Aipi - 03 02 018

AIRBUS
AIPI 03-02-018
Issue 2 Page 1 of 17 APRIL 2010
AIPI Airbus Process Instruction Manufacture of Structural Sandwich Parts with Thermosetting Fiber Reinforced Skins
Published and distributed by : AIRBUS S.A.S. MANUFACTURING ENGINEERING DIRECTORATE 31707 BLAGNAC Cedex FRANCE
Copyright AIRBUS S.A.S. 2007. All rights reserved Ref. no. AIPI 03-02-018
DocMaster: Uncontrolled copy when printed
AIPI 03-02-018 Issue 2
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Contents list
1 2 3 4 5 6 7 8 9
Scope Normative references Definitions, applicability and limitations Generalities Materials Facilities, tooling and equipment Materials preparation Prepreg and film adhesive cutting Core preparation
10 Tooling preparation 11 Manufacturing 12 Quality requirements Appendix I: Ancillary Materials List
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1 Scope
This Process Instruction establishes the requirements and defines the procedures for manufacturing of sandwich parts with metallic and non-metallic cores and thermosetting fibre reinforced skins, made of carbon fibre/organic matrix and glass fibre/organic matrix or hybrids, giving complete detailed in-house process instructions. This Process Instruction meets the requirements established in AIPS 03-02-018.
2 Normative references
This Process Instruction incorporates by dated or undated reference provisions from other publications. All normative references cited at the appropriate places in the text are listed hereafter. For dated references, subsequent amendments to, or revisions of any of these publications apply to this Airbus Process Instruction only when incorporated in it by amendment of revision. For undated references, the latest issue of the publication referred to shall be applied. A1016 ABD0076 AIMS 05-01-000 AIMS 05-02-000 AIMS 05-02-003 AIMS 05-27-000 AIMS 08-02-001 AIMS 10-01-000 AIMS 10-02-000 AIMS 10-03-000 AIMS 12-00-000 AIMS 12-01-002 AIPI 03-02-019 AIPI 03-03-006 AIPI 03-07-002 AIPI 03-07-019 AIPI 03-08-003 AIPI 06-01-003 AIPI 06-02-005 AIPI 06-02-006 AIPI 09-01-002 AIPS 03-02-018 AIPS 09-01-003 First Article Inspection. Composite Parts-Surface Status Requirements. Carbon Fibre reinforced epoxy prepreg. Glass Fibre Reinforced Thermosetting Prepreg. Glass Fibre Reinforced Prepreg. 1581, 7581 and 7781 style Glass Fabric (8 Harness Satin, 300 g/m2 dry fibre area mass). 180C Cure Temperature. High performance fibre reinforced epoxy prepreg. Glass fibre fabric (MIL-C-9084, Type VIII, Class 2) with epoxy resin for wet lay-up. Non structural application. Structural Adhesive Systems. Core Splicing Adhesive. Honeycomb Core Fillers. Ancillary materials. Technical Specification. Prepreg Peel Ply for structural bonding. Manufacture Monolithic Parts with Thermoset Prepreg Materials. Water Jet Cutting. Machining of Fibre Reinforced Plastic (FRP) Components. Hot forming of Thermoset Prepreg Materials. Rework of Structures Manufactured from Composite Materials (Laminates and Sandwich). Surface preparation for Thermosetting parts before structural bonding. Manufacturing of metallic sandwich parts-bonding process. Structural Bonding of Thermoset and Thermoplastic Matrices Composite Parts. Cleaning with liquid non-aqueous agents including vapour phase. Manufacture of Structural Sandwich Parts with Thermosetting Fiber Reinforced Skins. Cleaning with aqueous cleaning agents.
AIPI 03-02-018 Issue 2 AITM 1-0003 AITM 2-0037 AITM 3-0008 AP 2003 AP 2253 AP 5003 AP 5866 EN ISO 14644-1 EN ISO 14644-3 EN 2243-3 EN 2243-4 EN 2377 EN 2559 EN 2563
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Determination of the glass transition temperatures. Fluid Lightness test for sandwich specimens and structures. Determination of the extent of cure by Differential scanning calorimetry. Document Retention Requirements for Airbus Suppliers. Validation and Technical Qualification of Manufacturing Processes Manage Document Retention. First Part Qualification (FPQ). Cleanrooms and associated controlled environments. - Part 1: Classification of air cleanliness. Cleanrooms and associated controlled environments- Part 3: Test methods. Non-metallic materials-structural adhesives-Peeling test metal-honeycomb core. Non-Metallic Materials Structural Adhesives Test Method Part 4: Metal-Honeycomb Core Flatwise Tensile Strength Test. Glass Fibre Reinforced Plastics Test Method Determination of Apparent Interlaminar Shear Strength. Carbon Fibre Preimpregnates Determination of the Resin and Fibre. Content and the Mass of Fibre Per Unit Area. Carbon Fibre Reinforced Plastics Interlaminar shear strength.
3 Definitions, applicability and limitations

