1、Designation: E 1556 03Standard Specification forEpoxy Resin System for Composite Skin, HoneycombSandwich Panel Repair1This standard is issued under the fixed designation E 1556; the number immediately following the designation indicates the year oforiginal adoption or, in the case of revision, the y
2、ear of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon (e) indicates an editorial change since the last revision or reapproval.This standard has been approved for use by agencies of the Department of Defense.1. Scope1.1 This specification covers the
3、 requirements for an epoxyresin system intended for the repair of sandwich panels fordurable, rigidwall, relocatable structures. It must be usable in afield environment and shall not require the use of specialequipment such as autoclaves or presses. The epoxy systemcovered by this specification shal
4、l be usable for simultaneousimpregnation of a wet-layup composite skin and bonding ofthat skin to a substrate honeycomb core. The material shallwithstand exposure to temperatures from 54 to 93C (65 to199F) and high relative humidity, and also the combination ofstress, temperature, and relative humid
5、ity that are expected tobe encountered in service.1.2 The values stated in SI units are to be regarded asstandard where only SI units are given or where SI units aregiven first followed by inch-pound units; where inch-poundunits are given first followed by SI units, the inch-pound unitsare to be reg
6、arded as the standard.1.3 The following safety hazards caveat refers only to thetest methods described in this specification. This standard doesnot purport to address all of the safety concerns, if any,associated with its use. It is the responsibility of the user of thisstandard to establish appropr
7、iate safety and health practicesand determine the applicability of regulatory limitations priorto use.2. Referenced Documents2.1 ASTM Standards:C 297 Test Method for Flatwise Tensile Strength of Sand-wich ConstructionsD 792 Test Methods for Density and Specific Gravity (Rela-tive Density) of Plastic
8、s by DisplacementD 2344 Test Method for Strength of Polymer Matrix Com-posite Materials by Short-Beam MethodD 2584 Test Method for Ignition Loss of Cured ReinforcedResinsD 2734 Test Methods for Void Content of Reinforced Plas-ticsD 3165 Test Method for Strength Properties ofAdhesives inShear by Tens
9、ion Loading of Single-Lap-Joint LaminatedAssembliesE 874 Practice forAdhesive Bonding ofAluminum Facingsto Nonmetallic Honeycomb Core for Shelter PanelsE 1091 Specification for Nonmetallic Honeycomb Core forUse in Shelter Panels2.2 Military Specifications:MIL-I-24768 Insulation, Plastic, Laminated,T
10、hermosetting,Glass-Cloth, Epoxy-Resin22.3 Military Standards:MIL-STD-1916 DOD Preferred Methods for Acceptance ofProduct22.4 Commercial StandardsSAE-AMS-C-9084 Cloth, Glass, Finished for Epoxy ResinLaminates33. Physical Requirements3.1 Working Characteristics:3.1.1 ApplicationThe components of the e
11、poxy resin shallbe readily hand-mixed to a smooth consistency suitable forapplication. It shall be uniform and free of lumps. The resincomponents, once mixed, shall not settle out. The epoxymaterial shall be suitable for the wet-layup impregnation ofSAE-AMS-C-9084 glass cloth and for application to
12、corematerials over the temperature range of 16 to 38C (60 to100F) and at relative humidities of 30 to 75 %.3.1.2 Application LifeThe application life of a 200-g kitof the mixed epoxy system shall be at least 60 min when testedin accordance with 3.1.5. The epoxy shall be considered tohave reached the
13、 end of its application life when the viscosityof this 200-g quantity of mixed adhesive exceeds 20 000centipoise.3.1.3 CuringThe epoxy system shall be capable of curingat 23 6 2C (73 6 4F) in 7 days, or for no longer than3hat1This specification is under the jurisdiction of ASTM Committee E06 onPerfo
14、rmance of Buildings and is the direct responsibility of Subcommittee E06.53on Materials and Processes for Durable Rigidwall Relocatable Structures.Current edition approved Oct. 1, 2003. Published October 2003. Originallyapproved in 1993. Last previous edition appoved in 1998 as E 1556 98.2Available
15、from Standardization Documents Order Desk, Bldg. 4 Section D, 700Robbins Ave., Philadelphia, PA 19111-5094, Attn: NPODS.3Available from Society of Automotive Engineers (SAE), 400 CommonwealthDr., Warrendale, PA 15096-0001.1Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Consho
16、hocken, PA 19428-2959, United States.a temperature of 60 to 66C (140 to 151F), with a curingpressure not to exceed 14 psig. In a 236 3C cure, the curingpressure is not required to be maintained after the first 24 h. Ina236 2C cure, the epoxy material shall develop the propertylevels listed in Table
17、1 within the first 24 h of cure (see 7.3.5).In order to meet the requirements of this specification, theproperty levels listed in Tables 2-4 must be achieved with the7-day cure at 23 6 2C (73 6 4F).3.1.4 Storage LifeThe storage life period of the two partsof the epoxy resin system, when stored in ai
