application. (2) Dissimilar Metals Contact Other than Magnesium. (a) Interior and Exterior Application. 1) 2) 3) Dissimilar metal contact other than magnesium shall receive a minimum of two (2) coats of non-chromate primer on each contacting faying surface if the service temperature does not exceed 300°F. Parts which reach a service temperature between 300-500°F shall receive two (2) coats of heat-resistant enamel on both mating surfaces. Parts which reach a service temperature in excess of 500°F shall receive two (2) coats of silicone enamel on both mating surfaces. (3) Dissimilar Metal Contact in Presence of Phosphate Esters and Synthetic Turbine Oil. (a) Parts which require dissimilar metal contact protection subject to phosphate esters and synthetic turbine of] shall receive one (1) coat of epoxy primer on each contacting surface. 51-10-01 Page 4 Oct 1/82