3.1 Definitions
Bridging: lack of contact between upper and lower skin in the core / monolithic transition area, typically caused by core displacement. Cobonding: Process in which part of the composite materials or detail parts of the element are in preimpregnated condition and part of them are polymerized (precured). Cocuring: Process where the prepreg materials and adhesives are cured simultaneously. Compatibility: Implies that the performances of the structural materials shall not be adversively affected by others materials presents and vice versa. Core splicing: Joining of core segments. Crushing: A collapse, distortion or deformation by compression of the core. Delamination: Separation of plies from each other and/or facing plies from core. Disbond: Separation of bonded materials or detail parts. Discrepancy: Deviation in the normal physical structure or configuration of a material, part or assembly. Fabric deformation: Deviation of a fabric yarn from a straight line. Laminate: Any fiber-reinforced composite consisting of plies with one or more fibre orientations with respect to a reference direction.
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Lay-up: Stack of material in specific sequence and orientation including laminate, breather material, bagging material, etc, and so on as required for forming, compaction or curing. Manufacturer: The company or organization responsible for producing the part against an Airbus drawing. Manufacturing Shop(MS): The specific workshop at a specific site. MRB: Material Review Board. Body entitled to take the necessary decisions concerning the non-conformity material submitted to its criterion. NCS: Non-Conformance Sheet. Pinhole: Small hole in resin-fiber system on the part surface. Ply wrinkle: A ridge or fold-over of a ply. Porosity: Accumulation of small voids in a composite structure. Preimpregnated material (prepreg): Woven fabric or unidirectional tape impregnated with a matrix resin and suitably processed (e.g. B-staged) for storage, handling purposes and curing by heat and pressure without further additives. Reference Manufacturing Shop (RMS): A manufacturing shop selected in order to develop a manufacturing process and to improve on current processes. Reference Manufacturing Shop Group (RMSG): A group of experts responsible for a manufacturing process. This group is in charge of validation of the technical requirements and technical qualifications. For each manufacturing process, a RMSG is nominated. Resin richness: An area of excess resin. Resin ridge: A sharp build-up of resin on the part surface. Resin starvation (lack of resin): Incomplete resin filling of the surface in a composite structure. Rework: Reworks means the removal of production and assembly related non-conformances with the aim of reaching the required component condition defined in the engineering documents. Sandwich: Core of honeycomb (plastic/metal) or foam material covered by top layers (facings) made from fibre-reinforced plastics (FRP). Secondary bonding: The composite elements, which are going to form part of the element, are previously cured (precured) and joined in a final bonding operation by means of adhesive. Specific work conditions: Specific combination of temperature and relative humidity which deviates from normal work conditions. Storage life: The maximum time that the material may be used when stored in refrigeration under the conditions specified in the Material Specification, excluding work life. Surface depression: An indentation or low spot in a surface. Tack life: The maximum time at work conditions as specified in relevant Material Specification, that the material have sufficient tack to be used for manufacturing. Telegraphing: depression in skin corresponding to underlying honeycomb core cells. Unidirectional tape: Semifinished reinforcement material with the reinforcing fibers orientated in the same direction.
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Void: Empty space within the fiber-resin system not on the part surface. Warp direction: Direction of the thread in a fabric running along the selvage. Weft direction: Direction of the thread in a fabric, which is perpendicular to the warp direction. Work conditions: Environmental conditions, in particular temperature and relative humidity, under which uncured material is processed before start of cure. Work life The maximum time at work conditions as specified in the relevant Material Specification that the material can be used for manufacturing. Deviations of work conditions as hot forming process or application of heat for tack improvement can effect the Work life and therefore need to be validated by M&P. Woven fabric: Carbon or glass filaments yarns woven into a fabric of any two-dimensional weave pattern.
3.2
Applicability
This Process Instruction applies to manufacture sandwich composite parts with glass fiber or polyamide honeycomb core or metallic core or rigid foam core, by cocuring, cobonding or secondary bonding of reinforced skins, processed using Hand Lay-up (HL), Automatic Tape Laying (ATL) or Automated Fibre Placement (AFP) and subsequent autoclave or oven polymerisation. Reinforced skins will be manufactured of preimpregnated materials such as carbon, glass or hybrids with epoxy or bismaleimide resins. The process applies when called up on the drawing or through another document for the purpose previously stated. Unless otherwise specified, always use latest issue of this AIPI specification. For the purpose of this Process Instruction, the classification and description of requirements of composite parts are indicated in AIPS 03-02-001. When it is not indicated in the drawing, the part shall be Class 1.
3.3
Limitations
Special care shall be taken in order to use materials specifically defined as compatibles. Even prepregs and film adhesives coming from the same manufacturer shall be indicated as compatibles, in order to be used in the same curing process. Compatibility of uncured materials shall be specifically established in the drawing associated documentation, and always shall be subjected to validation by a qualification programme. This Process Instruction does not cover manufacturing of sandwich structures with metallic core/metallic skins, which is described in AIPI 06-02-005 Manufacturing of metallic sandwich parts-bonding process. This Process Instruction is not applicable to manufacturing sandwich reinforced skins with phenolic resins.
4 Generalities
Indications and requirements in the drawings and associated documents shall prevail over those stated in this specification. The particular and specific manufacturing conditions for each detail part shall be indicated in the drawing associated documents and in the corresponding Work Order.
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This specification does not include the necessary measures to be adopted from the Heath and Safety point of view. The user of this specification is liable for the compliance with the standards established by the Heath, Safety and Work Conditions Committee. Facilities, manufacturing and inspection equipment shall fulfil the requirements established by Airbus Quality, taking into account the indicated in the paragraph 6 of this Process Instruction and AIPS 03-02018. All the manufacturing process shall be carried out by authorized, trained and competent personnel, recognized by an approved training programme, fulfilling the requirements established by Airbus Quality. The process shall be qualified as AIPS 03-02-018 and AP-2253. All composite parts, according to their structural responsibility, shall be classified in three-classes/ levels, which goes from Class 1 (most responsibility) to Class 3 (least responsibility). Engineering shall establish this classification that will be indicated in the drawing or associated documents. If the classification is not indicated in the drawing or associated documents, the part will be considered as Class 1.
5 Materials
All materials must be clearly identified directly or through an information system, which guarantees traceability, with at least the following data: - AIRBUS designation. - Manufacturer designation. - Batch and/or lot number. - Roll, foil or block number, as applicable. - Storage temperature (when other than room temperature). - Expiring date (when applicable). - Accumulated hours of exposure at R/T or remaining shop life, if applicable. For structural materials and peel-plies used in structural bonding, quality control material is required for all materials batches, in accordance with the applicable Airbus normative. Unless otherwise specifically indicated, the prepreg materials, structural adhesives and resin systems shall be stored in the refrigerators at a temperature < -18C, in perfectly sealed polyethylene bags, and whenever possible, in their original containers, avoiding in any case excessive pilling up or incorrect placing, which could cause damage of the materials. During the defrosting and loading and unloading operations it is allowed to reach maximum peak temperatures of 12C in the refrigerator, controlled by an environmental thermocouple. The materials can be at a maximum temperature of 12C, for a maximum period of 15 minutes (a total of 60 minutes in 24 hours). Exceeding this maximum time and/or temperature, exposure hours shall be added to the materials.
5.1 Structural materials From Manufacturing point of view, structural materials are those incorporated in the final part manufactured. Structural materials shall be indicated in the drawing and in accordance with the corresponding AIRBUS Material Specification. Any change during the manufacturing will be cause of rejection and establishment of the corresponding discrepancy. Only qualified materials can be used in production. The storage conditions for each specific material in particular shall be those indicated in the corresponding Airbus Material Specification.
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All limited life materials used shall be within their useful life time (Storage life and Work life), indicated in the relevant Airbus Material Specification.
5.2 Ancillary materials Ancillary materials are used only during manufacturing, but they do not remain incorporated to the part. Only qualified materials according to AIMS 12-00-000 or materials included in the Ancillary Materials List, Appendix 1, shall be used. Specific materials used in each part should be indicated in the Manufacturing Work Order and will be in accordance with the documentation associated to the drawing. No change of material is allowed without specific indication in the associated drawing documentation. The storage of these materials shall be performed in accordance with the requirements of the applicable Airbus Material Specification, in order to avoid manufacturing problems during the cure cycle or even lack of final quality of the part. The release agent used should be defined in the documentation associated to the drawing or in the associated component-related process instruction. The use of peel plies has to be indicated in the documentation associated to the drawing or in the associated component-related process instruction. Reference to the relevant Material Specification must be included in the drawing. The limited life materials used shall be within their useful life time (Storage life and Work life), in case of this has been defined. Materials with PTFE in direct contact with structural materials are forbidden if they are not specifically approved for a particular application. All ancillary materials to be placed in direct contact with any non-cured material must be stored in sealed polyethylene bags and handled using qualified gloves. The purchase, supply and quality control income process shall be carried out in accordance with the applicable AIRBUS normative.
5.2.1.
Type A materials
Materials that are in direct contact with structural materials during previous operations, lay-up or curing, or which can affect the structural behaviour. Typical materials are: Peel plies for structural bonding. Peel plies for general use. Release films. Liquid release agents. Adhesive tapes. Spatulas. Gloves Protection materials for cutting tables. Polyethylene films for plies cutting Polyethylene films for plies bagging. Doubled faced self-adhesive tapes. Marking pencils. Tacking promoter for fixing prepreg layers on tool surface.
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5.2.2.
Type B materials
Materials that are not in direct contact with the structural materials during previous operations, lay-up or curing. For example: Bagging films. Breather and bleeder fabrics. Sealant tapes. Pressure sensitive tapes. Rubber pad. Silicone rubber. Compactation film. Verifilm. Cotton cloths. Antihumidity barriers and temporary protections. Hand creams.
5.2.3.
Solvents
General requirements for cleaning operations are described in AIPS-09-01-002 and AIPS 09-01-003. Only qualified solvents for each usage shall be used. Solvents will be Technical Grade. For solvents used for surface preparation prior bonding, AIPI 06-01-003 requirements must be followed. It is recommended to use pre-soaked wipes in solvent, for example isopropyl alcohol. Use of M.E.K. must be minimized due to Health Security and Environmental reasons.
5.2.4. -
Miscellaneous Thermocouple wire Cutters and cutting tools Edge dams. Marking pens. Vacuum hoses. Heat air generators.
6 Facilities, tooling and equipment
6.1
Lay-up area
Operations such as: Thawing, cutting, placing and shaping of prepregs and film adhesives. Placing, shaping, joining, potting and stabilization of cores. Vacuum bagging.
Shall be performed in clean isolates areas, with controlled temperature and humidity, which must be recorded and meet the requirement indicated in Figure 1.
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For AFP processes it is recommended a Relative Humidity in the range 35% to 40%, and a temperature between 18C and 22C. (1) Maximum time allowed for preimpregnated materials and adhesives at these conditions are indicated in the relevant AIMS or IPS. Figure 1: Clean room conditions Within the clean area it is strictly forbidden: Use, handling and application of uncured liquid release agents. To use engines or equipment releasing oils, greases, lubricants, fumes or any other type of contaminant. To use tools or utensils that have not cleaned and maintained appropriately. To eat, drink, smoke, and use waxes or non-polymerised silicones or any other substance detrimental to the good adhesion of the materials. Hand creams not authorized. Cleaning and maintenance of tools. Sanding and surface preparation before bonding. If it is not avoidable, retouching of parts by light sanding is allowed in restricted zones, providing that the powder is specifically eliminated. Any container that can contaminate the clean area. To install devices which allow the free circulation of water, except those required by Heath and Safety. Application of tacking promoter. If it is not avoidable, it can be done in the cleanroom guaranteeing the no transmission of this solution to others tools and/or prepregs materials or adhesives located around. Any operation of cutting, machining and cleaning of cores. When a core compressive type splicing is to be made and no separation between the core sections is allowed (for example: Radomes), whenever this is specifically authorized by Quality Department, the operation of core cutting is
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permitted within the clean area. In this case, a local vacuum system must be provided in order to remove continuously any dust, debris, produced. Peel plies removal from cured parts is allowed, providing that care is taken to avoid contamination of any adjacent non-cured material. The floor shall be paved with easily cleaned materials, and the walls shall be coated with non-releasable washable materials. The use of gloves and clean overalls is mandatory for any operation inside this area. In order to prevent any contamination coming from the outside of the lay-up area, it is recommended that a minimum of 5,0 Pa (0,5 mm water column) over pressure to be held inside it. This shall be controlled with a pressure differential measuring device with accuracy enough to assure such a requirement is met. It is also recommended for this area to be provided with a twin-door type gate system. In the case of direct exit outdoors, this shall be mandatory. Keep doors shall remain closed when not in use. Incoming air shall be clean and free of oil, water, dust and particles by a filtering system that shall be cleaned/replaced at least every month. Concentration control of particles with sizes in excess of 5 m inside this zone, by means of system of filters, which shall be periodically checked (at least monthly). Maximum permitted concentration of this type 3 of particles shall be 29300 particles per m of air (Class 8, as EN ISO 14644-1). Sample collection and particles count shall be performed at least monthly by an Optical Particles Counter (OPC) as EN ISO 14644-3. Work stations shall be visibly clean, requiring cleaning when visual inspection shows signs of dirt, dust or contamination.
6.2
Core cutting and machining areas
Cutting and machining of cores shall be carried out inside this specific area. Within this area it is absolutely forbidden: Use, handling and application of uncured liquid release agents. To use engines or equipment which emit oils, greases, lubricants, fumes or any other type of contaminants. To eat, drink, smoke and use waxes or non-polymerised silicones or any other substance detrimental to the good adhesion of the materials.
6.3
Mixing area
It is recommended to have a specific area for manual mixing of multi-component filler compounds, with good ventilation and weigh balances with 0,1 g accuracy.
6.4
Tooling
Tools shall be free of all types of contamination. Tools shall be identified, as minimum, with the following data:
AIPI 03-02-018 Issue 2 -
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Part Number (P/N) of the part. Direction 0 (fabric warp direction or fiber direction for tapes). Ribbon direction in case of core forming tooling.
The tooling concept shall be adapted to the difference of thermal expansion coefficients between tool and part materials. They must be stiff enough to produce parts within dimensional tolerances, and the tool bulk and material must be capable of complying with the curing cycle heating/cooling rate requirements. When it is not indicated in the drawing of the tool, the mould surface in contact with the part shall have a surface finish of 125 HRH (Ra= 3,2 m) or better. Whenever possible, the tool shall be designed so that the aerodynamic surface of the part is formed against its surface. Prior to manufacture, each new or repaired tool or tools with major modifications, must be checked and released with the airtightness test as follows: Cleaning and application of release agent (liquid or release film). Lay up 2 plies of glass fiber prepreg according to AIMS 05-02-003. Placement of thermocouples and vacuum intakes as sub clauses 6.8 and 6.9 of this specification. Manufacture a standard vacuum bag as per clause 10.1.1. Cure in autoclave with the following parameters: Temperature: (185 + 5)C. Cure time: between 2 and 3 hours. Pressure: 0.69 to 0.71 MPa. Demould the part. Check for leaks, which are detected by means of dark spots on the glass fiber fabric. The requirement of the test is that no leaks are allowed. If leaks are detected, rework/ repair the tool and repeat the leak test.
Alternative airtightness tests may be used with specific approval of AIRBUS.
6.5
Autoclaves and ovens for curing
They shall be able to: Reach and maintain the stabilization temperatures of the curing cycles, within a tolerance of + 5C. Perform heating/cooling rates between 0.5 to 5C/minute in empty and loaded conditions. Reach and maintain the required pressures during the curing cycles, within a tolerance of + 35 kPa (autoclave only). Reach and maintain the required vacuum during the curing cycles, within a tolerance of + 3,3 kPa.
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Automatically record continuously the temperature, pressure and vacuum, as applicable. If continuous recording is not possible, record at maximum intervals of ten minutes.
It is not recommended to use the same equipment for curing liquid release agents or silicones that will be used for curing FRP components.
6.6
Ovens and presses for core forming
They shall be able to: Reach and maintain the temperature of forming cycles within a tolerance of 5C. Perform heating/cooling rates between 0,5 to 5C/minutes. Reach and maintain during forming cycles, the pressures or vacuum, as applicable, within a tolerance of 35 kPa for presses or of 3,3 kPa for ovens. Automatically record continuously the temperature, pressure or vacuum, as applicable. If continuous recording is not possible, the applicable forming cycle shall be carried out, ensuring in the Work Order that parameters of the cycle has been correct.
6.7
Hot-forming equipment
If applicable, they shall comply with the requirements established in AIPI 03-07-019 specification.
6.8
Thermocouples
The Work Order and/ or documentation associated to the drawing, shall define the number and the location of thermocouples to be used for each part. Unless otherwise indicated in the documentation associated to the drawing, the following criteria are applicable: Number of thermocouples to be used: The parts and process control panels with an area 2 m2 shall be controlled with at least two thermocouples. The parts with an area > 2 m2 shall be controlled with at least one thermocouple per square meter or additional fraction, until a maximum of 15 thermocouples is reached. If the thermocouples are not incorporated in the tool, mark its location on it and, whenever possible, place them between plies in excess areas, inside the vacuum bag. In case of precured skins, the thermocouples must be placed as near as possible of the film adhesive, inside the vacuum bag. The location, distribution and number of necessary thermocouples shall be defined according to the result of thermal profile. The parts in which, according to Manufacturing Engineering criteria, a thermal profile is not required, the thermocouples shall be distributed uniformly as has been indicated in the previous paragraph. When several parts are manufactured on the same tool and under the same vacuum bag, a 2 thermocouple is to be located per each m of part area, with a minimum number of 2 thermocouples. In order to prevent any thermocouple displacement during the curing cycle, they shall be fixed with high temperature adhesive tape. Check electrically each thermocouple before the curing operation.
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The accuracy of the thermocouple splice box and the recorder must guarantee + 3C between 50C and 210C.
6.9
Vacuum intakes
The Work Order and/ or documentation associated to the drawing, shall define the number and the location of vacuum intakes to be used for each part. Unless otherwise indicated, two vacuum intakes shall be used per m2 of the part and/or process control panel, placed diagonally in opposite ends in the bag. One of these shall be used as a control gage and the rest as vacuum source. When several parts are manufactured on the same tool and under the same vacuum bag, a vacuum intake is to be located per each m2 of part area, with a minimum number of 2 vacuum intakes. Procedures for periodic checking of airtightness test in the vacuum hoses and their connections, especially in the vacuum valves, shall be established to guarantee performance.
6.10 Automatic Tape Laying (ATL) and Automated Fibre Placement (AFP) machines If applicable, these will have to meet all the requirements stipulated in drawings and specifications, with which the machine is going to work, especially those regarding gaps and layers linearity.
6.11 Plies cutting machines These will fulfill all requirements stipulated in drawings and specifications, with which the machine is going to work, especially those regarding to tolerance of layers direction.
6.12 Plies positioning equipment by layer If applicable, these will fulfill with all the requirements indicated in drawings and specifications with which the machine is going to work.
6.13 Freezers The freezers used to the storage of refrigerated materials must be capable of reaching and maintaining continuous temperatures 18C and be equipped with automatic temperature recording.
6.14 Core cutting and machining equipment In general, cutting/machining of cores shall be carried out manually (helping with a knife or cutter), with band saw or by wheels. For complex geometries, these operations can be performed automatically by C/N equipment.
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6.15 Non-destructive inspection equipment Equipment, automated and manual shall be suitable to perform those inspections noted in section 11.8.
7 Materials preparation
During cutting, machining, cleaning operations, materials shall be always handled with clean cotton gloves.
7.1
Prepregs and adhesives handling
All the prepreg and adhesive materials used in manufacturing detail parts shall be within the shelf life (Storage life and Work life) indicated in the corresponding MS or IPS specifications. It shall ensure that they have also stored in accordance with the requirements of the corresponding MS or IPS. For refrigerated materials a log shall be kept, recording the date and time of each transfer of the material in and out of the refrigerators and the remaining shop life. All packages or containers of refrigerated materials shall be allowed to reach room temperature before the waterproof seals are opened. The time since the material is removed from the refrigerator until the material package or containers can be opened shall be empirically determined. This time shall be checked by Quality. As a general rule, the packages must not be opened until condensation is not produced outside or inside the bag. As a reference, the following Tables 1 and 2 show the thawing times in accordance with the prepreg roll diameter.
Table 1. Thawing times for Fabrics
Roll dia. (mm)

< 150 150 to 300 > 300
Thawing time (h)

12 24 36
Table 2. Thawing times for Tapes
Roll dia. (mm)

480 > 480
Tape width (mm)

75 to 1200 75 to 300
Thawing time (h)

24 24
Work life time shall be determined specifically for each material and shall be indicated in the relevant IPS of the material. In case of more than one material is applied in one part, the applicable Work life is the one corresponding to the material with the smallest value. If a hot forming process is used in manufacturing the element, the Work life shall be determined as indicated in AIPI 03-07-019.
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The Tack life of the material, up to final lay-up, shall be indicated in the IPS of the prepreg or adhesive.
Figure 2: Storage life, Work life and Tack life Do not places the packages, containers or rolls of material onto surfaces, which might distort or deteriorate it.
7.2
Cores handling
Handling of cores shall be performed in such a way that no damage, contamination (greases, oils, dirt, etc) or other circumstances detrimental the physical and/or mechanical properties of the core can be produced.
8 Prepreg and film adhesive cutting

The prepreg fabrics/tapes or film adhesives, after cutting (manual or automatic), must not show: Contamination (dirt, moisture, substances from the machine) Shears. Cuts or geometry other than the one indicated in the drawing. Defects exceeding the requirements of its applicable AIMS specification (TS, MS, IPS) or in its defect, the acceptable values indicated in the Table 3.
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Table 3. General acceptance criteria for prepregs and film adhesives.

