Dorworth Presentation

Abaris Training, 2007 Abaris Training, 2007
Essentials of Advanced
Essentials of Advanced
Composite Repair
Composite Repair
Louis C. Dorworth Louis C. Dorworth
Abaris Training Resources, Inc. Abaris Training Resources, Inc.
www.abaris.com www.abaris.com
Why Repairs Are Necessary
Why Repairs Are Necessary
on Aircraft
on Aircraft
737 737- -800 is 4 feet taller than older 737 800 is 4 feet taller than older 737- -400 model 400 model
41 foot high tail Vs. 38 foot tall
41 foot high tail Vs. 38 foot tall
hanger door opening
hanger door opening
Boeing C
Boeing C
-
-
17 Tail Damage:
17 Tail Damage:
The The
Aircraft Aircraft
The Work The Work- -
Stand Stand
Damage Damage
Repairs are necessary in
Repairs are necessary in
motosports as well
motosports as well
Formula 1 Racing
Formula 1 Racing
Rally Car Racing
Rally Car Racing
Motorcycle Racing
Motorcycle Racing
Speed
Speed
-
-
Boat Racing
Boat Racing
Tug Racing
Tug Racing
Boats, Planes, Trains, etc,
Boats, Planes, Trains, etc,
etcRepairs are Required for
etcRepairs are Required for
Many Composite Structures.
Many Composite Structures.
Goal of Composite Repair Design
Goal of Composite Repair Design

Rebuild Fiber Load Path Through Structure
Rebuild Fiber Load Path Through Structure

Ideal to Match Original Properties:
Ideal to Match Original Properties:
Strength Strength
Stiffness Stiffness
Weight Weight

Trade
Trade
-
-
offs:
offs:
To match strength, repair is stiffer & heavier To match strength, repair is stiffer & heavier
To match stiffness, repair is weaker & heavier To match stiffness, repair is weaker & heavier
Cannot match all original properties Cannot match all original properties
Common Repair Methods
Common Repair Methods
Stepped Co
Stepped Co
-
-
bonded Repairs
bonded Repairs

Wet layup and prepreg materials & processes
Tapered
Tapered
-
-
Scarf Co
Scarf Co
-
-
bonded Repairs
bonded Repairs

Bolted Doubler Repairs


Pre
Pre
-
-
cured composite doublers
cured composite doublers

Stainless steel or Titanium doublers
Stainless steel or Titanium doublers
Stepped Removal & Repair
Stepped Removal & Repair
Idea comes from metal lap

Idea comes from metal lap
-
-
joint repair
joint repair
design concepts.
design concepts.
Each damaged layer is removed in steps

Each damaged layer is removed in steps
so as to provide a landing for each
so as to provide a landing for each
replacement layer in the repair.
replacement layer in the repair.
Each repair ply then overlaps the

Each repair ply then overlaps the
corresponding exposed layer in the
corresponding exposed layer in the
structure.
structure.
Typical Stepped Repair
Loads are distributed through
the repair via a lap joint into
the underlying layers
The resulting repair sits above the surface
Filler Ply
Filler Ply
Shear stress distribution in a stepped repair
Note peak stress concentrations at edges of each step within
the repair
Typical Stepped Removal Process
Typical Stepped Removal Process
Plies were removed in steps
using a knife to cut through
each ply and then scrape off
the ply to the correct level
Stepped Repairs
Stepped Repairs
Pros
Pros
:
:
Easy to conceptualize & design.

Easy to conceptualize & design.

(It looks good on paper!)
(It looks good on paper!)
Feasible for flat panel repairs made with

Feasible for flat panel repairs made with
discernable materials.
discernable materials.
Co
Co
-
-
bonded layers makes for intimate
repair contact at faying surfaces.
???
???
Stepped Repairs
Stepped Repairs
Cons
Cons
:
:
Requires meticulous machining of each

Requires meticulous machining of each
layer in the damaged laminate so as not to
layer in the damaged laminate so as not to
damage the underlying plies. (This takes
damage the underlying plies. (This takes
exceptional skill!)
exceptional skill!)

Difficult to do on curved surfaces.
Difficult to do on curved surfaces.

Damage to underlying layers is common and
Damage to underlying layers is common and
often overlooked in the industry.
often overlooked in the industry.
Stepped Repairs
Stepped Repairs
Cons
Cons
:
:
Requires careful fabrication and

Requires careful fabrication and
placement of repair plies so that they fit
placement of repair plies so that they fit
into each step w/o gaps or overlaps.
into each step w/o gaps or overlaps.

Requires precise templates or tracings to
Requires precise templates or tracings to
ensure repair
ensure repair
-
-
ply fit.
ply fit.

Unwanted gaps and overlaps often result in
Unwanted gaps and overlaps often result in
defects in the final repair.
defects in the final repair.
Stepped Repairs
Stepped Repairs
Cons
Cons
:
:
Takes a trained technician approximately

Takes a trained technician approximately
2 x the time to perform a stepped repair
2 x the time to perform a stepped repair
compared to a tapered
compared to a tapered
-
-
scarf repair.
scarf repair.