18、rtight containers at23C (73F), shall be at least 12 months from the date ofshipment when tested in accordance with 7.3.5.3.1.5 ViscosityThe viscosity of a 200-g kit of the mixedresin system shall be determined at 23 6 2C (73 6 4F) usinga Brookfield viscometer with a No. 3 spindle at 20 rpm. Aviscosi
19、ty curve shall be determined by taking a readingimmediately after mixing, and every 5 min thereafter until theviscosity exceeds 20 000 centipoise.The viscosity immediatelyafter mixing shall not exceed 14 000 centipoise.3.2 Mechanical PropertiesMechanical properties of testspecimens prepared and test
20、ed as specified in Section 7 shallmeet the respective requirements listed in Tables 2-4.3.3 Instruction SheetThe manufacturer shall provide adated, coded, and titled instruction sheet outlining instructionsfor use of the epoxy system in impregnating and bondingSAE-AMS-C-9084 glass composite skins to
21、 honeycomb cores(Specification E 1091, Types I or II). These instructions shallbe supplied by the manufacturer with the test report whenrequesting qualification (see 6.3) and also with each shipmentof epoxy material (see 9.2). The following information shall beincluded:3.3.1 All of the information l
22、isted in 5.3.1-5.3.11.3.3.2 The application life of the mixed epoxy system at 236 2C (73 6 4F) and 38 6 2C (100 6 4F).3.3.3 Mixing instructions shall be stated in detail for theepoxy resin system in the particular container supplied.3.3.4 Application, impregnating, and curing instructions,including
23、the spreading method, thickness range, andtemperature/relative humidity working limitations.3.3.5 Material Safety Data Sheets and necessary safetyprecautions to be observed throughout all operations.3.3.6 Any other pertinent information relative to the use andstorage of the two-part system (resin an
24、d curing agent) package(see 9.2).4. Significance and Use4.1 Epoxy resin systems used in the repair of composite skinsandwich panels for durable, rigidwall, relocatable sheltersmust have a combination of mechanical property levels andenvironmental resistance that will assure long-term durabilityof th
25、e skins and the skin-to-core adhesive bonds when exposedto severe climatic exposures. In addition, these epoxy materialsmust have processability characteristics that permit their use ina variety of repair scenarios and environments.TABLE 1 Property Requirements for 24-h, 23C CureProperty Test Condit
26、ionNumber ofSpecimensAverage Must Exceed Minimum Must Exceed,AMPa (psi) MPa (psi)Tensile Lap Shear Strength in accordancewith 7.2.1, 7.3.123C (73F), dry 5 6.9 (1000) 5.85 (850)Apparent Horizontal Shear Strength inaccordance with 7.2.2, 7.3.223C (73F), dry 5 15.5 (2250) 13.15 (1910)AAll specimens tes
27、ted must exceed these minimum values.TABLE 2 Tensile Lap Shear Strength Requirements (See 7.3.1)Test ConditionNumber ofSpecimensAverage Must Exceed Minimum Must Exceed,AMPa (psi) MPa (psi)40C (40F), dry 5 13.8 (2000) 11.7 (1700)23C (73F), dry 5 13.8 (2000) 11.7 (1700)93C (200F), wetB5 6.9 (1000) 5.9
28、 (850)AAll specimens tested must exceed these minimum values.BWet = tested immediately after 30 days exposure to 60C (140F) and 95 to 100 % R.H.TABLE 3 Apparent Horizontal Shear Strength RequirementsTest ConditionNumber ofSpecimensAverage Must Exceed Minimum Must Exceed,AMPa (psi) MPa (psi)23C (73F)
29、, dry 5 31.0 (4500) 26.3 (3820)93C (200F), wetB5 13.8 (2000) 11.7 (1700)AAll specimens tested must exceed these minimum values.BWet = tested immediately after 30 days exposure to 60C (140F) and 95 to 100 % R.H.TABLE 4 Flatwise Tensile Strength RequirementsTest ConditionNumber ofSpecimensAverage Must
30、 Exceed Minimum Must Exceed,AMPa (psi) MPa (psi)40C (40F), dry 5 2.8 (406) 2.4 (345)23C (73F), dry 5 2.8 (406) 2.4 (345)80C (176F), wetB5 1.38 (200) 1.17 (170)AAll specimens tested must exceed these minimum values.BWet = tested immediately after 30 days exposure to 60C (140F) and 95 to 100 % R.H.E15
31、560324.2 Intended UseEpoxy systems conforming to this speci-fication are intended for use in the repair of honeycomb panelsat the maintenance field level. The material is intended for usewith SAE-AMS-C-9084 glass cloth.4.2.1 This is a procurement control document for theprocurement of the epoxy syst
32、em and designers shall be awarethat the test values specified herein are based upon testsperformed with specific glass-resin composite adherends andshall not be used for design data.4.2.2 Epoxy systems covered by this specification are notintended for use in production bonding of sandwich construc-t
33、ion.5. Material and Ordering Information5.1 General DescriptionThe material shall be a two-partthermosetting epoxy system containing no asbestos, whichshall not have a deleterious effect on the components beingimpregnated and bonded. It shall have physical characteristicsthat meet the requirements o
