1、MILITARY STANDARDIZATION HANDBOOK ADHESIVE BONDED AEROSPACE STRUCTURE REPAIR FSC 8040 W Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-337 AO 0 9799770 0007563 b 0 “. DEPARTMENT OF DEFENSE WASHINGTON, D.C. U L MIL-HDBK- 337 Repair of Adhesi
2、ve Bonded Aerospace Structures 1. This handbook was developed by the Department of Defense in accordance with established procedures. 2. This publication was approved on 1 December 1982 for printing and inclusion in the military standardization handbook series. 3. This handbook provides information
3、on material and fabrication procedures for repairing adhesive bonded aerospace structure and parts thereof. This handbook is not intended to be referenced in purchase specification except for informational purposes nor shall it supersede any specification requirements. 4. Every effort has been made
4、to reflect current information. It is intended to update this handbook periodically. Comments on this hand- book are encouraged. Comments should be addressed to the Materials Laboratory, Wright Aeronautical Laboratories, Attention: AFkAL/MLSE, Wright-Patterson Air Force Base, OH 45433. i Provided by
5、 IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK- 337 1 December 1982 TABLE OF CONTENTS 1.0 INTRODUCTION 1.1 Scope aGi Limitations . 1.2 Instructions 1.2.1 Manual Usage 1.2.2 Personnel Qualifications 1.2.3 Workmanship 1.2.4 Repair Atmospheric Environmen
6、t 1.2.6 Quality Assurance 1.3 Safety Precautions . 1.4 List of References 1.2.5 RepairMaterials . Page 1-1 1-1 1-2 1-3 1-3 1-3 1-3 1-4 1-4 1-5 1-7 2.0 DAMAGE ASSESSMENT . 2-1 2.1 General . 2-1 2.2 Typical Damage Assessment Methods 2-2 2.2.1 External Damage . 2-2 2.2.2 Internal Damage . 2-4 3.0 REPAI
7、R METHOD SELECTION 3-1 4.0 MATERIALS AND PROCESSING . 4.1 Material Selection . 4.1.1 Adhesives. Metal-to-Metal and Metal-to-Core . 4.1.2 Adhesives. Core Splice . 4.1.3 Aerodynamic Smoothers . 4.1.4 Potting Compounds. Core Filler 4.1.5 Potting Compounds. Injectable Honeycomb . 4.1.6 Sealants/Aerodyna
8、mic Smoothers . 4.1.7 Honeycomb Cores . 4.1.8 Glass Fiber Resin 4.2 Repair Materials 4.2.1 Materials Incorporated in the Repair 4.2.2 Materials Not Incorporated in the Repair c . 4.3 Materials Processing 4.3.1 Preparation and Application of Primer . 4.3.2 Application of Film Adhesives 4.3.3 Preparat
9、ion and Application of Liquidpaste Adhesives . 4.3.4 Preparation and Application of Potting Compounds 4.3.5 Preparation and Application of Chromate Conversion Coating. MIM-5541. Class IA (e.g., Alodine 1200) . 4.3.6 Preparation and Application of Sealants and Aerodynamic Smoothers ; . . 4-1 . 4-1 .