Airlines are not likely to do step repairs as a
Airlines are not likely to do step repairs as a
result of the extra labor involved.
result of the extra labor involved.
Tapered
Tapered
-
-
Scarf Repairs
Scarf Repairs
A tapered
A tapered
-
-
scarf angle is machined through
scarf angle is machined through
the composite structure so as to expose
the composite structure so as to expose
each layer along a gently
each layer along a gently
-
-
angled slope.
angled slope.
Each repair ply then lays over the

Each repair ply then lays over the
corresponding exposed layer along the
corresponding exposed layer along the
tapered angle.
tapered angle.
Typical Repair Approach
Typical Repair Approach
Determine plies/orientations in the
original structure & develop repair
Replace plies/orientations to
match the original structure
First remove damaged material and prepare area for repair
Example of a Tapered
Example of a Tapered
-
-
Scarf
Scarf
Removal Process
Removal Process
Practicing a tapered scarf on an Aramid
fiber reinforced epoxy sandwich structure
You Can Clearly See the Layers in This
You Can Clearly See the Layers in This
Tapered CFRP Sandwich Panel
Tapered CFRP Sandwich Panel
Typical Tapered
Typical Tapered
-
-
Scarf Repair
Scarf Repair
Loads are transferred directly through the
edges of the repair plies, in plane, on
axis, in shear, to the underlying structure
The resulting repair is flush with the surface
Typical Tapered
Typical Tapered
-
-
Scarf Repair
Scarf Repair
Uniform shear stress distribution
through a tapered scarf joint
Big Ply Down Scarf Repair
Big Ply Down Scarf Repair
Loads are transferred directly through the
big ply laid down first, fully loading this
ply in the axis of its orientation prior to
transferring load to adjacent plies
Abaris Training does not recommend this Abaris Training does not recommend this
repair technique for highly loaded or repair technique for highly loaded or
optimized composite structures! optimized composite structures!
Tapered
Tapered
-
-
Scarf Repairs
Scarf Repairs
Pros
Pros
:
:
Fast & easy to machine taper

Fast & easy to machine taper
-
-
angle and to
angle and to
fabricate repair plies.
fabricate repair plies.
Perfect size and fit of repair plies is less

Perfect size and fit of repair plies is less
important to performance.
important to performance.
Flush surface is attainable.

Flush surface is attainable.

Important for critical aerodynamic surfaces &
Important for critical aerodynamic surfaces &
L.O. structures
L.O. structures
Tapered
Tapered
-
-
Scarf Repairs
Scarf Repairs
Pros
Pros
:
:
Can machine a taper with a die grinder or

Can machine a taper with a die grinder or
jitter
jitter
-
-
bug sander.
bug sander.

No special tools or devices necessary.
No special tools or devices necessary.
Less risk of damaging underlying layers in

Less risk of damaging underlying layers in
tapered area.
tapered area.
Co
Co
-
-
Tapered
Tapered
-
-
Scarf Repairs
Scarf Repairs
Cons
Cons
:
:
Not applicable to repairs of thick structures

Not applicable to repairs of thick structures
as one might do more damage to the
as one might do more damage to the
original structure attaining the correct scarf
original structure attaining the correct scarf
angle ratio
angle ratio
Minor risk of damaging good structure

Minor risk of damaging good structure
within and outside the scarf area
within and outside the scarf area
???
???
Typical Wet Layup Repair Process
Remove damaged
skin & core then
taper-scarfed skin
Repair/fill core cavity as
required & machine flush
Apply wet resin to dry
fabric, cover with
plastic, and squeegee
the resin throughout
the layer as needed
Wet-out the surface with an interface coat of
resin and layup each repair ply to match the
orientation of corresponding plies in structure
Apply peel ply, bleeder, & breather materials and vacuum bag for cure
After curing, remove breather, bleeder, & peel ply and inspect the repair
Prepreg Repairs Follow a Similar
Prepreg Repairs Follow a Similar
Process and Typically Require an
Process and Typically Require an
Elevated Temperature Cure Using
Elevated Temperature Cure Using
Portable Hot
Portable Hot
-
-
Bond equipment
Bond equipment
Historically the norm for metal structural

Historically the norm for metal structural
repairs
repairs

Also bonded metal doublers for thin skin
Also bonded metal doublers for thin skin
metal structural repairs
metal structural repairs
Normally reserved for thicker, solid