TIPICAL DEFECTS Weave anomalies. Lack or rupture of reference thread, fuzz thread slices. 2 Defect of a single thread. Little stressed twisted, bridged or broken thread ACEPTABLE VALUES WITHOUT REWORK ACEPTABLE VALUES WITH REWORK REWORK METHODS
N 1
As per AIMS 05-27-000 or AIMS 05-02-000 None Not applicable
As per AIMS 05-27-000 or AIMS 05-02-000 Overlap the cut with a piece of the same prepreg and orientation. Overlap from 12 to 25mm. None Not applicable
3 Cut in prepreg plies (1) None A cut with length below 50 mm per meter of prepreg.
Folds or wrinkles on plies
A fold of 300mm maximum provided that the fibers are not damaged None If the fibers are damaged, a fold of 50 mm maximum length per each meter of prepreg.
Remove with the help of hot air
Smooth with the help of hot air, and treats as a cut (point 3 of this table)
5 Fabric deformation (2)
Depending on the deviation (d) and the distance (L). If d > 6 mm, L/d shall be > 10. If d < 6 mm, L/d may have any value. None Not applicable
Resin flash or resin starved areas Fiber misalignment on unidirectional tapes Other defects
As per AIMS 05-27-000, AIMS 05-02-000, AIMS 10-01-000 or AIMS 1201-002
None
Not applicable
As per AIMS 05-27-000 As per AIMS 05-27-000, AIMS 05-02-000, AIMS 10-01-000 or AIMS 1201-002
None
Not applicable
None
Not applicable
NOTES: (1) The stagger between consecutive cuts shall be at least 25 mm. (2) Deformation of the fabric according to the following sketch.
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For automatic cutting of plies both contact surfaces shall be protected by a polyethylene film or a backing paper. Based on the elements to manufacture and with the purpose of reducing as much as possible the exposure of the materials to room temperature, it is advisable the preparation of kits. In order to prevent any contamination, tables for manual cutting material must be covered with an approved material. The material already cut in kits which is not being used immediately, shall be placed into polyethylene bags, and identified directly or through an information system which guarantee traceability, as minimum with the following data: Part number (P/N). AIRBUS designation of the material. Lot and roll number. Accumulated hours of exposure at R/T or remaining Work life. Expiring date.
The sealed bag shall be stored in the refrigerator, avoiding the formation of wrinkles and folds when placing the prepreg in the bag and/ or in the refrigerator. Cutting, identification and storage operations must be performed reducing as much as possible the time that the material remains at room temperature. If plies are cut manually, perform this by means of templates, perfectly clean and identified with the following data: - Identification with reference to the P/N of the element or assembly. Location (according to drawing part list). Direction 0 (fabric warp direction, or fibre direction for tapes).
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9 Core preparation
Core cutting and machining operations shall be carried out in areas that fulfil the requirements established in paragraph 6.2. During cutting and machining, avoid any contamination or tear in the core; any discrepancy shall be evaluated according to Table 4. Once the core has been cut and machined, and after removing the glass fiber fabric, adhesive paper, etc used to these operations, proceed to clean and store them in polyethylene sealed bags, identifying on the outside of the bag with the P/N of the detail part. The removal operations of the glass fibre fabric, adhesive paper, etc shall be carried out in the cutting and machining areas. Cores shall be handled with clean cotton gloves during cutting, machining and cleaning operations and any later operation.
AIPI 03-02-018 Issue 2 TABLA 4:

N
1
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General acceptance criteria for honeycomb cores, splices and fillers