10、4-1 . 4-3 . 4-3 . 4-3 . 4-3 4-3 . 4-9 . 4-9 . 4-9 . . * 4-9 . 620 . 4-20 . 4-20 . 4-27 . 4-29 . 4-29 . 4-30 . 4-33 W . ii . . Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-337 80 W 4999970 00075b5 T f MIL-HDBK-337 TABLE OF CONTENTS (Contin
11、ued) 4.3.7 Preparation and Application of Finish Coatings! 4.4.1 Wedge Panels. Specimens. and Test Procedure 4.4 Material Compatibility . 4.5 Material Property Data . 4.5.2 Honeycomb Core Materials 4.5.3 Adhesives 4.5.4 Potting Compounds 4.6 Adhesive Receiving Acceptance Tests 4.5.1 Honeycomb Sandwi
12、ch Facing Materials . 1 Decenber 1982 Page . 4-33 . 4-33 . 4-34 . 4-34 . 4-36 . 4-37 . 4-37 . 4-38 . 4-38 5.0 SURFACE PREPARATION PROCEDURES 5-1 5.1 General 5-1 5.2 Cleaning of Aluminum Core for Bonding . 5-4 5.3 Aluminum Surface Preparation . 5-4 5.3.1 Tank Processes . 5-4 5.3.2 Nontank Processes 5
13、-14 5.4 Titanium Surface Preparation . 5-23 5.5 Fiberglass Surface Preparation . 5-24 5.6 Stainless Steel Surface Preparation . 5-24 5.6.1 300-Series Stainless Steel . 5-25 5.6.2 Carbon Steels and 4i3-Series and PH Stainless Steels . 5-26 6.0 REPAIR METHODS. SMALL 6-1 6.1 General . 6-1 6.1.1 Common
14、Errors and Problems-Causes and Results . 6-2 6.1.2 Fabrication of Small Honeycomb Core Details . 6-2 6.2 Repair . of Scratches. Skin Surface 6-5 6.2.1 Light Scratches . 6-6 6.2.2 Deep Scratches. Aluminum and Titanium . 6-8 6.3.1 Repair Procedures for Dents 6-15 6.4 Hole in One Sandwich Skin or Skin
15、Delamination. No Core Damage 6-16 6.4.1 Repair Procedures for a Hole in One Skin or Delamination. No 6.3 Dents. Skin Surface 6-13 Core Damage 6-19 6.5 Hole in One Sandwich Skin. Damaged Core 6-24 6.5.1 Honeycomb Core Plug Repair 6-27 6.6 Hole Through Both Sandwich Skins . 6-36 6.5.2 Potted.Plug Repa
16、ir. Optional Method . 6-34 6.6.1 Honeycomb Core Plug Repair. Nonflush 6-39 6.6.2 Potted Plug Repair. Optional Method . 6-46 6.6.3 Honeycomb Core Plug Repair. Flush One Surface 6-48 iii J Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-. MIL-HDBK- 33
17、I MIL-HDBK-337 80 7779770 0007566 L W 1 December 1982 TABLE OF CONTENTS (Continued) Page 6.7 Panel Zee Edge Close-Out Damage 6-55 6.7.1 Edge Closure Repair Procedure . 6-59 6.8 Wedge Section Trailing-Edge Damage 6-69 6.8.1 Arrowhead Trailing-Edge Repair . 6-71 6.8.2 Laminated Trailing-Edge Closeout
18、Repair . 6-79 6.8.3 Wrap-Around Trailing-Edge Repair 6-87 6.9 Metal-to-Metal Laminated Repairs . 6-92 6.9.1 Damage to One or More Layers of Laminates 6-95 7.0 LARGE AREA REPAIRS . 7-1 7.1 Introduction 7-1 7.2 Damage Evaluation . 7-1 7.3 Damage Removal Methods 7-2 7.3.1 Removal of Skin and Doubler Ma
19、terial 7-2 7.3.2 Use of Dry Ice 7-3 7.3.3 Removal of Core Material . 7-8 7.3.4 Removal of Surface Corrosion . 7-10 7.3.6 Removal of Moisture . 7-11 7.5 In-Process Quality Assurance . 7-13 7.5.1 General 7-13 7.5.2 Bake or Cure Cycle Process Control . 7-14 7.S.3 Evaluation of Process Control Results .
