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Repair On Aircraft Composite

What
Composite is a mixture of two or more material that different in composition. The material do not mix
with each other and can be easily identified between of the material.
How
Before doing any repair on the composite part we need to do damage assessment:
1.
2.
3.
4.
5.
6.

Do a visual inspection and determine the damage and extent of damage


Check for oil, water, fuel, dirt or other foreign contamination
Check for delamination around the damaged area
Check for any subsurface damage
By referring manufacturers manual, determine the damage
Determine the proper repair procedure as per manufacturers manual

Cost
The cost for repairing a composite part is more higher then metal part. At some point composite
repairing are cheaper then metal repairing in term of painting
Repair ability or maintenance
The repair damage can be classify in one of three category:
1.Negligible

Damage that can be repair without flight restriction

2.Repairable

Damage that can be repair but need to restrict the aircraft flight schedule

3.Non-Repairable

Damage that beyond the repair ability and need to be replace

Recyclability
Two factor need to be discussed before recycling method are explored:
Economics
-

Information need to be gather about what the particular type of recyclate will be and what the
market
Will the process be economically viable

Technical Aspect
-

Recoverability and separation method depend on the size of the waste


Determine if the matetial is thermoplastic or thermoset
Determine the contamination level

Recycling Method:
-

Landfill Disposal
Incineration
Chemical Technique
Thermo-mechanical Technique

Problems
One of major issue in composite repair is time and labor. Manual repairs are time-consuming and
therefore expansive. Composite WorldThere is also the potential for interfacial bonds between components to fail as the adhesive degrades
over time. pg 31 , FSA July-Aug 09Example
There are few example of composite repair method:
1. Vaccum-Bagging Process
2. Potted Repairs
- Undercut Potted Repair
- Mislocated Potting Compound
3. Laminate Structure Repair
- Laminate Cosmetic Repair
- Delamination Repair
4. Sandwich Structure Repair
- Puncture Repair
- Honeycomb Repair
- Aluminium alloy-faced honeycomb

References

Aviation Consumer.com, Composite Versus Metal: No Relief in cost to own , Volume 40


,Number 8 ,August 2010
Jeppesen A&P Technician Airframe Textbook
Composite Recycling and Disposal : An Environmental R&D Issue. BOEING Environmental
Technotes. 4, November 2003, Vol 8.
The Markets : Sports and Recreation. Composites World, November 2009.
FSA July-Aug 09 , Maintaining Ageing composite-material aircraft

UNIVERSITI KUALA LUMPUR


MALAYSIAN INSTITUTE OF AVIATION TECHNOLOGY

BACHELOR OF AIRCRAFT ENGINEERING TECHNOLOGY (HONS)


MECHANICAL

SUBJECT:
AIRCRAFT COMPOSITE REPAIR

NAME:
MUHAMMAD AIMULLAH RAZI BIN A.RAZAK
THIWAGAR S/O MUNIANDY

53259112150

53211114276

CLASS: 7 BME 1
SUBMIT TO: DR. NURUL ZUHAIRAH BINTI MAHMUD ZUHUDI