ACCEPTABLE VALUES WITHOUT REWORK ACCEPTABLE VALUES WITH REWORK
Maximum 1% of the surface area of the core (1) (2)
TYPICAL DISCREPANCES
Contour: a) Cell tear out
CORRECTION METHODS
A cell tear out every 150 mm, with maximum 2 dimension of 160 mm area and a depth L 12 mm
Splice a new core section or fill with core filler (AIMS 10-03-000)
b) Waviness
Core cut tolerance is 1,3mm (unless otherwise specified on drawing)
Unlimited (1) (2)
Smooth by means of soft abrading or splice a new core section or fill with core filler. (AIMS 10-03-000)
c) Machining burrs
The flock will have a length below 0,15mm.
Unlimited (2)
Remove by cutting and straighten with tweezers if necessary. Splice a new core section, or fill the affected area with core filler. (AIMS 10-03-000)
Interior: a) Partial node bond separation
5% maximum of the total number of nodes and 25% maximum of the nodes contained in the most 2 unfavorable area of 45 cm . 1% maximum of the total number of nodes and 2 nodes maximum in an area 50mm x 50mm.
Up to a maximum of 10% of the core may be reworked (1) (2)
b) Total node bond separation of nodes
Splices: a) Partially unbonded areas.
The cumulative length of partially unbonded areas shall not exceed 3 times the cell diameter in any length < 300 mm Up to 0,15 mm (3)
Unlimited (1) (2)
Fill with core filler (AIMS 10-03-000) or remake the splice.
b) Step in the splice line.
Unlimited (2)
Sand core smoothly to adjust thickness, with 150 grit or finer sand paper
c) Depression of the bonding line.
-On the bag side: One single depression with 0.5 mm maximum depth per 13 mm of greater dimension every 30 cm length (3). -On the tool side: None
Unlimited
Fill the depression with core filler (AIMS 10-03-000) Fill the depression with core filler (AIMS 10-03000) Remake the splice.
Unlimited
d) Excessive separation in the core splice
Max. Separation permitted shall be as per paragraph 9.6.2.
It can be reworked if it does not exceed 1.5 times maximum separation permitted in paragraph 9.6.2. with a maximum cumulative length of 300 mm.
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N 4
TYPICAL DISCREPANCES Surface depressions.
ACCEPTABLE VALUES WITHOUT REWORK One single depression of 0.5 mm maximum depth per 13 mm of greatest dimension, in an area of 30 cm x 30 cm. The depressions must be separated at least 150 mm from the section changes and other depression. (3)
ACCEPTABLE VALUES WITH REWORK Depression < 25 mm in length (1) (2)
CORRECTION METHODS Fill the depression with resin AIMS 10-03-000 or foam adhesive AIMS 10-02-000
Depression > 25 mm in length Unlimited (1)(2)
Remove defective area and splice a new core section.
Cell collapsed
The maximum collapse length shall be 50 cm in the parallel direction to the ribbon. There will not be more than 3 collapsed lines.
Unlimited
Remove the affected area and splice a new core section.
Contraction of the core fill
Up to 0.75 mm depth measured from the core surface (3) Up to 150 mm2 surface with depth < 0,5 mm
Unlimited
Fill with resin used during potting, or with resin AIMS 10-03-000 Fill in with core filler AIMS 10-03-000 Remove the affected area and splice a new core section Remove affected area and splice a new core section, or fill in with core filler AIMS 10-03000 Not applicable
Crushed core.
Up to 5% max. of core surface (1) (2) Unlimited (1) (2)
Bubbles/Pores in the union adhesive or filler resin
Up to a pore size below cell diameter in longest dimension.
Unlimited (1)
Other defects such as incorrect cell size, double cells, etc.
As per the corresponding core MS, IPS or TS.
None
NOTES: (1) (2) (3) The maximum permitted weight increment in the total core rework is 10%. Provided the required final core dimensions are maintained. If the core is going to be subsequently bonded with a pre-cured skin, no unevenness or depression is permitted. When the defect is considered acceptable without rework, place an additional ply of film adhesive, the same as the one that is to be used, in the bonding on the defective area.
9.1
Cutting and machining operations
Cutting operations may be performed helping by templates perfectly clean and identified with the following information: P/N of the core detail Ribbon direction
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Machining operations can be performed manually or by numerical control machines. For these operations may be necessary to stabilize the core in order to facilitate the fixing of it.
9.2
Cleaning operations
If accumulation of dust on the core occurs, it shall be removed by blowing with clean and dry air or vacuum, being the last method preferred. For honeycomb cores with density 32 kg/m3, if the core is stabilizated at one face, cleaning by blowing air is not allowed. For metallic cores, the cleaning shall be carried out as follow: a) Degreasing in vapour phase: the core shall be inserted in the degreasing machine during 30 to 120 seconds, after which they shall removed and cooled at room temperature. The degreasing in vapour phase is not applicable to organically protected cores. If the cores present dirt after this operation, they shall be rejected. Once the cores have been removed from the machine, they must be air dried at room temperature for, at least, 30 minutes. Solvents used shall be handled in areas prepared for cleaning operations with a good ventilation.
9.3
Drying of polyamide honeycomb cores
When it is indicated in the drawing associated documentation, the polyamide cores shall dried before the operations of lay-up integration, stabilizing, forming or splicing. This drying shall be performed at 805C for a minimum time of 5 hours (or alternatively at 505C for 12 hours minimum), maximum 12 hour before processing. If different drying conditions are applicable, these will be indicated in the associated drawing documentation. After drying, cores will be incorporated in the lay-up of the part before 12 hours; if it is not possible, cores will be located inside sealed polyethylene bags. 9.4 Core stabilization
It is performed to facilitate: handling, avoiding distorsions, rupture or crushing during machining, forming, laying-up and curing operations. Any core stabilization system, which involves a weight increase of the finished part, shall be indicated in the drawing or associated documentation. The most commonly used methods are the following:
9.4.1 Pegging This system is exclusively applicable to glass fiber cores, on chamfered zones where local consistency or stiffness is needed. A piece of glass fiber core, of the same material as the element to be stabilized, is used as indicates the Figure 3 in such a way that the pegged area does not exceed the zone to stabilize more than two cells.
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This stabilization method aids the machining operation in zones with difficult geometry or chamfers with angles < 30.
Figure 3: Core pegging
9.4.2 Film adhesive This method facilities machining or forming operations and prevents a great of the crushing of the cells during the curing. This system is exclusively used when so called out in the drawing or associated documentation. Place film adhesive indicated in the drawing on the stabilization zone, on one or both surfaces of the core; cover the adhesive with a peel ply film and prepare the corresponding vacuum bag. Cure as indicates the associate drawing documentation. The peel ply film shall be kept in position up to the lay-up operation, thus avoiding contamination.
9.4.3 Filling or potting of core This method is used to prevent crushing, displacement or collapse of cells core during the curing of the part or for machining purposes. This operation shall be performed as is indicated in section 9.5.
9.4.4 Stabilization with adhesive paper This method is exclusively applicable for machining of cores. The adhesive material is not tacky at room temperature. Cut the appropriate size of adhesive paper, leaving sufficient excess (at least, 25 mm excess in each side) to facilitate its handling. The core shall be placed on a table with the surface where the paper is to be placed facing upwards. Remove the protection film from the adhesive paper and place the adhesive coat in contact with the core.
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Apply heat and a slight pressure with a hot plates press or a domestic vapor less iron. In this case, place a clean lint free cloth over the paper. The temperature shall not exceed 120C. The heat shall be maintained until the adhesive has softened and become fluid in the core cell walls (approximately 1 minute). Leave to cool maintaining a slight contacting pressure. Machining the core. After machining, the adhesive paper is removed, heating again during 10 to 30 seconds and pulling by hand when it is hot.
9.4.5 Restraining by rough strips or sand paper This stabilization method is used to prevent core displacement during the curing cycle. This is performed during lay-up operations and consists of the use of metallic rough strips bonded to the tool or else, sandpaper attached to the tool by means of adhesive tape and on which fiber layers are secured. Depending on the part configuration the attachment may be limited to the layers of each side, in contact with the core or to additional layers, to prevent core displacement. See Figure 4.
Figure 4: Stabilization by rough strips or sandpaper
9.4.6 Stabilization by glass fiber prepreg This method is exclusively applicable to the stabilization of cores for machining. Place a glass fiber layer on one or both core surfaces. The glass fiber material to be used must be previously approved for this purpose (for example G.F. MXB7668/120 manufactured by CYTEC). Prepare the vacuum bag and cure, as per cycle indicated in the associated drawing documentation. In the case of the MXB7668/120 glass fiber prepreg, the applicable cure cycle is the following: Before starting the cure cycle, apply vacuum until a manometric pressure inside the vacuum bag -16 kPa. Heating rate: 0,5 4,5 C/min.
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Stabilization temperature: 160 5C. Stabilization time: 90 120 min. Cooling rate: 5C/min. Pressure: 260 300 kPa. Demoulding temperature: 60C.
The vacuum bag shall be vented to the environment when pressure reaches 70 kPa. After curing the prepreg, the core can be machined. Once the core is machined, remove the glass fiber by manual peeling.
9.4.7 Stabilization by carbon fiber prepreg and film adhesive This process is used for keeping the shape of the core during curing and is performed by bonding, on one or both sides of the honeycomb core, a carbon fiber layer of the same material used on the part, with the film adhesive, called out in the applicable drawing. This method shall be carried out when called out in the part drawing. This process implies the incorporation of peel ply, which shall be removed to avoid contamination just before its incorporation in the lay-up. The bonding surface shall be prepared as per AIPI 06-01-003. The curing cycle shall be indicated in the drawing associated documentation.
9.5
Core potting
It shall be performed when called out in the drawing. The potting operation shall be carried out in the clean area (as paragraph 6.1). The most common reasons for use are: Potting zones of the core where inserts are going to fitted. Potting/filling core edges.
The potting material shall be indicated in the drawing and it shall be cured as indicates the associated drawing documentation. The potting shall not exceed 10 mm more than the given dimensions of the zone to be potted, indicated on the drawing. If applicable, once the potting compound is cured, remove the protrusions by soft abrasion or fill in contractions with a new addition of material, in such a way that the surface is left totally smooth. Subsequently, abrading the surface softly and cleaning with solvent. During abrading operations, it is recommendable to remove continuously dust, debris, etc., by a vacuum method. The potting using solid materials shall be carried out by removing the core until a good fitting of the filler piece is obtained, and subsequently bonding with paste or foam adhesive, as indicated in the drawing.
AIPI 03-02-018 Issue 2 9.6 Core splices
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Shall be carried out when called out in the drawing using one of the following procedures:
9.6.1 Splicing by pegging This type shall be exclusively applicable to glass fiber cores. Perform a prior test to check that the core density permits this type of splicing. Otherwise, apply procedure 9.6.2. Assemble two core sections with width of 2 to 4 cells. If the height of the core exceeds 25 mm, the joint can be chamfered as per Figure 5.
Figure 5: Two core sections pegging When dimensional difficulties exist, a third piece of the same core can be pegged through the splicing joint, as is represented in Figure 6.
Figure 6: Pegging with a third piece
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9.6.2 Splicing by bonding The cores shall be kept firmly joined during the curing of foam adhesive indicated in the drawing, not permitting separations over those indicated in Figure 7. The number of adhesive plies shall depend on the real separation between the cores and the part configuration.
Figure 7: Honeycomb core splicing The curing cycle of the foam adhesive shall be indicated in the associated drawing documentation, or else, the one applicable to the composite part, if it is a co-curing process. The bonding line shall be continuous, with a maximum width of 2 cells. Once the splicing has been performed and in the case that it is not a co-curing process, the core shall be incorporated in the part lay-up before 12 hours; if it is not possible, the core shall be inserted in a polyethylene sealed bag until its subsequent use. Before lay-up of the prepreg plies, a soft abrasion of the foam adhesive bead shall be carried out. It is recommended, to eliminate continuously by a vacuum method the abrasion dust.
9.7
Chamfers and fillet radio
Unless otherwise specifically indicated on the drawing or associated documentation, chamfers or fillet radio shall not be permitted on the lower contour of the core chamfer, being the maximum edge height 1.25 mm, as shown in Figure 8, detail A.
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Figure 8: Chamfers and fillet radio on cores 9.8 Forming Core
The forming of cores, except the rigid foam cores, which will be formed per paragraph 9.9.5 will be generally performed applying mechanic pressure over the previously heated core. This process can also be made in oven with vacuum bag, taking into account that the ancillary materials are adequate for the cycle parameters. The specific conditions for the forming cycle of a part (temperature, time, pressure) shall be indicated in the drawing associated documentation, depending on the core configuration, thickness, cell size The temperature and times used for forming the core shall not deteriorate it, in order to the requirements of the corresponding core material specification do not be exceeded. The polyamide core drying previous to the forming, as indicates the paragraph 9.3, will avoid the formation of blisters in the resin and nodal separation of the core during its forming. Depending on the final configuration of the formed core, may be necessary to stabilize the core with film adhesive at the same time that the core is forming. After finishing the core forming, a visual inspection of it will be performed; the requirements of Table 5 shall not be exceeded. Otherwise indicated in the drawing associated documentation, it is not allowed to make a new forming operation. The formed cores will be stored inside perfectly closed polyethylene bags, until the core is incorporated to the assembly.
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9.9
Preparation of rigid foam cores
The normal sequence and requirements are: Cutting Drying Heat treatment (if required) Machining Forming (if required) Cleaning Integration in the lay-up
9.9.1 Cutting The core shall be cut to the required dimensions with suitable tools, which dont produce damages or contamination on the element, with the help of templates. The cut shall be performed in specific areas established for that purpose, which will fulfil the requirements established in paragraph 6.2.
9.9.2 Drying The core plates shall be dried in an oven at 1305C for 180 (+15, -0) minutes (applicable to plates with thickness 30 mm) of for 360 (+15, -0) minutes (applicable to plates with thickness > 30 mm). In the drying operation the plates shall be separated and placed in such a way that a hot air flow exists all around the foam plate. Once dry, the foam core shall be stored at clean area conditions inside polyethylene sealed bags, for a maximum of 28 days. The maximum time elapsed since the drying oven or removal of core from the bag, up to the next operation shall be 72 hours or the indicated in the Material specification (for example, in the case of Rohacell WF71, this time will be 50 hours). If any of these two times have been exceeded, the core shall be dried once again.
9.9.3 Heat treatment This treatment shall be carried out whenever the core is to be used in processes that requires curing temperatures above 115C. It will be performed according to the following indications: Place the plates inside the oven on a flat and perforated surface, avoiding contact between plates and ensuring that air flows around the plates. Heat to a temperature of (1905)C. Hold at this temperature during 48
+2 -0
hours.
Cool to a temperature 60C, opening the oven doors.
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After the treatment, the core plates shall be stored under clean area conditions (paragraph 6.1) inside polyethylene sealed bags for 20 days maximum. Storage (in sealed bags) is optionally permitted at 655C for a maximum of six months. The maximum time from the extraction of the core from the bag, up to the next operation, shall be 72 hours. If any of these conditions is exceeded, the drying shall be done again.
9.9.4 Machining If necessary, the machining shall be carried out after applying heat treatment and with the appropriate jigs and tools, which do not produce tears or contamination of the foam core, if required. The use of doublefaced adhesive tape for restraining the core during machining is permitted. During the machining, aspiration will be applied continuously to remove swarf, dust and dirt, etc The machining can be performed prior to the heat treatment, if it is indicated in the drawing associated documentation. Machining operations shall be carried out in areas that fulfil the requirements established in paragraph 6.2. After machining, the core shall be bagged with polyethylene sealed bag, until the following operation.
9.9.5 Forming The forming procedure, if required, shall be carried out according to the following indications: Place the foam plates in an oven or hot plate press. Heat at (1905)C during a time of 1 minute per millimeter of core thickness. If applicable, transfer the core from the oven to the forming tool, applying forming pressure immediately to avoid the core cooling. Cool, holding pressure, up to a temperature 60C.
After performing the above steps, formed cores shall be stored in sealed bags at room temperature conditions for 20 days maximum or at 655C for a maximum of six months. The maximum time from removal of core from the bag, which must be carried out in the clean area zone, up to use it in the lay-up of the part, shall be 72 hours. If any of these times are exceed, the core shall be dried once again.
9.9.6 Cleaning The cleaning step shall be carried out, at least immediately after cutting, machining and forming operations and shall consist of the removal of swarf, dust and dirt, etc. by means of vacuum cleaning. If necessary (cores contaminated by foreign materials or incorrect handling), a degreasing in vapour phase in accordance with AIPI 09-01-002, with Airbus approved solvents shall be carried out during a maximum time of 2 minutes, repeating the procedure, if necessary, twice as maximum. After the degreasing in vapour phase, proceed to dry the core once again as per paragraph 9.9.2. After cleaning operation, the core shall be handled with clean cotton gloves and inserted inside closed polyethylene bag until it is used in the following operation.
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9.9.7 Integration in the lay-up Before integration, requirements established in the previous sections shall be complied with. The positioning of the film adhesive, prepreg material, core, etc., shall be carried out following the process and applicable work documentation.
10 Tooling Preparation (release agent application)