20、 7-14 7.6. Fabrication of Details 7-15 7.6.1 Sheet Metal . 7-15 7.6.2 Processing of Honeycomb Core . 7-16 7.7 Prefit of Details . 7-20 7.8 Surface Preparation for Bonding 7-23 7.9 Application of Bonding Materials 7-24 7.1 O Assembly of Components for Cure . 7-24 7.1 I . 1 Vacuum Bagging Sequence . 7
21、-29 7.12 Flash Removal and Clean Up 7-35 7.13 Seal and Finish . 7-35 7.14 Post Inspection . 7-35 7.3.5 Removal of Organic Surface Finishes . 7-10 7.4 Repair Material Selection . 7-13 7.11 Vacuum Bagging Techniques in Preparation for the Cure Cycle 7-27 i “ t iv . 8.0 TOOLS. EQUIPMENT AND FACILITIES
22、. 8-1 8.1 Tools for Damage Removal 8-1 8.1.1 High-speed Router 8-1 8.1.2 Hole Saw and Fly Cutter 8-5 8.1.3 Portable Saws and Sanders . 8-7 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-. “. MIL-HDBK-337 80 W 7779770 0007567 3 MIL-HDBK-337 1 Decembe
23、r L982 c TABLE OF CONTENTS (Concluded) Page 8.1.4 Skin Peeling Tool 8-7 8.2 Core Machining and Forming . 8-10 8.2.1 Equipment for Surface Machining 8-10 8.2.2 Core-Forming Equipment . 8-13 8.3 Processing Facilities . 8-13 8.3.1 Surface Preparation Tanks . 8-13 8.3.2 Primer Application Area 8-16 8.3.
24、3 Controlled Atmospheric Layup Areas . 8-16 8.4 Curing Equipment and Facilities 8-21 8.4.1 Autoclaves . 8-21 8.4.2 Curing Ovens 8-23 8.5 Hand Tools and Miscellaneous Equipment 8-23 9.0 TOOL FABRICATION 9-1 9.1 Metal Versus Fiberglass Tools . 9-4 9.2 Metal Tool Fabrication 9-4 9.2.1 Fairing Bars . 9-
25、9 9.2.2 Pressure Bars and Mandrels . 9-10 9.2.3 Vacuum Blanket Support Details 9-11 9.2.4 Handling Provisions 9-12 9.3 Fiberglass Laminate Tool Fairication 9-13 10.0 NONDESTRUCTIVE INSPECTION . 11 O- 10.1 General 10-1 1 O . 1.1 Introduction 10-1 10.1.2 How to Use the ND1 Section 10-1 1 O . 1.3 Termi
26、nology and Definitions 10-1 10.1.4 Personnel Qualifications 10-7 10.1.5 Test Standards 10-8 10.1.6 Prerepair Inspection 10-9 10.1.7 Postrepair Inspection . 10-9 10.2 General Description of ND1 Methods and Equipment 10-10 10.2.2 Visual . 10-13 10.2.1 Method Sensitivity 10-10 10.2.3 Tapping 10-1 3 10.
27、2.4 Ultrasonic 10-13 10.2.5 Radiography . 10-25 10.2.6 Eddy Current 10-38 10.2.7 Holography . 10-40 . 10.2.8 Thermography 10-43 10.2.9 Acoustic Emission . 10-43 V Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-337 80 7777770 0007568 5 m MIL
28、-HDBK-337 No . 2- 1 2-2 2-3 2-4 2-5 2-6 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 5-1 O 5- 1 5-2 5-3 6-4 6-5 6-6 6-7 6-8 6-9 6-1 O 6-1 1 6-1 2 6-1 3 6-14 6-1 5 6-16 LIST OF ILLUSTRATIONS Dents in Surface of C-141 Wing Trailing-Edge Panel F-1 11 Damaged Weapons-Bay Lower
29、 Door . Puncture in Honeycomb C-14 1 APU Access Panel . Delamination of Trailing-Edge Panel Localized Crushed Core . Corrosion in Honeycomb Core . Preval Pressurized Spray Bottle to Apply Adhesive Primer Fillet Sealing of Bonded Repairs Wedge Test Specimen Configuration Test Panel Assembly Lap Shear
30、 Test Specimen Configuration . Metal-to-Metal Peel Test Panel Blank Metal-to-Metal Peel Test Panel Assembly and Specimen . Honeycomb Peel Test Panel Blank . Honeycomb Peel Test Panel Assembly . Aluminum Failure Surfaces-Solvent Cleaned Before Bonding Aluminum Failure Surfaces-Phosphoric Acid Anodize
31、d Before Bonding Polarized Light Test-Verification of Anodic Oxide Film Saturating Gauze Covering Repair Detail with Phosphoric Acid Anodizing Aluminum Repair Details Anodizing in Process Removing Acid By Gently Wiping With Wet Gauze . Inspecting the Phosphoric Acid Anodized Surface With a Polarized
