1、MIL-HDBK-803 73 W 7773770 00558Lb 7 INCH -POUND I MILHDBK-803 20 April 1990 SUPERSEDING July 1960 NAVSEA o900-LP-006-0010 GLASS REINFORCED PLASIIC3 PREVENTIVE MAINTENANCE AND REPAIR AMSC NIA FSC 9330 DISTRIBUTION STATEMENT k Approved for public release; distribution is unlimited. Provided by IHSNot
2、for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-803 73 W 7777970 0055837 9 m MLHDBK-803 . ,. FOREWORD 1. This military handbdok is approved for use by all Departments and Agencies of the Department of Defense. 2. * Beneficial comments (recommendations, ,additi
3、ons, deletions) and any pertinent data which may be of use in improving this documentshould be addressed to: Commander, Naval Sea Systems Command, SEA 5523, Department of $he, Navy,: Washington,:DC. 20362-5101 by using the self- addressed Standardization Document,Jmprovement .: . .“ .Proposal -. (DD
4、Form, -r . . 1426) appearing at the end of this document or by letter. 3. This document provides basic and fundamental information on the preventive maintenance and repair procedures for glass reinforFd.plastic equipment. This handbook is not intended to be referenced in purchase specifications,. -5
5、 . . ., . . ,I* . . .: , , ; ,. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIGHDBK-803 PARAGWH PAGE 1 . SCOPE 1 1.1 Scope . 1 1.2 Purpose . 1 2 . APPLICABLE DOCUMENTS . 1 2.1 Government documents 1 2.1.1 Specifications 1 2.2 Order of precedence
6、. 2 3 . DEFINITIONS . 2 3.1 Definitions . 2 4 . 4.1 4.2 4.3 4.4 4.4.2.1 4.4.2.2 4.4.2.3 4.4.2.4 4.4.2.5 4.4.3 4.4.4 4.5 5 . 5.1 5.1.1 5.1.1.1 5.1.1.2 5.1.1.3 5.1.1.4 5.1.2 5.1.2.1 5.1.2.2 5.1.2.3 GENERAL REQUIREMENTS . 9 Preventive maintenance (PM) 9 Failure reports . 9 Rationale . 10 Fastener or co
7、nnection areas 10 Stiffeners . 11 Metal supports or connections to GRP equipment 11 Other laminate areas . 11 Corrective action . 11 Removal of marine growth 11 Periodic inspection and general preventive maintenance guidance 10 Areas around openings in a laminate . 11 Summary 12 DETAILED REQUIREMENT
8、S 12 Materials . 12 Reinforcing materials 12 Woven glass cloth 13 Woven roving . 15 Chopped strand mat . 15 Glass materials combinations . 15 Unidirectional glass reinforcements . 16 Carbon fibers 16 Aramid fiber . 16 Special reinforcing materials 16 . . 111 Provided by IHSNot for ResaleNo reproduct
9、ion or networking permitted without license from IHS-,-,-MIL-HDBK-803 43 m 4997770 0055837 2 m 5.1.3 5.1.3.1 5.1.3.2 5.1.4 5.1.4.1 5.1.4.2 5.1.4.3 5.1.4.4 5.1.4.5 5.1.5 5.2 5.3 5.4 6 . 6.1 6.2 6.3 6.4 6.4.1 6.4.2 6.4.3 6.5 6.5.1 6.5.2 6.5.3 6.5.3.1 6.5.3.2 6.5.3.3 6.6 6.7 6.8 6.9 6.10 7 . 7.1 MILHDB
10、K-803 PARAGRAPH o PAGE Resins . 16 Polyester resin . 17 Epoxy resins . 18 Core material 19 End-grain balsa wood . 19 Polyvinyl chloride (PVC) foam . 19 Aramid honeycomb 20 Urethane foam . i . 21 Nonstructural foams . 21 Surface fillers . 21 Tools . 21 Safety . 22 Repair kits . 23 REPAIR PROCEDURES 2
11、3 Introduction 23 Surface cracks and abrasions . 25 Surface fractures . 28 Delamination . 36 Small edge delamination 37 Bubble type delamination . i . 40 Stiffener delamination 40 Laminate punctures . 40 Laminate punctures accessible from both sides . 43 Laminate punctures accessible from the exteri
12、or only 47 Glass laminate backing . 47 Screwed-in-place-backing 53 Foam backing . 54 Fractures in foam core structures 57 Punctures through foam core structures 65 Balsa core structures 67 Honeycomb structures 67 Tubular structures 68 Punctures through complex surfaces . 47 FINISHING 70 Introduction
13、., 70 v Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-803 73 m 7797770 0055820 7 m MIGHDBK-803 PARAGRAPH PAGE 7.1.1 Surface finish 70 7.2 Coatings . 71 7.2.1 Surface resin 72 7.2.2 Paint . 73 7.3 Gelcoat . 73 8 . SUMMARY 75 9 . 9.1 9.2 9.3
14、 FIGURES 1 . 2 . 3 . 4 . 5 . 6 . 7 . 8 . 9 . 1 o . 11 . 12 . 13 . 14 . 15 . 16 . 17 . 18 . 19 . 20 . NOTES . 75 Intended use 75 Issue of DODISS . 75 Subject term (key word) listing 75 Woven glass cloth 13 Woven roving . 14 Chopped strand mat . 14 End-grain balsa wood or GRP sandwich construction 19
15、Typical honeycomb panel construction . 20 Illustration of repairs to solid and cored reinforced plastic laminates 25 Small gouge in surface (less than 1/8-inch deep with no serious . structural damage) 26 Surface abrasion 26 Smoothing surface crack 27 Working resin into damaged area 28 Open type sur
16、face fracture 29 Hairline fracture on pleasure craft . 29 with heavy-duty sander . 30 Damaged area with scarf 31 Removing damaged fiberglass from outside area smoothly and evenly . Cutting paper template to proper size . 32 Materials for repair and mixing resin 34 Reinforcement being wetted out with