10.1 Surface tooling cleaning Before application of release agent, tool surface must be cleaned removing oxidation, dirt and contamination, using clean cloths or if necessary Scotch-Brite Type A or S, soaked in solvents, carrying out this operation carefully to maintain tool surface finish requirements. Once the tool surface is clean, it must be completely dry before applying release agent. If the release agent is to be applied on tool surfaces previously treated with another type of release agent, this previous agent must be eliminated using the same process indicated before. When the liquid release agent application is performed by spray with automatized equipment, the removing of the previous release agent can be also performed by means of a laser coupled to the same equipment; in this case, previous tests must be carried out to guarantee that the laser does not deteriorate the tool surface (as example: excessive surface heating or erosion).
10.2 Application of liquid release agents Applicable release agent shall be indicated in the documentation associated to the drawing or in the associated component-related process instruction. The application and curing (if applicable) shall be made following the procedure indicated in the corresponding Work Order. Do not use different liquid release agents on the same tool surface. 10.2.1 Facilities requirements Equipment for curing liquid release agents or silicones shall not be used for curing of film adhesives, thermoset prepreg materials, primers or dried parts that shall be later bonded, primed or painted. Always keep containers tightly closed when not in use and only open immediately before use. The area of application must be a separate area and for solvent base release agents must have outside ventilation. It is forbidden to perform this operation in clean areas, cutting/machining cores areas or another contamination controlled zone. It is advisable to apply the liquid release agent to a Controlled Room Temperature. It is forbidden the application by spray of liquid release agents, except in specific areas with a high application control.
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10.2.2 Equipment requirements When the release agent is applied by spraying, this application will be made with an aerographic gun, which uses dry air from the general line network. The pressure of the air line in the gun must be fitted to a value of 300 kPa (3,0 kg/cm2) approximate; and the gun vessel pressure will be 50 kPa (0,5 kg/cm2). Different extensions may be used in order to reach better all the tool surface and most typicals extensions are: 200 mm; 600 mm. or 2200 mm. with an exit of 90. The spraying application may be automatized; in this case the equipment used shall be qualified fulfilling the Quality/Manufacturing requirements.
10.2.3 Application and curing The liquid release agents shall be applied using clean brush or clean and lint-free cotton cloths or by spraying. Before the release agent application, mask with adhesive paper tape or fixed polyethylene film the tool area where the vacuum bag sealant tape is going to be sticked, except tooling which is to be envelope bagged. (A) Manual application (Cloths/brushes/pre-soaked material) Spread some light and uniform cross coats, allowing the complete evaporation of solvent between coats. Excessive or unnecessary use of release agents on tools shall be avoided. Pouring of the release agent on tool surface is forbidden. Tool temperature prior application, number of coats, time for solvent evaporation between coats, and final curing of release agents shall be as indicated in TABLE-5. (B) Spraying application (gun) The release agent shall be applied with the specified gun (10.2.2 paragraph) and with the appropriate extension in order to reach all the tool surface. The gun to be utilized will use dry air from the air line network. Adjust the pressure in the gun up to approximately the level indicated in paragraph 10.2.2. Spread out light and uniform cross coating, covering with each coat progressively, small areas of the tool (from 1 to 2 m2) starting from one side of it to the other. When spraying ensures that the nozzle is 20 cm. to 25 cm. from the tool surface. If the product were gathered in drops in located areas, remove with a clean and dry cloth this excess, taking care of not rubbing. The tool temperature prior application, number of coats, time for solvent evaporation between coats, and final curing of release agent shall fulfil the indicated in TABLE-5: For water base release agents, the applied coat must be very light and it is critical that every applied coat is totally dry before applying the next coat.
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RELEASE AGENT Frekote 700NC (Solvent base) Frekote 44 NC (solvent base) Marbocoat TRE 45 ECO (Solvent base) Departure (Water base) Frekote B-15 (Mold Sealer) NOTES:
NUMBER OF COATS 3
TOOL T (C) RT 60
TABLE.5 TIME OF SOLVENT EVAPORAT BETWEEN COATS (minutes) 10 to 15 5 to 10 10 to 15 5 to 10 10 to 15 10 to 15 10 to 15 30
T OF FINAL CURE (C) RT 60 60 RT 60 60 RT 60 RT RT RT 100
TIME OF FINAL CURE (minutes) 60 30 30 210 90 90 30 15 30 30 1440 60
RT 60
4 3 (2) 4 (1) 2
RT RT RT RT
(1) For manual application. After 2 minutes have elapsed since the application of every coat, buff off the coat with a clean cloth. (2) For application by spray. In case of reapplication, the number of coats to be applied after a soft cleaning of the mould, will be determinated by shop trials. 10.2.4 Application and curing for Mold Sealer This product must be treated as a release agent. Its application on tool is recommendable in the following cases: a) When the quality of the tool surface in contact with the part is bad; for example a high superficial porosity. b) Prior to the manufacturing process, for a new lay-up tool, or repaired or changed with major modifications, before carrying out the airtightness test. The application may be performed by spraying, brushing, dipping or wiping with a clean, lint-free cotton cloth following the indicated in paragraph 10.2.3. The tool temperature prior application, number of coats, time for solvent evaporation between coats, and final curing of release agent shall fulfil the requirement in TABLE-5.
10.2.5 Frequency of renewal The frequency of renewal of the release agent depends on the tool material and configuration, the curing cycle conditions it is subjected to, the surface damages suffered during the demoulding operation and the type of release agent used (see Table-5). Consequently, the surface condition of the tool shall be revised once the part is demoulded, indicating if necessary, the total (as is indicated in paragraph 10.2.3) or partial (as per paragraph 10.2.6.) cleaning of the tool surface.
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10.2.6 Release agent repairs Unless otherwise specified, when materials remain adhered in a localized manner on the tool surface, or when scratches are produced during the demoulding of the part, proceed as follows: 1) Mark affected area with adhesive tape. 2) Clean, removing release agent from the area according to paragraph 10.2.3. 3) Apply the same releasing agent as on the rest of the tool, overlapping the last coat of it, over at least 30 mm. with the surface of the non-damaged area.
11 Manufacturing
11.1 Lay-up
Lay-up is performed either by hand or using appropriate machines (ATL and AFP). When the prepregs and film adhesives are removed from the refrigerator, care shall be taken not to open the container before bringing it to room temperature, checking that there is not condensation on the outer surface of the bag. The extraction shall be exclusively done inside the lay-up area. Kits of the materials with risk of humidity penetrating inside due to breakage of the bags, incorrect closure of the same, etc. shall be rejected. Once the prepreg materials have been brought to room temperature and the corresponding patterns cut, remove the release film or protection paper from one face of the prepreg, performing this operation with extreme care so as not to detach strands, alter their alignment or produce damages. The prepreg plies shall be placed one on top of one another, respecting the orientations called out in the applicable drawing and minimizing the amount of air occluded below the ply. In the case of prepregs with protection film on both sides, place the second ply keeping the protection film on its external face, subsequently removing it just before application of the second prepreg ply. During the lay-up process, special attention shall be paid to prevent leaving any piece of protection film or backing paper incorporated to the part. The lay-up area, only the use and handling of clean cores, is allowed inside. Attention shall be paid to the nodal core orientation (Ribbon), the prepreg fabric ply orientation and the 0 reference tapes direction.
Unless otherwise indicated in the drawing, the following orientation tolerances shall be applied: Prepreg fabric: Prepreg tape: Honeycomb core: + 5 as regards the warp direction. + 3 as regards the fiber direction. 5 as regards the ribbon direction.
The tolerance of the positioning for the end of one ply which does not coincide with a ply splice, shall be + 2,5 mm: Avoid air entrapment and formation of wrinkles during lay-up of the plies. To achieve this in manual lay-up, comb with spatulas manufactured with polyamide in parallel direction to the fibers or the warps in the case of fabric. The use of teflon spatulas is prohibited. In order to improve the mating and tack of the prepreg, hot air blowers or any other means approved by Airbus may be used, provided the temperature does not exceed 65C, for a maximum time of 2 minutes.
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Place film adhesive on the entire core surface, and on those places called out on the drawing or part drawing associated documentation.
Figure 9: Placing of film adhesive around core surface When an adhesive splice is necessary, it shall be performed with overlap or butt, with a maximum gap as indicates the Table 9. If the lay-up is suspended, the laminate shall be covered with a temporary vacuum bag maintaining a minimum vacuum of 13,2 kPa (manometric pressure inside the bag). During the lay-up, inspection of the materials shall be performed and if any discrepancy is observed, it shall not exceed the acceptable limits indicated in Tables 4 and 5. If these acceptable limits are exceeded, the corresponding Non Conformance Sheet shall be established.
11.1.1 Compaction In order to avoid air entrapment between plies, compaction between plies shall be adequate. On automatic processes, this can be achieved by a roll pressure and on hand processes the following procedures may be used for compaction or lay-up adaptation purposes, provided that it shall be required by the documentation associated to the drawing or by the Manufacturing Work Orders. The specific parameters used in the process shall be indicated in documentation associated to the drawing or in the associated componentrelated process instruction, as they depend on the material and form of element to manufacture. Unless otherwise indicated in the associated drawing documentation or Work Order, the following criteria will be applied: A) Cold compaction Cover the lay-up with temporary vacuum bag. Apply vacuum until a manometric pressure inside the vacuum bag -66kPa for plies previously incorporated to the core and -33 kPa for the later plies when the core density is 48 kg/m3 or -16 kPa when the core density is < 48 kg/m3. As a general rule, the compactation time shall be between 5 and 6 minutes. Take off the vacuum and remove the vacuum bag. Continue the manufacturing.
B)
Hot compaction (Debulking) Cover the lay-up with temporary vacuum bag. Apply pressure or vacuum. For plies incorporated before core: apply vacuum until a manometric pressure inside the vacuum bag -66kPa or pressure outside the vacuum bag > 600 kPa. For plies incorporated after core: apply vacuum until a manometric pressure inside a vacuum bag -33 kPa or pressure outside the vacuum bag > 300 kPa. Heat up to a temperature 55 5C.
AIPI 03-02-018 Issue 2 -
Page 36
Keep this temperature for 10 to 15 minutes. Cool down, maintaining the pressure or vacuum, to a temperature 40C. Take off the pressure or vacuum and remove the vacuum bag inside the clean area. Continue the manufacturing.
The temporary vacuum bag scheme is indicated in Figure 10 as an example.
Figure 10: Temporary vacuum bag scheme NOTES: (1) The surface breather shall be overlapped to the contour breather. (2) The release film shall be extended to the centreline of the contour breather. Contamination through the holes must be avoided. (3) Place at least 3 plies of breather with a minimum wide of 25 mm and place on it the vacuum bag connections.
11.1.2 Hot forming The Hot Forming process is specifically described in the process instruction AIPI 03-07-019. The specific parameters used in the process shall be indicated in documentation associated to the drawing or in the associated-related process instruction and depending on material, and type of element to be manufactured.
11.1.3 Peel-Ply Peel-ply layers shall be applied to the surfaces of those parts that require a subsequently bonding or painting process when it is indicated in the applicable drawing or associated documentation. In the first case follow the rules established in AIPI 06-02-006 Process Instruction.
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11.1.4 Waterproof films Method 1 Waterproof film (Tedlar) shall be only used if it is so required by the drawing. It shall be placed in direct contact to the bag side part. The waterproof film shall be free of any defect, specially cuts or punctures, in all the stages of the process. If possible, use always one single piece of film. If it is not possible, overlap 1520 mm. Adhesive film AIMS 10-01-000 must be used in the overlap areas to assure the joint between them. In irregular surfaces some cuts are allowed on the film. A piece of 2030 mm width of waterproof film shall be introduced along the cuts bonded with adhesive film AIMS 10-01-000. In order to improve adaptation of the waterproof films, hot air blowers may be used, provided that the temperature does not exceed 65C. Rough and/or sharp edges (such as pressure plates, etc.) are prohibited on surfaces that are placed on the waterproof film. Once the waterproof film is placed, a cold compaction (as per sub-clause 11.1.1.A) shall be performed during 5 to 10 minutes or according to the associated component-related process instruction. Formation of wrinkles or bridging on the waterproof film is not allowed. In the core corners, curved chamfers and irregular surfaces, cuts may be made on the waterproof film so as to adapt it. There shall be no gap between these cuts, and due to this, an additional strip of waterproof film, 2030 mm of width, shall be placed under the cut. To avoid waterproof film bridging on laminate zones between core chamfers, cut the waterproof film towards to the centre of the laminate area, and place under the cut, an additional 2030 mm wide strip. Method 2 PVF foil, required by the drawing, and applied in direct contact to the tool side part. Using scissors or a knife, the foil is to be cut according to the contour of the component, allowing for sufficient oversize. The bonding surface of the foil must be protected against contamination. Static charging must be eliminated by suitable discharge devices (e.g. de-ionizing bars). The foil must be applied and fixed in position without folds. A release agent between the foil and tool is not required for PVF foils. Areas of the tool, which are not covered with PVF foil, must be coated with release agent according to the associated component-related process instruction. Caution: If the foil can be bonded on one side only, make certain that the bonding side faces the component. The curing conditions (including multiple curing) are determined by the component prepreg system used and are laid down in the component-specific manufacturing instructions.
11.1.5 Splice allowance Tables 6 to Table 8 call out the dimensions, tolerances and types of splice allowed in the prepreg plies, unless otherwise stated in the drawings or associated documentation.
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Requirements of film adhesive and peel ply splices are included in Table 9. Splice tolerances for materials AIMS 05-05-000 and AIMS 05-12-000 shall be specifically indicated in the drawing or associated documentation. No modification for these materials is allowed without specific approval of Engineering.
Table 6. Hand Lay-up processes. OVERLAP SPLICE PREPREG Overlap (mm) Fabric 12-25 Stagger (mm) (1) 25 min. Maximum gap (mm) Stagger (mm) (1) BUTT SPLICE
Not permitted
Splice line not parallel to Not permitted (2) Not permitted the fibre Tape Splice line parallel to the Not permitted 1 214 fibre (1) If there are at least 4 intermediate plies between 2 splices, it is not necessary to apply the stagger required (Figure 11 and 12). (2) Two overlapped splices maximum are allowed with a minimum distance between them of 2 m in the fibre direction and 1 m in other directions. Overlap shall be in a range between 12 and 25 mm.
Table 7. Automatic Tape lay-up processes. OVERLAP SPLICE PREPREG TAPE Overlap (mm) Splice line not parallel to the fibre Stagger (mm) BUTT SPLICE Maximum Stagger gap (mm) (mm) Not permitted
Not permitted (1)
Splice line parallel to the fibre Not permitted (2) 2,5 (3) 214 (1) Three maximum overlap splices are allowed per part, with a minimum distance between splices of 2 m in the fibre direction, and 300 mm in other directions. Overlap shall be in a range between 12 and 25 mm. If there are 4 plies between two splices, the minimum staggering spacing is not required (Refer to Figures 11 and 12). (2) For A.T.L. processes, in which overlapping is unavoidable, a 1 mm overlap is to be allowed with a 12 mm. staggering. In special cases, deviations from the above can be allowed, provided it is previously agreed between Engineering and Manufacturing. (3) Maximum accumulated gap stall be 30 mm over a length of 300 mm.
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Table 8. Fibre Placement. OVERLAP SPLICE PREPREG (1) Overlap (mm) Stagger (mm) BUTT SPLICE Maximum gap (mm) Stagger (mm)
Splice line not parallel to the strip Splice line parallel to the strip
Not permitted (2) Not permitted (3)
Not permitted 2,5 (4) (5)
(1) A strip of F.P. preimpregnated material corresponds to a machine head run. Each run of the machine head features a specific number of preimpregnated tows (e.g., 32 tows of 3,175/6,35/12,7 mm wide each). Gaps and overlaps criteria are defined for strips. For tow splices, see AIMS of the prepreg material). (2) Splicing three strips per part as maximum is allowed. In case two splices are within a 1 m area, there shall be at least three plies between tem. Splices within the same ply shall be spaced 3 m minimum. Minimum length of overlap shall be 25 mm and the maximum advisable 75 mm. (3) In the convergence area, when the machine is programmed to a fixed angle, an overlap with the tow width maximum dimension may exist. An overlap of 1 mm between tows from the same strip in the parallel direction of the fibres will be allowed. (4) The maximum accumulated gap (strips + tows) shall be 5 mm over a length of 300 mm (measured in the perpendicular direction to the strip). The maximum gap allowed between two tows from the same strip is 0,3 mm, unless otherwise agreed between Engineering and Manufacturing. (5) Not permitted for fixed angle. For parallel angle, not permitted unless otherwise agreed between Stress and Manufacturing and indicated in the drawing or associated documentation.
Figure 11: Overlap splice. See tables 7,8 and 9
Figure 12: Butt splice-See tables 7,8 and 9
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Table 9. Adhesive and peel-ply splicing. MATERIAL EPOXY FILM ADHESIVE PEEL PLY MAXIMUM GAP MAXIMUM OVERLAP --REQUIREMENTS 1,5 mm 10 mm Butt splice (1)
(1): Peel-ply splices must be avoided whenever possible. 11.1.6 Structural bonding The process, If applicable, shall be carried out according to AIPI 06-02-006 Process Instruction.
11.2 Vacuum bag General requirements and recommendations are indicated in this clause for the vacuum bag set-up. The specific conditions applicable to each part in particular shall be indicated in documentation associated to the drawing and Manufacturing Work Order. With the exception of peel-plies and release films, the materials used in the construction of the vacuum bag shall not be in direct contact with prepreg plies. Exceptions shall be qualified. Vacuum bag construction must be performed so that there will be minimum lateral pressurization during the cure cycle, because it would crush the core, since sandwich construction only can absorb very small forces in this plane during curing. The vacuum bag shall be checked for leaks when the lay-up process is finished in accordance with the requirements established in the Manufacturing Work Order for each production part. If not specified, the following procedure shall be carried out: Connect the vacuum bag to the vacuum network and wait until a manometric pressure inside the 3 vacuum between -33 kPa when the core density is 48 kg/m or -16 kPa when the core density is 3 < 48 kg/m is reached and steady inside the vacuum bag. Disconnect or close connection to the vacuum line network. Perform a first pressure measurement inside the vacuum bag. After 2 minutes, perform a second measurement inside the vacuum bag. Unless otherwise stated in the Manufacturing Order, the vacuum bag shall not leak over 2,6 kPa within 2 minutes. If the vacuum leakage is over that one allowed, the leak shall be corrected and the airtightness test repeated until no leaks appear.
After vacuum bag preparation, a minimum manometric pressure inside the bag of 13,2 kPa shall be maintained until introducing it into the autoclave or oven for curing the part. Figure 13 represents a typical scheme of vacuum bag, applicable to sandwich parts.
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NOTES: (1) Surface breather shall communicate with the contour breather. (2) The release film shall extend to the centre line of contour breather. (3) The part edge shall be least 20 mm away from the contour breather. (4) Place at least 3 plies of contour breather fabric with a minimum width of 25 mm, and place the vacuum connections. (5) Caul plates shall be used only if it is indicated in the drawing associated documentation. Figure 13: Vacuum bag scheme
11.3 Curing Cycle and Postcuring Cycle (whenever required) The specific cure cycle of each composite element depends on the material or materials used in the part and the type and configuration of the element to be manufactured. The cure cycle applicable to each specific part shall be indicated in the documentation associated to the drawing and in the Manufacturing Work Order or in associated component-related process instruction, and shall be in line with the processing window specified in the relevant MS or IPS. When more than one material is included in one part, the selected cure cycle must fulfil the processing window of all materials used in the part. The temperature, pressure and vacuum parameters shall be automatically and continuously recorded, as applicable. If it is not possible, recording at maximum intervals of 10 minutes is allowed. If pressure leakage is found to one vacuum bag during the autoclave cure cycle, unless otherwise indicated in the documentation associated to the drawing or in the associated component-related process instruction, the following criteria must be accomplished to all the production parts and all the cycles: - Any leak pressure > 50 kPa above the vacuum established in the applicable cycle, if the cycle has not reached half of the minimum hold time of latest step, will be considered as a discrepancy and shall be established the corresponding NCS. The conditions of postcuring (if it is applicable) shall be specified in the documentation associated to the drawing and in the Manufacturing Work Order. Postcuring is usually accomplished in an oven, at high
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temperature, in the majority of the cases without pressure being applied (in this case without vacuum bag). Make sure that the components are no damaged during postcuring. Unless otherwise indicated in the drawing associated documentation, postcuring cycle of the precured elements which are going to be bonded, will be carried out at the same time than the curing of the bonding adhesive. Cured parts which are exposed to successive temperature cycles during manufacturing or rework, need to be justified in a sufficient way if Tg onset, according to AITM 1-0003, of any of its structural materials has been exceed. 11.4 Manufacturing control test panels Process control test coupons shall be made just in case they are called out by Manufacturing Engineering, depending on the maturity, reliability and experience in the manufacturing process used. The need to manufacture or not the panels and applicability (per cure load or per part) shall be stated in the applicable documentation associated to the drawing. The panels (dimensions, configuration, materials, etc), tests to be carried out and requirements shall be defined in the applicable documentation associated to the drawings. The process control tests will be mainly the following indicated in Table 10. The manufacturing of the control test panels shall be carried out using the materials that best represent the element (if specimens per part are required) or the cure load (if specimens per load are required). The samples must be constructed in a way hat allows to check the component-critical curing parameters (e.g. heat up rate, temperature, curing time). Unless otherwise indicated, use for manufacturing the control test panels a standard honeycomb core, one single type of prepreg (tape or fabric) and adhesive from the lot and type of material which predominates in the manufacturing of the parts, not being permitted splices of cores, prepregs or film adhesives. Depending on the type of the part and its classification, panel manufacturing criteria are established, indicated in the applicable documentation associated to the drawing, on process control per part or per cure load. Table 10. Process control tests for sandwich parts (1) (2) (3) (4) (5) PROCESS TEST I.L.S.S. Flatwise tensile Climbing drum peel COCURING Tg Void content (8) Degree of cure D.E.A. (9) SPECIFICATION EN 2563 (6) EN 2377 (7) EN 2243-4 EN 2243-3 AITM 1-0003 EN 2559 AITM 3-0008 AITM X-XXX ---Test requirements are found in the corresponding IPS of the material used in the production of the test specimens. REQUIREMENTS
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(1) Specific tests to be performed for each part shall be indicated in the drawing or associated documentation. (2) When there is no indication in drawing or associated documents about the tests to be performed, only I.L.S.S. and Flatwise tensile for Carbon Fibre parts or I.L.S.S. and Climbing drum peel for Glass Fiber parts, shall be carried out. (3) As general rule, process control specimens should be performed for each Class 1and Class 2 parts, cured in the same vacuum bag as the part they represent, and if that is not possible, bags shall be communicated. For Class 3 elements, one set of process control specimens should be done for each cure load. In this case, as many process control panels as necessary shall be manufactured and tested as necessary to represent each of the different types of panels called out in the documents associated to the drawing for the parts cured in the same load. (4) When enough experience has been reached in conformity of process control tests for one specific part and for Class 3 elements, it is possible to manufacture test specimens, and to perform the test only in case of doubts relating the final quality of the part. This possibility is only applicable in case a specific approval of The Responsible Design Office has been reached and when all the parameters of the process, including the cure cycle, are correct, and the NDT, visual and dimensional inspection are satisfactory. In exceptional cases, this approach might be applicable for specific Class 2 parts. (5) As a general rule, 5 specimens shall be tested for mechanical trials (ILSS, Flatwise Tensile and Climbing drum peel) and 3 specimens for physicochemical tests. Unless otherwise stated in the documents associated to the drawing, all mechanical tests shall be performed at R/T with no special prior conditioning. If possible, test panels should be manufactured in order to include the specimens for mechanical and physicochemical tests. (6) For carbon fiber composite materials. (7) For glass fiber composite materials. (8) Void content shall be made by acid attack unless otherwise specified in the drawing or associated document. (9) D.E.A. (Dielectric Analysis). Prepare a specimen for each type of resin existing in the cure cycle load.
11.5 Demoulding of parts Parts must not be disassembled from the curing tool until reaching a temperature 80C. For Health and Safety reasons, it is recommended to demould parts with a temperature below 60C. If applicable, before disassembly of the part, coordination holes for trimming and machining must be drilled. Use pressurized air and wooden or plastic wedges to remove the assembly from the tool, avoid the use of metallic tools. Special care shall be taken so as not to damage parts or tools. During this operation, demould and identify the process control panels from the part or cure load they represent.
11.6 Trimming and machining These processes shall be performed in accordance with AIPI 03-07-002 and AIPI 03-03-006 Process Instruction.
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11.7 Rework criteria for finished parts Visual inspection shall be performed for each part with ABD 0076 specification. Dimensional inspection (geometry, radius, thickness, etc) shall be in accordance with the drawing or associated documentation. Unless otherwise indicated in the drawing or associated documentation, Non Destructive Inspection will be carried out according to AITM 6-0011. Typical discrepancies, acceptance values with and without rework, and rework methods are included in Table 11. For discrepancies that exceed the acceptable values with rework, or discrepancies not included in this table, they shall be subject to a MRB disposition. Basing on the part category, documents associated to the drawing may set discrepancy acceptance criteria different to those stated. Some applicable rework procedures are described in AIPI 03-08-003 specification.
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Table 11. General acceptance criteria for finished parts