34、f Sections 3 and 6.5.1.1 Formulation ChangesThe epoxy material shall beapproved only for the formulation that has passed the qualifi-cation tests and shall be used by the fabricator as approved.Any changes by the manufacturer, such as the adding orchanging of pigments, hardeners, or fillers, or chan
35、ges in thetype or method of manufacture, changes in formulation of thebasic resin, or any other changes, shall be cause for designatingthe adhesive as a new product that shall not be consideredapproved. The changed epoxy resin system shall be given anew code number and shall be resubmitted for appro
36、val underthis specification.Anew instruction sheet for this reformulatedmaterial shall be submitted by the manufacturer to the quali-fying activity for approval (see 3.3 and section 10.3.2.3).5.1.2 Identification of ProductThe manufacturer shallidentify each epoxy resin system submitted under this s
37、pecifi-cation according to the type of container furnished for it (seeSection 9). In addition, the manufacturer shall designate eachepoxy system by a trade name and code number that shall beused to identify it.5.2 QualificationIn the case of epoxy systems for whichthe purchaser requires qualificatio
38、n, the procurement documentshall state that awards will be made only for epoxy systems thatare, at the time set for opening for bids, qualified, according tothe requirements in Section 3, for inclusion on the applicablequalified products list.5.3 Procurement DocumentsProcurement documentsshall speci
39、fy the following:5.3.1 Title, number, and date of this specification,5.3.2 Epoxy resin system type and manufacturers tradename,5.3.3 Date of manufacture,5.3.4 Manufacturers name and address,5.3.5 Manufacturers batch/lot designation,5.3.6 Contract number,5.3.7 Date of shipment,5.3.8 Expiration dates
40、when stored at 23 6 2C (73 6 4F),5.3.9 Manufacturers recommended storage temperature,5.3.10 Quantity required, and5.3.11 Manufacturers certification that the batch and lotmeet the requirements of this specification.6. Quality Assurance Provisions6.1 Responsibility for InspectionUnless otherwise spec
41、i-fied in the contract or purchase order, the supplier is respon-sible for the performance of all inspection requirements asspecified herein. Except as otherwise specified in the contractor purchase order, the supplier is permitted to use any facilitysuitable for the performance of the inspection re
42、quirementsspecified herein, unless disapproved by purchaser. The pur-chaser reserves the right to perform any of the inspections setforth in the specification where such inspections are required toensure that supplies and services conform to prescribed re-quirements.6.2 Classification of TestsThe in
43、spection and testing ofthe epoxy system shall be classified as qualification tests (see6.3) and quality conformance tests (see 6.4).6.3 Qualification Tests:6.3.1 Sampling Instruction:6.3.1.1 Epoxy Resin System SamplesThe manufacturershall submit two 1-qt samples of the base epoxy resin, alongwith th
44、e necessary curing agent, from a single-numberedproduction batch of material being presented for qualification.The manufacturer shall submit two additional 200-g kits of thetwo-part system (resin and curing agent) from the sameproduction batch for storage life tests (7.3.4). These four 200-gkit epox
45、y resin samples shall each be from a batch of mostrecent production-scale manufacture, and are not required to befrom the same batch as that used in preparing the duplicatepanels specified in 6.3.1.3.All samples shall be identified as to:(1) Name and address of manufacturer,(2) Manufacturers designa
46、tion (trade name and codenumber),(3) Type of epoxy resin,(4) Batch number,(5) Date of manufacture,(6) Date of submittal,(7) Expiration date, and(8) Identification of agency submitting the samples.6.3.1.2 A statement indicating that the products have notbeen rebranded shall accompany the samples. If
47、rebranded, thenames of the original manufacturers and original designationsof the products shall be indicated. All information submittedwill be treated as confidential.6.3.1.3 Duplicate PanelsThe manufacturer shall submit,along with the epoxy material samples called for in 6.3.1.1,aset of three pane
48、ls, prepared in accordance with the proceduresdescribed in 7.2.1-7.2.3, respectively. These three panels shallbe duplicates of those used in the generation of data for the testreport (6.3.2). These panels shall be prepared with epoxy resinsamples from the same numbered batch, and shall be codemarked
49、 the same as the panels from which the data in the testreport (6.3.2) were obtained.6.3.2 Test ReportA dated and numbered report, certifiedby notarized affidavit, shall be furnished, giving the results ofall applicable tests listed in Tables 2-4. The individual speci-men and average values for each test shall be reported (seesection 10.3.2). Each value reported shall be shown as beingfor a uniquely numbered specimen, the numbering of whichshall be coded in the report in such a manner as to clearlyE1556033e