17、 resin . 35 Working out air and excess resin with roller 36 Edge delaminations 37 Materials for edge delamination repair 38 V Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-PARAGRAPH PAGE 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 3
18、6. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48, 49. 50. 5i. 52. vi Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-PARAGRAP1 TABLES NIL-HDBK-803 73 m 7777970 0055822 2 m MIGHDBK-803 CONTENTS - Continued PAGE I. Thicknesses (dry) for various glass
19、reinforcements . . . . . . . . . . . . . . . . . . . . . 15 II. Typical percentages by weight of reinforcement and resin for fiberglass . . . . . . III. Catalyst requirements for 1 quart (32 ounces) polyester . . . . . . . . . . . . . . . . . 18 N. Variation in polyester resin life and laminate gel
20、time at differing . . . . . . . . . . V. General guide to reinforcement selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 VI. Guide for step-back in making reinforcement template . . . . . . . . . . . . . . . . . 33 VII. Guide to estimating amount of resin for a 3/8-inch thick repai
21、r . . . . . . . . . . . 34 reinforced laminates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 temperatures and catalyst ratios (illustrative only) . . . . . . . . . . . . . . . . . . . . . 18 vii Provided by IHSNot for ResaleNo reproduction or networking permit
22、ted without license from IHS-,-,-MIL-HDBK-803 73 m 9777970 0055823 LI m MIL-HDBK-803 1. SCOPE 1.1 Scope. This handbook provides guidance for preventive maintenance of glass reinforced plastic (GRP) items, as well as instructions and illustrations on proper repair techniques for minor damage to reinf
23、orced plastic structures. Some specific equipments have their own dedicated repair instructions. For example, guidance on repair procedures for major repairs of boat hulls shall be in accordance with NAVSEA 0982-LP-019-0010; for submarine SONAR domes, see SE 300 BA-MMA-OlO/SONAR dome. Complete expla
24、nations of laminate properties and behavior, fabrication techniques, installation procedures, and other similar technical details do not fall within the scope of this handbook. This handbook does not cover repairs to very high performance applications such as aerospace structures, missile motor case
25、s, pressure vessels, or filament-wound articles or repairs to articles primarily made with reinforcing fiber other than glass. This handbook does not apply to MIL-P-24608 products or to repair of GRP piping materials. This handbook is limited to the practical considerations of preventive maintenance
26、 and to repair procedures based upon the use of the Navys standard reinforced plastic repair kit or readily available repair materials. By following the procedures in this handbook carefully and applying common sense for unusual circumstances, all personnel, including those without previous experien
27、ce working with GRP, can make effective and lasting repairs to GRP equipment. 1.2 Purpose. Over the past 30 years, the Navy has been researching, designing, and acquiring equipment made from GRP. Early applications of this material were generally restricted to small craft hulls. However, as fabricat
28、ion techniques and materials technology have advanced, a wider variety of GRP equipment has come into use. With the increased use of GRP, it is important that all hands become familiar with the preventive maintenance and repair procedures for all types of GRP structures and equipment. 2.1 Government
29、 documents. 2.1.1 Specifications. The following specifications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the issue of the Department of Defense Index of Specifications and Standards (DODISS) and suppleme
30、nt thereto, cited in the solicitation (see 9.2). SPECIFICATIONS MILITARY MIL-C- 19663 MIL-R-19907 Cloth, Woven Roving, or Plastic Laminate Repair Kit, Glass Reinforced Plastic Laminate 1 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-803 73
31、 m 7777770 0055824 b m MIGHDBK-803 (Unless otherwise indicated copies of military specifications are available from the Naval Publications and Forms Center, (A“It NPODS), 5801 Tabor Avenue, Philadelphia, PA 19120- 5099.) 2.2 Order of precedence. In the event of a conflict between the text of this do
32、cument and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 3. DEFINITIONS 3.1 Definitions. This section contains a list of terms and definitions used
33、in this handbook. Other terms commonly used in working with GRP are also included for additional information. 3.1.1 Accelerator. An oxidizing material used in conjunction with a catalyst to produce curing at room temperature of liquid polyester resin. It is usually obtained from the resin supplier a