No. 1 TYPICAL DISCREPANCIES Superficial scratches ACCEPTABLE VALUES WITHOUT REWORK Unlimited provided that fibres are not damaged and do not exist exposed fibres. ACCEPTABLE VALUES WITH REWORK Fibres damaged: None Exposed fibres, but not damaged: Unlimited REWORK METHODS Not applicable Rework with resin (AIMS 08-02-001) This method does not apply if the reworked surface of the part is to be subsequently bonded 2 Surface depressions on: a) Tool face side Unlimited if the depressions have a depth < 0,13mm Unlimited if the depression depth is between 0,13 and 0,25mm by 25 mm of greatest dimension in an area of 30 cm x 30 cm Depressions shall be separated at least 150 mm from the part contour, from a hole or from another depression Unlimited if the depressions have a depth < 0,5mm 5% maximum of the part surface if depressions have a depth < 0,5mm and the greatest dimension is < 50 mm Fill with aerodynamic epoxy paste smoother.
Depressions shall be separated at least 150 mm from the part contour, from a hole or from another depression 5% maximum of the part surface if the depressions have a depth < 1 mm and the greatest dimension is < 100mm Depressions shall be separated at least 150 mm from the part contour, from a hole or from another depression --Fill with aerodynamic epoxy paste smoother and reapply the PVF film if applicable
b) Bag face side
Depressions shall be separated at least 150 mm from the part contour, from a hole or from another depression 3 Delaminations, voids disbonds and others defects detected by NDT. In accordance with the associated documentation to the drawing
Bridging on: a) Core contour and fillet radius at core section
A lack of contact with maximum dimensions of 3 mm width by 12 mm length (as a total of all the lengths of all the discrepancies) every 300 mm of contour length.
A lack of contact with maximum dimensions of 6 mm width by 50 mm length (as a total of all the lengths of all the discrepancies) every 300 mm of contour length
Inject resin (AIMS 08-02-001)

