Composite Repairs – Miscellaneous

in Advanced Composite Materials

Saturation Techniques

For wet layup repair, impregnate the fabric with resin. It is important to put the right amount of resin on the fabric. Too much or too little resin affects the strength of the repair. Air that is put into the resin or not removed from the fabric also reduces the repair strength.


Fabric Impregnation With a Brush or Squeegee

The traditional way of impregnating the fabric is by using a brush or squeegee. The technician puts a mold release compound or a release film on a caul plate so that the plies will not adhere to the caul plate. Place a sheet of fabric on the caul plate and apply resin in the middle of the sheet. Use a brush or squeegee to thoroughly wet the fabric. More plies of fabric and resin are added and the process is repeated until all plies are impregnated. A vacuum bag will be used to consolidate the plies and to bleed off excess resin and volatiles. Most wet layup processes have a room temperature cure but extra heat, up to 150 °F, are used to speed up the curing process. [Figure 7-51]

Figure 7-51. Fabric impregnation with a brush or squeegee: A) wet layup materials; B) fabric placement; C) fabric impregnation; D) squeegee used to thoroughly wet the fabric.

Figure 7-51. Fabric impregnation with a brush or squeegee: A) wet layup materials; B) fabric placement; C) fabric impregnation; D) squeegee used to thoroughly wet the fabric.

Fabric Impregnation Using a Vacuum Bag

The 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 tightknit weaves and when near optimum 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.

Vacuum-assisted impregnation consists of the following steps:

  1. Place vacuum bag sealing tape on the table surface around the area that is used to impregnate the material. The area should be at least 4 inches larger than the material to be impregnated.
  2. Place an edge breather cloth next to the vacuum bag sealing tape. The edge breather should be 1–2 inches wide.
  3. Place a piece of solid parting film on the table. The sheet should be 2-inches larger than the material to be impregnated.
  4. Weigh the fabric to find the amount of resin mix that is necessary to impregnate the material.
  5. Lay the fabric on the parting film.
  6. Put a piece of breather material between the fabric and the edge breather to provide an air path.
  7. Pour the resin onto the fabric. The resin should be a continuous pool in the center area of the fabric.
  8. Put vacuum probes on the edge breather.
  9. Place a second piece of solid parting film over the fabric. This film should be the same size or larger than the first piece.
  10. Place and seal the vacuum bag, and apply vacuum to the bag.
  11. Allow 2 minutes for the air to be removed from the fabric.
  12. Sweep the resin into the fabric with a squeegee. Slowly sweep the resin from the center to the edge of the fabric. The resin should be uniformly distributed over all of the fabric.
  13. Remove the fabric and cut the repair plies.

Vacuum Bagging Techniques

Vacuum bag molding is a process in which the layup is cured under pressure generated by drawing a vacuum in the space between the layup and a flexible sheet placed over it and sealed at the edges. In the vacuum bag molding process, the plies are generally placed in the mold by hand layup using prepreg or wet layup. High-flow resins are preferred for vacuum bag molding.

Single Side Vacuum Bagging

This is the preferred method if the repair part is large enough for a vacuum bag on one side of the repair. The vacuum bag is taped in place with tacky tape and a vacuum port is placed through the bag to create the vacuum.

Envelope Bagging

Envelope bagging 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 installation of a single-side bag vacuum. 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. [Figure 7-52]

Figure 7-52. Envelope bagging of repair.

Figure 7-52. Envelope bagging of repair.

Alternate Pressure Application
Shrink Tape

Another method of pressure application for oven cures is the use of shrink wrapping or shrink tape. This method is commonly used with parts that have been filament wound, because some of the same rules for application apply. The tape is wrapped around the completed layup, usually with only a layer of release material between the tape and the layup. Heat is applied to the tape, usually using a heat gun to make the tape shrink, a process that can apply a tremendous amount of pressure to the layup. After shrinking, the part is placed in the oven for cure. High quality parts can be made inexpensively using shrink tape.

C-Clamps

Parts can also be pressed together with clamps. This technique is used for solid laminate edges of honeycomb panels. Clamps (e.g., C-clamps and spring clamps) are used for pressing together the edges of components and/or repair details. Always use clamps with pressure distribution pads because damage to the part may occur if the clamping force is too high. Spring clamps can be used in applications where resin squeeze-out during cure would require C-clamps to be retightened periodically.

Shotbags and Weights

Shotbags and weights can be used also to provide pressure, but their use is limited due to the low level of pressure imposed.

Curing of Composite Materials

A cure cycle is the time/temperature/pressure cycle used to cure a thermosetting resin system or prepreg. The curing of a repair is as important as the curing of the original part material. Unlike metal repairs in which the materials are premanufactured, composite repairs require the technician to manufacture the material. This includes all storage, processing, and quality control functions. An aircraft repair’s cure cycle starts with material storage. Materials that are stored incorrectly can begin to cure before they are used for a repair. All time and temperature requirements must be met and documented. Consult the aircraft structural repair manual to determine the correct cure cycle for the part that needs to be repaired.

Room Temperature Curing

Room temperature curing is the most advantageous in terms of energy savings and portability. Room temperature cure wet layup repairs do not restore either the strength or the durability of the original 250 °F or 350 °F cure components and are often used for wet layup fiberglass repairs for noncritical components. Room temperature cure repairs can be accelerated by the application of heat. Maximum properties are achieved at 150 °F. A vacuum bag can be used to consolidate the plies and to provide a path for air and volatiles to escape.

Elevated Temperature Curing

All prepreg materials are cured with an elevated temperature cure cycle. Some wet layup repairs use an elevated cure cycle as well to increase repair strength and to speed up the curing process. The curing oven and heat bonder uses a vacuum bag to consolidate the plies and to provide a path for air and volatiles to escape. The autoclave uses vacuum and positive pressure to consolidate the plies and to provide a path for air and volatiles to escape. Most heating devices use a programmable computer control to run the cure cycles. The operator can select from a menu of available cure cycles or write his or her own program. Thermocouples are placed near the repair, and they provide temperature feedback for the heating device. Typical curing temperature for composite materials is 250 °F or 350 °F. The temperature of large parts that are cured in an oven or autoclave might be different from that of an oven or autoclave during the cure cycle, because they act like a heat sink. The part temperature is most important for a correct cure, so thermocouples are placed on the part to monitor and control part temperature. The oven or autoclave air temperature probe that measures oven or autoclave temperature is not always a reliable device to determine part curing temperature. The oven temperature and the part temperature can be substantially different if the part or tool acts as a heat sink.

The elevated cure cycle consists of at least three segments:

  • Ramp up: The heating device ramps up at a set temperature typically between 3 °F to 5 °F per minute.
  • Hold or soak: The heating device maintains the temperature for a predetermined period.
  • Cool down: The heating device cools down at a set temperature. Cool down temperatures are typically below 5 °F per minute. When the heating device is below 125 °F, the part can be removed. When an autoclave is used for curing parts, make sure that the pressure in the autoclave is relieved before the door is opened. [Figure 7-53]
Figure 7-53. Autoclave cure.

Figure 7-53. Autoclave cure.

The curing process is accomplished by the application of heat and pressure to the laminate. The resin begins to soften and flow as the temperature is increased. At lower temperatures, very little reaction occurs. Any volatile 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 apply additional pressure, typically 50–100 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 lets the resin finish curing and attain the desired structural properties.