32、 Filter Set Up for Anodizing Both Sides of Aluminum Detail- . HoneycombCore-Slicing Equipment Adjusting the Slope of Angle Plate . Angle Plate in Use Application of Masking Tape Prior to Surface Cleaning Detail of Beveled Metal Overlap Patch for Repair of Deep Scratches . . Marked Coordinate Lines f
33、or Centering Patch Over Hole or Delamination Beveled Edge of Patch Plate . Beveled Patch Plate With Coordinate Lines PasaJell 105 Applied to Aluminum Surface for Bonding . Marked Coordinate Lines for Centering Patch Plate Over Scratch . Schematic of Repair of Surface Puncture or Delamination Applica
34、tion of Masking Tape Prior to Surfacecleaning . Finished Layup Ready for Adhesive Cure Schematic of Repair for Damage to One Sandwich Face and Core . Detail of BeveledPatch Plate and Coordinate Lines Through-Repair Marked Coordinate Lines for Centering Patch Over Core Plug Repair . . Application of
35、Core-Splice Adhesive and Metal Shim Plug for a Partial 1 December 1982 i Page . 2-3 . 24 . 2-5 . 2-6 . 2-7 . 2-8 . 4-28 . 4-32 . 4-35 . 439 . 4-40 . 4-41 . 4-42 . 4-43 . 4-43 . 5-2 . 5-3 . 5-13 . 5-17 . 5-18 . 5-19 . 5-20 . 5-21 . 5-21 . 5-22 . 6-3 . 6-4 . 6-4 . 6-7 . 6-11 . 6-12 . 6-17 . 6-19 . 6-2
36、1 . 6-21 . 6-22 . 6-23 . 6-28 . 6-29 . 6-30 . 6-31 vi P Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-. LIST OF ILLUSTRATIONS (Continued) 1 December 1982 No . Page 6-1 7 6-1 8 6-1 9 6-20 6-21 6-22 6-23 6-24 6-25 6-26 6-27 6-28 6-29 6-30 6-3 1 6-32
37、6-33 6-3 4 6-3 5 6-3 6 6-3 7 6-38 6-3 9 6-40 6-4 1 6-42 6-44 6-46 6-48 6-43 6-45 6-47 6-49 6-50 6-5 1 6-5 2 6-5 3 6-54 6-5 5 6-5 6 Patch Plate Secured With Polyester Tape . 6-33 Typical Setup of Single Heating Blanket With Backup Pressure for Thin Sandwich Repair . 6-34 Lay-Up for Heat Curing the Po
38、tted Core Plug 6-36 Damage Through Both Skins and Honeycomb Core . 6-37 Application of Masking Tape Over Potted Plug Repair 6-35 Schematic of Repair Using Nonflush Honeycomb Core Plug 6-40 Marked Coordinate Lines for Centering Patch Over Core Plug Repair . 6-40 Application of Core-Splice Adhesive to
39、 Core Plug Repair 6-43 Application of Masking Tape Prior to Surface Cleaning 6-44 Patch Plate Secured With Polyester or Nylon Tape 6-45 Schematic of Repair Using Potted Core Plug 646 Patch Plates Used as Caul Plates to Cure Potting Compound 6-47 Schematic of Repair. Flush One Side. for Hole Through
40、Both Sandwich Skins . 6-48 Cavity Cleaned for Installation of Honeycomb Core Plug Repair Details . 6-49 Detail of Beveled Patch Plate and Coordinate Lines . 6-41 Detail of Beveled Patch Plate and Coordinate Lines . 6-50 Schematic of Repair Details for Initial Cure Cycle 6-52 Positioning Doubler and
41、Skin Plug 6-52 Strip of Foaming Core-Splice Adhesive Around Edge of Cavity . 6-53 Application of Masking Tape Prior to Surface Cleaning . 6-54 Typical Edge Close-Out Damage . 6-56 Typical Edge Close-Out . 6-59 Edge Repair With External Nonflush Patch Plate 6-60 Application of Router Template to Repa
42、ir Area . 6-61 Primary Router Cut to Remove Damage 6-62 Secondary Router Cut to Remove Outer Skin . 6-62 Layout for Router Removal of Edge Doublers . 6-63 Beveled Edge of Patch Plate 6-65 Layout of Cutting Pattern forDamage Removal . 6-72 Damage Removed and Area Ready for Prefit of Repair Details .