5 Resin ridges a) Bag face side, and nonaerodynamic surfaces
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Unlimited if the maximum height is < 0,5 mm, provided that the final dimensions be within the permitted tolerance. Unlimited, provided it does not contain fibres Remove by means of soft sanding
b) Tool face side or coupling surfaces
Unlimited if the maximum height is < 0,1 mm and provided it does not affect the coupling requirements None One inclusion of 10 mm maximum dimension for each 30 cm x 30 cm, provided that second ply suffers no damage The inclusions must be separated at least 150 mm between them Remove inclusion and fill with resin (AIMS 08-02-001) Reapply the glass fiber or tedlar if applicable
Inclusions of foreign materials at the surface
Ply wrinkles. Unlimited if: d < 2 mm L/d 5 Number of plies affected 25%
None
Not applicable
Depression on the core contour
10% maximum of the contour length, with a maximum depth of 0,25 mm.
None
Not applicable
Lack of flatness on coupling surfaces
A maximum of + 0,25 mm except in ply splicing or ending areas, where the drawing shall indicate the tolerance
None
Liquid shim for fitting
10
Part warping.
Unlimited in case warping or torsion -to maintain detail parts at position on a flat surface meeting drawing requirements- is removed applying finger pressure.
None
Not applicable
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11
Of the waterproof (Tedlar) film: Cuts, wrinkles, ridges, separations on splices, lack of Tedlar, unbonded or burnt Tedlar, etc.
None NOTE: ridges or wrinkles with height 0,25 mm are acceptable
100% of the surfaces provided that the fibers are not damaged
Rework the waterproof film
12
Unravelled areas, burrs or small delaminations on the machined contours NOTE: It shall only affect the last ply
If the last ply is fabric: 2 mm maximum, measured perpendicularly to the contour with a total maximum length (all defects) 100mmm per each meter of contour trimming part
If the last ply is tape: 1 mm maximum, measured perpendicularly to the contour with a total maximum length (all defects) 100mm per each meter of contour trimming part 13 Defects of the core in sandwich structures: a) Partial node bond separation b) Total node bond separation Maximum 5% of the total number of nodes, and maximum 25% of the nodes contained in an area of 45 cm2 Maximum 1% of the total number of nodes, and maximum two nodes in an area of 50 mm x 50 mm
. 4 mm max. measured perpendicularly to the contour in a total maximum length (all defects) 100 mm each meter of contour trimming part . Unlimited for burrs
Cover with resin (AIMS 08-02-001) Remove burrs by soft sanding
None
Not applicable
c) Core chamfer or contour waviness 14 Lack of resin (resin starvation) on surface and pinholes
Up to 1,5 mm Pinholes unlimited provided that the pore is 0,5 mm and the number of pores is < 15 per cm2 Lack of surface resin, S1<1 cm2 and S2<5%A, where: S1: local lack of resin area S2: Total surface areas with lack of resin A: Total surface of the element
Pores of 0,5 mm and the number of pores 15 per cm2
Apply epoxy pore filler
For lack of surface resin, unlimited, provided that no fibres without resin appears on the surface and it does not affect the second layer
Apply resin (AIMS 08-02-001)
15
Telegraphing on sandwich structures (Telegraphing)
Tool side: Unlimited, provided it has a depth < 0.05 mm. Bag side: Unlimited, provided depression is below 25% of core cell diameter, not exceeding 1 mm depth.
Tool side: Unlimited if depth of depression is comprised between 0.05 and 0.1 mm. None
Fill with material (A) 1 (EA 960 F A/B) Not applicable

16 Delaminations visible from the exterior Lack of material in the laminate edges
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None
Maximum depth 3 mm measured perpendicular to the contour Maximum width 1 mm and maximum length 50 mm
Inject resin from the edge (AIMS 08-02-001) Use wet lay-up resin (AIMS 08-02-001) with Aerosil and apply on the surfaces a type 120 glass fabric layer with resin (AIMS 08-02-001) Apply on the surface a type 120 glass fabric layer with wet lay-up resin (AIMS 08-02-001)
17
Drawing tolerances
18
Absence or displacement of the exterior glass fabric layer in Carbon fabric composite materials
None
Unlimited
TABLE 11 (Cont) (A)

MATERIAL(1) COMMERCIAL MANUFACTURER DESIGNATION EA 960 F A/B HENKEL CORP. MIX Parts by weight: MIXING MIX POT LIFE QUANTITY (min)(3) (4) (4) (g) 100 CURE(3) CURE AT LOW TEMP. CURE AT HIGH (4) TEMP.
A: 100 1 B: 50 0,5
Parts by weight:
30 at 23C
24 hours at 1 hour at 70C 23C (2) 2 hours at 25C + 2 hours at 65C
EPIBOND 156 A/B
HUTSMAN
A: 100 1 B: 6 0,1
100
30 at 23C
3 days at 23C (2)
Notes: (1) The use of materials EA 960 F (aerodynamic smoother) or EPIBOND 156 A/B (pore filler) shall depend on the type and size of the pore, gap or other defect. (2) It is possible to work 6 hours after application. (3) The temperature indicated in the table shall have a 5C tolerance. The times indicated are minimum times in the case of curing times and maximum for application times. (4) These are guideline values.
11.8 NDI for finished parts Non Destructive Inspection (NDI) will be carried out according to AITM 6-0011. Drawing and/or associated documentation shall indicate the Class/Level of the part and, in function of it, the requirements of NDI.
12 Quality requirements
Quality shall assure the fulfilment of the requirements established in this specification, as well as those are included in the drawing and in the documentation associated to the drawing. First Article Inspection will be carried out in accordance with A1016 procedure. For class/ level 2 and 3 elements, this inspection can be made per family of parts as Airbus Quality criteria. Serial production parts
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requires Airbus Quality acceptance of the First Part Qualification according to AP-5866 and the First Article Inspection and First Article Reinspection.
12.1 Materials At least, the following controls will be made: The structural materials shall meet the requirements indicated in their corresponding Airbus Material Specification. Quality Control material income process is required in each batch for all structural materials and peel plies for structural bonding. The storage and handling of prepregs, resin and ancillary materials shall be performed in accordance with the requirements of this document and with the applicable Airbus Material Specification. All limited life materials used shall be within their useful life time (Storage life and Work life), All ancillary materials and solvents used shall be products approved by AIRBUS.
12.2 Manufacturing Process At least, the following controls shall be made: Quality shall assure the correct working of Autoclaves, Ovens, Freezers, Hot forming equipment, etc., as well as their registers and measuring equipment, checking that they are within the validity time of their calibration. Temperature, humidity and cleanliness in the lay-up area. Thawing of refrigerated materials. Contamination-free tools and appropriate application of the mould release agent. Mixing of prepregs from different suppliers shall not be done during the lay-up, except if they are specifically qualified as compatibles. Removal of protections from the prepregs, stabilized cores and film adhesives prior to the lay-up. Number, ply orientation and identification for cutting operations. Adequate core preparation. If defect exits on the prepreg and/or cores, these shall be found within the acceptance limits, with or without correction and the correction system when applicable shall be carried out in accordance with the indicated in Tables 4 and 5. Ply number and orientation for lay-up operations. Core orientation for lay-up operations. Do not exceed the maximum permitted temperature, if any compaction, draping or hot-forming process of the lay-up is carried out. Splices and gaps of prepregs, cores and film adhesives within the permitted tolerances.
AIPI 03-02-018 Issue 2 -
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Placement of waterproof films and/ or peel plies called out in the drawing or in the associated documentation. Correct performance and no leaks of the vacuum bag. In curing cycles: Number and correct position of the thermocouples. Number and correct position of the vacuum intakes. Leak test of the vacuum bag and pressure leakages inside the vacuum bag. Pressure, vacuum, temperature, time and heat up/cold down rates of cure cycle and postcuring cycle (if applicable). Meet the requirements established in the drawing associated documentation.
Identification of the process control test panels. Ensure that personnel carries out the work complies with the indicated in paragraph 4.
Procedures for periodic checking of pressure in the vacuum hoses and their connection shall be established in order to guarantee their perfect working.
12.3 Finished parts At least, the following controls shall be carried out: If discrepancies exist, these shall be found within the acceptance limits with or without rework, indicated in Table 11. When applicable, the correction methods used for removing the acceptable discrepancies with rework will be carried out in accordance with Table 11. The test results of the manufacturing control panels shall comply with the requirements indicated in the documentation associated to the drawing. All cured parts shall be visually inspected with regards to deformation and surface defects. If these are observed, they shall be evaluated according to Table 11. The dimensions, geometry, radius, thickness, etc of the finished parts shall meet the requirements of the drawing or associated documentation. Specific process requirements shall be prepared for all carbon and glass fiber composite sandwich parts, in which, among other requirements, the vacuum bag applicable, the parameters of curing/ postcuring cycle, the type of NDT which shall be carried out, the types of control panels, the process control tests and acceptance criteria shall be indicated. The manufacturing process of sandwich composite structures shall guarantee that the final elements are leak tight. The Tightness Test shall be performed whenever is indicated in the drawing associated documentation. This test will made according to AITM 2-0037 specification. During handling and transportation of parts it shall be ensured that no damages, which affect the quality of the finished part, are produced.
12.4 Control records Quality assurance shall establish a procedure for control of the documentation, which guarantees an adequate traceability, both as regards the raw materials (materials, lot, roll, specification, manufacturing date, incoming test results, etc.) as well as the manufacturing process of each element (curing cycle and postcuring- if it is applicable-, P/N, test and inspection results, etc.), in accordance with specifications AP2003 and AP-5003.
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APPENDIX I
Ancillary Materials List
Type of material 1 Peel plies * General use 60-B/R PFG style 60001 finish 060 color 0005 F-08111 * Structural bonding F161/43%/F08111 Hysol EA 9895 0.033 PSF 2 Release agents * Liquid (solvent base) Frekote 700 NC Frekote 44 NC Marbocoat TRE 45 ECO * Liquid (water base) * Mold sealer 3 Releases * Film
(1)
Trade name / Manufacturers reference
Manufacturer
Remarks[nature / max. use temp.C, etc] Nylon Polyester Polyester Polyester Polyester
Tygavac Advanced Materials Precision Fabrics (PFG) NCV Industries (Porcher) Hexcel composites S.L. Henkel corp.
Henkel Loctite Corp. Henkel Loctite Corp. Marbo Italia S.P.A. Zyvax Henkel Loctite Corp See requirements and application process defined in AIPI 03-02-019
Departure Frekote B-15
A 4000 (perforated and not perforated) A 5000 (perforated and not perforated ) A 5000 ST (Shrink Tubing ) WRIGHTLON-5200 (perforated and not perforated) VAC-PAK A-6200 (perforated and not perforated) RF-242-R (perforated and not perforated) WRIGHTLON 4600 VAC-PAK E-4760 WRIGHTLON-4500 transparent Tedlar E 3760 white
(2) (2)
Airtech Richmond Aircraft Prod. Richmond Aircraft Prod. Airtech Richmond Aircraft Prod. Tygavac Advanced Materials Airtech Richmond Aircraft Prod. Airtech Du Pont / Richmond or FUS Airtech Tygavac Advanced Materials Tygavac Advanced Materials Airtech
FEP / 260C FEP / 260C FEP / 260C ETFE / 260C ETFE / 232C ETFE / 230C PMP / 193C / For Hot Forming and low temperature cure cycle PMP / 205C / For Hot Forming PVF / 204C PVF / 204C glass+PTFE / 288C glass+PTFE / 260C glass+PTFE / 260C 260C
* Fabric
RELEASE-EASE 234 TF (porous and non porous) TFG-S-075 (porous and non porous) TFG-S-125/1
* Self- adhesive 4 Gloves * Cotton gloves

(3)
Tooltec CS-5
White cotton gloves mod. POLA G-10 Abna Gloves P/2800-LH Mallncolm Ltd 4100, 4300, 4330 Mac Tuk 335024
Larraaga Aguirre Confecciones Pomares Deinsa Deinsa KCI Deinsa Larraaga Aguirre
* Polyamide gloves
(3)
Dermatril, article 740 Mallncolm Ltd. Mod. PA/10F White nylon gloves PG-10
5 Protection materials for cutting tools Durocast table top Tromp-90/3 Polyurethane CA 90 Shore Airtech Deinsa Arthur Krger KG Polyurethane / For manual cutting Polypropilene / For manual cutting Polyurethane / For manual cutting
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Film polietileno blanco 0paco ref.5891 Polyethylene film 5321 LDPE Plastotrans Ref.16000 Gofrado-124 Conveyor belt Aster 20 AF 6 Bagging films * Vacuum bag film
(4)
Plasinco s.a Dail Plastic Co. 4p Folie Forchheim Esbelt, S.A., Barcelona
Polyethylene / For automatic and manual cutting Polyethylene / For automatic and manual cutting Polyethylene / For automatic and manual cutting For automatic and manual cutting
VAC-PAK HS-6262.002 and .003 IPPLON DPT1000 Securlon L-2000 IPPLON WN 1500 QUICK DRAW HS 8171 (embossed) VAC-PACK HS 8171 WRIGHTLON-7400
(5)
Richmond Aircraft Prod. Airtech Airtech Airtech Richmond Aircraft Prod. Richmond Aircraft Prod. Airtech / Aero Consultants Airtech Tygavac Advanced Materials Richmond Aircraft Prod.
Nylon / 232C Nylon / 246C Nylon multilayer / 218C Nylon / 246C Nylon 6 / 205C Nylon 6 / 205C Nylon 6 / 204C Nylon 6 / 177C Nylon /140C Copolimer / 121C / For furnishing parts only
* Compaction film
WL-5400 NBF-125C PRO RAP
7 Bleeders * Glass fibre fabric