Normally reserved for thicker, solid
composite laminate structures where a
composite laminate structures where a
scarf or step repair would not be feasible.
scarf or step repair would not be feasible.
Damage
Removed
Typical Doubler Section
Typical Doubler Section
Inside Doubler
Outside Doubler
Laminate Structure
Fasten as prescribed
Plug
Seal all around
the patch
Determining when to use Determining when to use
a doubler can be tricky. a doubler can be tricky.
If the laminate is less If the laminate is less
than than inch thick: inch thick:
tapered tapered- -scarf repair scarf repair
If the laminate is greater If the laminate is greater
than inch thick: doubler than inch thick: doubler
repair repair
In between: do a repair In between: do a repair
design analysis design analysis
Bolted Doubler on CFRBMI Panel
Bolted Doubler on CFRBMI Panel
Tapered Scarf Repair on
Tapered Scarf Repair on
Similar CFRBMI Panel
Similar CFRBMI Panel

Pros
Pros
:
:

Can be faster and easier to accomplish
Can be faster and easier to accomplish
compared to taper
compared to taper
-
-
scarfed or stepped co
scarfed or stepped co
-
-
bonded repairs.
bonded repairs.

Requires less removal of original structure
Requires less removal of original structure
(compared to step or tapered
(compared to step or tapered
-
-
scarf repairs) to
scarf repairs) to
accommodate the repair.
accommodate the repair.

Most mechanics are already trained in drilling &
Most mechanics are already trained in drilling &
fastener installation procedures.
fastener installation procedures.
Cons
Cons
:
:
Doublers must be made to closely match

Doublers must be made to closely match
surface contour.
surface contour.

Can be problematic in compound areas
Can be problematic in compound areas
Additional tooling may be required to

Additional tooling may be required to
facilitate fabrication of repair patch.
facilitate fabrication of repair patch.
Autoclave cure of composite patch may be

Autoclave cure of composite patch may be
required to achieve properties.
required to achieve properties.
Cons
Cons
:
:
Risks associated with drilling into

Risks associated with drilling into
underlying structure for fasteners.
underlying structure for fasteners.
Expensive Ti fasteners required in carbon

Expensive Ti fasteners required in carbon
reinforced structures.
reinforced structures.
Sealing of the repair questionable and not

Sealing of the repair questionable and not
often durable.
often durable.
Summary
Summary
The goal is to replace the structure to

The goal is to replace the structure to
serviceable strength and stiffness.
serviceable strength and stiffness.
It takes special training and practice to do

It takes special training and practice to do
top quality composite repairs.
top quality composite repairs.
One approach does not fit all types of

One approach does not fit all types of
damage.
damage.
Repair technicians have to know their

Repair technicians have to know their
materials and processes in order to
materials and processes in order to
accomplish good quality repairs
accomplish good quality repairs
Next Event Reminder!
Next Event Reminder!
Please plan to attend the next SME Tech Please plan to attend the next SME Tech- -
Group Webinair event on Tuesday, June 12 Group Webinair event on Tuesday, June 12
th th
, ,
2007 at 1:00 2007 at 1:00- -2:00 pm EDT! 2:00 pm EDT!
Rich Rich Emrich Emrich from from Integran Integran Technologies will be Technologies will be
presenting a novel and innovative new tooling concept presenting a novel and innovative new tooling concept
involving the use of Nanovar involving the use of Nanovar

surface technology surface technology
designed to improve the durability of advanced designed to improve the durability of advanced
composite molds and fixtures used in manufacturing. composite molds and fixtures used in manufacturing.
This event promises to be a real learning experience! This event promises to be a real learning experience!
Contact Victoria Townsend at vtownsend@sme.org
for more information about this exiting event!
Thank You For Attending!
Thank You For Attending!
Feel free to contact me directly if you have Feel free to contact me directly if you have
additional questions after this session. additional questions after this session.
Louis C. Dorworth Louis C. Dorworth
Technical Director Technical Director
Abaris Training Resources, Inc. Abaris Training Resources, Inc.
5401 Longley Lane, Suite 49 5401 Longley Lane, Suite 49
Reno, NV 89511 Reno, NV 89511
lou@abaris.com lou@abaris.com
775 775- -827 827- -6598 x228 6598 x228

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Abaris Training, 2007 Abaris Training, 2007

Bolted Doubler Repairs

Idea comes from metal lap

Each damaged layer is removed in steps

Each repair ply then overlaps the

Easy to conceptualize & design.

Feasible for flat panel repairs made with

Requires meticulous machining of each

Requires careful fabrication and

Takes a trained technician approximately

Each repair ply then lays over the

Fast & easy to machine taper

Perfect size and fit of repair plies is less

Flush surface is attainable.

Can machine a taper with a die grinder or

Less risk of damaging underlying layers in

Not applicable to repairs of thick structures

Minor risk of damaging good structure

Historically the norm for metal structural

Normally reserved for thicker, solid

Doublers must be made to closely match

Additional tooling may be required to

Autoclave cure of composite patch may be

Risks associated with drilling into

Expensive Ti fasteners required in carbon

Sealing of the repair questionable and not

The goal is to replace the structure to

It takes special training and practice to do

One approach does not fit all types of

Repair technicians have to know their

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