43、6-64 Typical Damage to Arrowhead-Type Trailing-Edge Close-Out 6-72 Trailing Edge With Damaged Area Removed 6-73 Notches Cut in Arrowhead Fitting to Receive Replacement Part 6-74 Schematic of Repair for Arrowhead-Type Trailing-Edge Damage 6-76 Application of Masking Tape Prior to Surface Cleaning 6-7
44、7 Assembly With Core Plug and Tip Fitting in Place 6-78 Completed Repair of Arrowhead-Type Trailing Edge . 6-79 Typical Damage to Laminated Trailing Edge 6-80 Layout of Damaged Trailing-Edge Area to be Removed 6-80 Damage Removal Schemes for Laminated Trailing Edge 6-81 vi i Provided by IHSNot for R
45、esaleNo reproduction or networking permitted without license from IHS-,-,-. MIL-HDBK-337 No . 6-5 7 6-5 8 6-5 9 6-60 6-6 1 6-62 6-63 6-64 6-65 6-6 6 6-67 6-68 6-69 6-70 7- 1 7-2 7-3 7-4 7-5 7-6 7-7 7-8 7-9 7-1 O 7-1 1 7-1 2 7-13 7- 1 4 7-1 5 7-1 6 7-1 7 7-1 8 7-1 9 7-20 7-2 1 7-22 7-23 MIL-HDBK-337
46、AO 7979970 0007570 3 W 1 December 5982 LIST OF ILLUSTRATIONS (Continued) Page Schematic of Repair for Laminated Trailing-Edge Damage . 6-84 Beveled Edge of Patch Plate 6-85 Application of Masking Tape Prior to Surface Cleaning 6-85 Completed Repair of Laminated Trailing Edge 6-88 Typical Damage to W
47、rap-Around-Type Trailing-Edge Close-Out . 6-88 Trailing-Edge Damage Removed and Repair Details Prepared 6-90 Beveled Edge of Patch Plate 6-90 Assembly With Lower Splice Plate. Core Plug. and Edge Doubler in Place . 6-87 Trailing-Edge Repair With Core Plug in Place 6-91 Completed Repair of Wrap-Aroun
48、d-Type Trailing Edge 6-91 Delamination of Double- or Triple-Layered Laminate and Typical Repair Scheme . . 6-92 Dented Skin and Typical Repair Scheme With Nonflush Patch Plates . 6-92 Schematic of Dented Skin With Typical Repair for Aerodynamic Smoothness . 6-93 Repair of a Delaminated Skin Area 6-9
49、7 Using High Speed Router to Remove Damaged Material 7-3 Router Cuts to Remove Edge Damage on Landing-Gear Door-Repair Details Also Shown . 7-4 Use of High Speed Router to Remove Strip of Sandwich Skin 7-5 Peeling Skin Strip From the Honeycomb Core . 7-5 Removal of Large Skin Sections . 7-6 Honeycomb Panel Skin Cut in Strips to Facilitate Removal 7-7 C02 Retort to Facilitate Skin Removal 7-8 Removal of Core With Sharpened