34、long with the resin. 3.1.2 Acetone. A cleaning fluid used to remove uncured plastic resin from brushes and clothing. 3.13 Activator. For the definition of activator, see 3.1.1. 3.1.4 Adhesion. The sticking together of two surfaces in contact with each other. 3.1.5 Air-inhibited resin. A type of poly
35、ester resin in which curing of the surface is inhibited or prevented by the presence of air. The surface remains slightly tacky or sticky. 3.1.6 Alligatoriag. A laminate surface flaw resembling the texture of alligator skin. 3.1.7 Bias. The direction 45 degrees from direction of weave of a fabric. 3
36、.1.8 Bond strength. The load per inch or per square inch-required to cause failure of a bond. 3A.9 Benzoyl peroxide (BPO). A catalyst, typically supplied in paste form. 3.1.10 Bonding angle. A connecting angle of several plies of reinforcement and resin. used to connect two parts. 3.1.11 Catalyst. A
37、 substance which initiates or markedly speeds up the cure of a compound. Herein it refers to curing of polyester and vinylester resins. BPO and methyl ethyl ketone peroxide (MEW) are catalysts. 3.1.12 Chine. The line formed by the junction of bottom and side of a boat hull; generally termed chine on
38、ly when a definite angle is formed. 2 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-B03 73 m 7777970 0055825 B m MIL-HDBK-803 3.1.13 Cloth. Twisted strands of fiberglass (or other reinforcement) woven together to form a cloth material, usu
39、ally somewhat coarse compared to ordinary clothing material. It is much finer in texture than woven roving (3.1.108). 3.1.14 Color pigments. Ground coloring materials supported in a thick liquid. Added to the resin to give it color. 3.1.15 Compressive strength. The maximum compressive stress which a
40、 material is capable of resisting, based on the original area of the cross-section. 3.1.16 Core. A lightweight material separating faces of a. sandwich panel. Examples are structural foams, balsa wood and honeycomb. 3.1.17 Crazing. Hairline cracks either within or on the surface of a laminate, cause
41、d by stresses generated during cure, removal from mold, impact, or flexing. 3.1.18 Cross-linking. The setting up of chemical links between chains of molecules in a resin. This occurs in all thermosetting resins and is the basic mechanism for solidifying or curing of the resin. 3.1.19 Cure. The cross
42、-linking of the molecules of a resin which alters the properties of the material and changes it from a liquid into a solid. 3.1.20 Cure time. The time required for the liquid resin to reach a cured or fully hardened state after the catalyst or hardener has been added. 3.1.21 Curing temperature. The
43、temperature to which a resin or adhesive is subjected during cure - not the temperature of the material itself during cure which may differ from the temperature of the atmosphere in the vicinity. 3.1.22 Delamination. The separation of reinforcement layers in a laminate due to bond failure. 3.1.23 Di
44、mensional stability. The ability to retain constant shape and size. 3.1.24 Doubler. Extra plies of reinforcement added to a laminate in areas of high stress. 3.1.25 Dry spot. An area of low resin content in a laminate. 3.1.26 Dry strength. The strength of a laminate after conditioning in the standar
45、d laboratory atmosphere. 3.1.27 Duplication mold A mold made by casting over or duplicating another article. 3 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-=- MIL-HDBK-803 93 m 9999970 005582b T W MIL-HDBK-803 3.1.28 Epoxy. A type of thermosetting
46、 resin made from compounds containing the epoxy structure characterized by high strength and good adhesion to many materials. 3.1.29 Exothermic heat. The heat released during a chemical reaction such as the curing of a resin, Peak exotherm is the pint of highest temperature of a resin during cure. 3
47、.130 Fatigue. A type of structural loading of a material involving the repeated application of stress. 3.131 Filament. A single, hairlike fiber of glass characterized by extreme length which permits its use in yam with little or no twist. 3.132 Fill or sanding resin. A general purpose polyester resi
48、n used to impregnate and fill reinforcing material in the final lay-up of a surfacing application; usually contains wax. 3.133 Fill, The direction perpendicular to the length or long direction of a cloth. 3.134 Faers. Any one of a number of inexpensive substances that are added to plastic resins to
49、increase the volume, improve properties, or lower the cost of the article being produced. 3.135 Fmish. The surface treatment applied to fibrous glass to promote adhesion between the glass and resin. Sometimes mistakenly called size or “sizing“. 3.136 Fue retardancy. The property of a resin, by its nature or when combined with certain chemicals, to have a reduced tende