(6)
Glass fiber fabric 120 FINISH TF-970 Glass fiber fabric 91.111 FINISH Z6040 & 8.4544.6 Glass fiber fabric Y-0807 FINISH 287 Fabrics 1581 & 7781 FINISH TF-970 Fabrics 91.945 & 92.626 FINISH Z6040 Glass filament fabric 8.4567.6 & 8.4568.6 & 8.4565.6 7781 dry glass 70132/1270 Glass filament fabric 8.4546.6
Hexcel-Fabrics PD Interglas Fothergill Eng.Fabr. Hexcel-Fabrics PD Interglas PD Interglas Fothergill Eng.Fabr. PD Interglas
Style 120, 4HS, 105 g/m2 Style 120, 4HS, 105 g/m2 Style 120, 4HS, 105 g/m2 Style 181 (181, 1581 & 7781) , 8HS, 295 g/m2 Style 181 (181, 1581 & 7781) , 8HS, 295 g/m2 Style 181 (181, 1581 & 7781) , 8HS, 295 g/m2 Style 7781 , 8HS, 295 g/m2 Style 1543, 4HS, 288 g/m2
8 Breathers AIRWEAVE N-4 A 3000 AIRWEAVE N-10 NW-339-HA RC-3000-10 and RC-3000-10 FR Airtech Richmond Aircraft Prod. Airtech Tygavac Advanced Materials Richmond Aircraft Prod. Airtech Local purchasing Poliester / 204C / 50 psi / 140 g/m2 Polyester / 205C / 50 psi / 114 g/m2 Poliester / 204C / 100 psi / 340 g/m2 Poliester / 205C / 100 psi / 339 g/m2 Poliester / 205C / 150 psi / 339 g/m2 Nylon 6,6 / 232C / 150 psi / 339 g/m2 Glass
ULTRAWEAVE 1032 Edge Breather glass fabric 9 Vacuum bag sealant tapes GS-43 MR SM-5126 (Schnee-Morehead) GS 213-3 10 Pressure sensitive tapes * Fixing adhesive tape VAC-PAK HS-8171-PS
(2)
Airtech Richmond Aircraft Prod. Airtech
232C 232C 232C
Richmond Aircraft Prod.
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(High temperature)
SCOTCH 855 FLASHBREAKER 1, 2, 5

(2)
3M Co. Airtech 3M Co. Permacel Inc. Permacel /Stokvis Hexcel Composites Tesa Beiersdorf A.G. Tesa Beiersdorf A.G Tesa Beiersdorf A.G
SCOTCH 8901, 8902, 8905 P-904, P-904 HD Permacell PS1 rot * For honeycomb cores CORDUX 654 TESA 4432 TESAKREPP 4316 TESA 4964 11 Rubbers * Rubber pad
(4)
AIRPAD CUREPAD TYGAPAD Vacfilm 430 Tygavac LRB 100 Tygavac LRB 160
Airtech Richmond Aircraft Prod. Tygavac Advanced Materials Aerovac Tygavac Advanced Materials Tygavac Advanced Materials
Non silicone rubber (uncured) / 204C Non silicone rubber (uncured) / 205C Non silicone rubber (uncured) / 204C Multilayer Nylon&PE / 120C / For compaction and hot forming. Latex / 100C / For compaction and hot forming. Latex / 100C / For compaction and hot forming. 230C / For hot forming. 240C / For hot forming. 232C 232C 205C
* Silicone rubber (cured)
(4)
Mosites 1453-D SRB-220
Mosites Rubber Co. Tygavac Advanced Materials Airtech Airtech Tygavac Advanced Materials Aerovac
* Silicone rubber (uncured)

(4)
AIRCAST 3700 A/B AIRCAST 3800 RTV-60 A/B ASSRI
12 Clothes * Dry White cotton colthes AMS-3819 TYPE 1 Gauze Sponges n.582556 Rymplecloth n. 201, 300 or 301 Sontara AC Cloth Wipes White cotton cleaning cloths 1A Sontara HDH blue (veils) Wypall X80 blue (veils) * Pre-saturated Satwipes C86 with MEK Satwipes C86 with IPA Satwipes C86 with Diestone DLS 13 Temporary (8) protections White polyethylene film opaque ref.5891 Polyethylene film 5321 Transparent polyethylene film, tubular shape Hose foil Tipolen FB 24355 Plasinco s.a Dail plastic Co. Local purchasing Fa. Hermann Kohlhof Polyethylene Polyethylene Polyethylene Polyethylene
(7)
Local purchasing American Fiber & Fin. American Fiber & Fin. Socomor Cramer and Mundt Du Pont / Itex Kimberly Clark Socomor Socomor Socomor

14 Edge Dam * Cork
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Edge dam cork Grade 1237/410 Edge dam cork CK07 AIRDAM I
Deinsa Cirsa Airtech Cirsa Broncesval Deinsa Fa. AW Schulze Fa. Tecno Plast Industr. Technik, Duesseldorf
* Cured silicone
Silicone tubes Silicone-177 profile Spongy silicone SPS Silicone tube SSI 6.10-8 Silicone tube Biosil Tp red/opak
15 Miscellaneous Spatulas (Polyamide) Abrasives * Abrasive felt * Abrasive paper * Blasting abrasive Handcream Scotch-Brite (CF) Type A (fine and very fine) Alumina abrasive paper size150-350 grit Rsler Duroplast RDP II ARRETIL MANOL 100 SBS 40 Cewi-san-E protective emulsion Physioderm skin care cream Antihumidity barrier and temporary protections * Polyethylene film Opaque, white polyethylene film Ref. 5891 Polyethylene film 5321 Hose foil Tipolen FB 24355 Transparent polyethylene film, tubular shape *Others Dry pack 3600 Seet C-303 Mylar film Papel kraft Pressure sensitive tapes TESA 4432 TESA 4443 TESAFILM 4128 TESA 7387 SCOTCH 853 (CLEAR) SCOTCH 850 (METALLIZED) TESA 4137 (ALUMINIZED) SCOTCH 8560 Marker * Marking pencil (prepregs) Prismacolor pencil, white EDDING 750, 751, 780, 3000 Sanford Edding AG. Plasinco SA. Dailplastic Fa. Hermann Kohlhof Local purchasing Richmond S.E.E.T. Dupont de Nemours Local purchasing Tesa Beiersdorf A.G. Tesa Beiersdorf A.G Tesa Beiersdorf A.G Tesa Beiersdorf A.G 3M Co. 3M Co. Tesa Beiersdorf A.G 3M Co. 3M Co. Local purchasing Rsler Oberflchentechnik GmbH M.S.A. Espaola Larraaga Aguirre Drager Dr. Carl Wilden Neu Isenburg Therm GmbH Dr. Carl Thoma Nylon 6 and 6/6 Local purchasing
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* Marking pen (cured parts)
Staedtler 313, 316, 317, 318, 352 EDDING 750, 751, 780, 3000
Local purchasing Edding AG. Cytec Engineered Engelhard corp. 3M Co. Permacel Inc. Tesa Beiersdorf A.G. Tesa Beiersdorf A.G. Local purchasing Local purchasing
Verifilm Desiccant Double faced adhesive tape
FM-641 Desiccite 25 Scotch 415 P-50 TESA 4965 TESA 4964
Gloves for general use
Rubber gloves
Solvent for composite Isopropyl alcohol (IPA) parts cleaning Metil-etil-Ketone (MEK) Diestone DLS
(7)
Local purchasing Socomor
NOTES: (1) (2) (3) (4) (5) The release films micro-perforated to allow the volatiles escape without any leakage of resin. High financial priority (into equivalent products) . For use in direct contact with fresh prepregs, cores, etc. No direct contact with fresh prepregs, cores, etc. Only for protection of Fiber Placement tool
(6) The glass fibre fabric included in this point, is a material with different sizings. These materials are only approved as auxiliary materials for vacuum bags manufacturing, unless otherwise indicated in a relevant point of this specification. (7) (8) Use of MEK must be minimized due to HSE reasons as well as technical (see AIPS 09-01-002). For this same reason it is recommended to use pre-saturated wipes in solvents. For protection of fresh prepregs, cores, etc., during the manufacturing process
Page 56
The following table includes the Key Process Parameters (KPP's) to be controlled on this process, in order to assure the fulfilment of the Key Characteristics (KC's) established in AIPS 03-02-018 KPP AIPI Related KPP Designation KPP Description/Limit requirements numbering Structural materials and peel plies for structural bonding: quality control income process is required for all batches (resin content, resin flow, prepreg mass, fibre mass, Tg, tensile..etc) Material storage Control of all limited life materials Use only ancillary materials approved by Airbus Equipment: ATL and AFP Freezers Calibration of equipment and registers
According to the corresponding AIMS
According to the corresponding AIMS 01. Storage life: According to the corresponding IPS 02. Work life: According to the corresponding IPS Official Ancillary Materials List in Appendix I Complying the splice allowances established in Tables 6 and 7 Reaching, maintaining (<-18C) and automatic recording of temperature ( 6.13 ) Calibration validity ( 12.2) 01.Temperature: T + 5C Complying with the tolerances 02. Heat up rate: 0,55 C/min (as applicable):( 6.6) 03. Pressure: P + 35 kPa 04. Vacuum: V + 3,3 kPa 05. Autoclaves and Ovens for curing: Recording (automatically in continuous or at maximum intervals of 10 minutes): temperature, pressure and vacuum as applicable ( 6.5) 06. Presses and Ovens for core forming: Recording (automatically in continuous or, if not possible, ensuring in the W.O. that parameters of cycle have been correct ( 6.6)
4 5 6 7
Autoclaves, ovens and presses
9 10
Weigh balances Core cutting machine area
Accuracy of weigh balances for mixing components (g) ( 6.3) Separated zone ( 6.2) 01. Control and record: Temperature (C) ( 6.1) 02. Control and record: relative humidity (%) ( 6.1)
11
Lay-up area
03. Contamination (particles size > 5 m)( 6.1) (particles / m3 air) 04. Checking incoming air: free of oil, water dust,..., check filter system (< 1 month) ( 6.1)
AIPI 03-02-018 Issue 2 12 13 14
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Liquid release agent Curing tools Shop personnel
Application and curing: fulfilment with Table 5 01. Performing thermal profile tool/part ( 6.4) 02. For new, repaired or modified tooling Airtighness test ( 6.4) Authorized, trained and competent: courses, knowledge of Airbus normative ( 4) 01. Thawing of refrigerated materials inside lay-up area ( 7.1) 02. Assure a correct storage of kit's 03. Correct cleaning and handling of cores ( 7.2) 04. Correct cutting, machining, forming, splicing and filling of cores (Table 4)
15
Process
05. Correct stabilization to avoid distorsions, rupture or crushing ( 9.4) 01. Temperature: 80 + 5 C 06. Correct drying of (alternative: 50 + 5 C) polyamide honeycomb cores, 02. Time: > 5 hours if required by CER ( 9.3) (alternative: > 12 hours) 07. Preparation of rigid foam cores (if applicable): cutting, drying, heat treatment, machining, Forming, cleaning and lay-up ( 9.9) 01. Check leaks: maximum leak allowed in 2 minutes -2,6 kPa 02. Pressure inside the bag until start curing of the part (< -13,5 kPa) ( 11.2) 03. Preparation according to the corresponding CMR of the part 04. Number and position of thermocouples and vacuum intakes according to CMR
16
Vacuum bag
17
01. Fulfil the cycle parameters (pressure, vacuum, T, time, heat Forming/Heat treatment/ up/cold down rates...) established in the CMR (if applicable) /Curing/postcuring cycles 02. Assure no leaks of pressure inside the vacuum bag during the autoclave curing/postcuring cycles Process control tests Part inspections KPP Designation Equipment: Freezers, ATL and AFP machines, autoclaves, ovens, plies cutting machines, plies positioning by laser, core cutting and machining, presses,NDT, liquid release agent application gun, etc... Temperature uniformity Manufacturing of control test panels and testing of specimens established in the CMR. Evaluate test results Perform of inspections (visual, NDT, dimensional, tightness, etc..) required by the CER KPP Description
18 19 KPP non AIPI Related numbering
20
Maintenance
21
01. Autoclaves, presses and ovens (C) 02. Freezers (C)
T + 5 C T + 3 C

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AIPI 03-02-018 Issue 2

10 Tooling preparation 11 Manufacturing 12 Quality requirements Appendix I: Ancillary Materials List

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3 Definitions, applicability and limitations

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6 Facilities, tooling and equipment

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Core cutting and machining areas

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AIPI 03-02-018 Issue 2 -

Alternative airtightness tests may be used with specific approval of AIRBUS.

Autoclaves and ovens for curing

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Ovens and presses for core forming

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Prepregs and adhesives handling

Table 1. Thawing times for Fabrics

Roll dia. (mm)

Thawing time (h)

Table 2. Thawing times for Tapes

Roll dia. (mm)

Tape width (mm)

Thawing time (h)

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8 Prepreg and film adhesive cutting

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Table 3. General acceptance criteria for prepregs and film adhesives.

As per AIMS 05-27-000 or AIMS 05-02-000 None Not applicable

Folds or wrinkles on plies

Remove with the help of hot air

5 Fabric deformation (2)

As per AIMS 05-27-000, AIMS 05-02-000, AIMS 10-01-000 or AIMS 1201-002

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AIPI 03-02-018 Issue 2 TABLA 4:

General acceptance criteria for honeycomb cores, splices and fillers

Core cut tolerance is 1,3mm (unless otherwise specified on drawing)