American Airlines

Printed: 4/19/2020; 8:29pm. A319_A321_LAA_and_LUS_A321NX

Release 6.0 A321 Structural Repair Manual

Task 51-77-11-911-023
Curing
Weight Variant Number: A321-100 WV000, A321-100 WV002, A321-100 WV003, A321-100 WV004, A321-100 WV005, A321-100
WV006, A321-100 WV007, A321-100 WV008, A321-200 WV000, A321-200 WV001, A321-200 WV002, A321-200 WV003, A321-200
WV004, A321-200 WV005, A321-200 WV006, A321-200 WV007, A321-200 WV008, A321-200 WV009, A321-200 WV010, A321-200
WV011
Effective on: ALL

WARNING: OBEY THE MANUFACTURER'S INSTRUCTIONS WHEN YOU USE CLEANING AGENTS, ADHESIVES, SEALANTS AND
PAINTS. THESE MATERIALS ARE DANGEROUS.
WARNING: WEAR THE CORRECT PROTECTIVE GLOVES AND FILTER MASK WHEN YOU CUT, ABRADE OR DRILL COMPOSITE
MATERIALS. THE DUST FROM COMPOSITE MATERIALS CAN GET INTO YOUR LUNGS OR ON TO YOUR SKIN AND CAN
BE THE CAUSE OF INJURY AND SKIN IRRITATION.
WARNING: CARBON DUST IS ELECTRICALLY CONDUCTIVE AND CAN CAUSE AN EXPLOSION. WHEN YOU WORK WITH CFRP
COMPOSITE MATERIALS IMMEDIATELY REMOVE DUST WITH A VACUUM CLEANER.
WARNING: USE AN ISOLATION TRANSFORMER WHEN YOU USE MAINS ELECTRIC POWER ON THE AIRCRAFT. YOU MUST ONLY
USE POWER TOOLS AND EQUIPMENT THAT ARE EXPLOSION PROOF.
NOTE: There are risks to you and other persons when you work with composite repair materials. To prevent any risks, read and
obey the warnings given above.
1. Task Supporting Data

A. General

(1) The information in this topic is about the general procedures for the preparation of the
repair areas and the repair materials. General data for the procedures are included. The
applicable material data is also provided.

(2) When you make permanent repairs the material must, as a general rule, match the
original material as follows:

• only carbon fiber material to repair carbon fiber structures,

• only glassfiber material to repair glassfiber and aramid fiber structures.

(3) The content of this chapter is applicable for material application of curing.

B. Area of Applicability

C. Weight Variant Applicability

D. Limits/Restrictions

E. Repair Category

F. Inspections

G. Job Set Up Information

(1) Material References

(2) References
Chapter 51-77-10

2. Repair Procedure

CAUTION: DURING THIS STEP THE TEMPERATURE MUST BE STRICTLY CONTROLLED.

A. Room Temperature (RT) Repair - Accelerated Cure by Heating

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NOTE: For this procedure radiant heaters, ovens or heating blankets can be used. Which
ever source of heat is used, the source must be controlled.
When a heating blanket is to be used refer to Chapter 51-77-11 Code 911 NUM
003 for details of the equipment, calibration and check.
When a radiant heater is to be used refer to Chapter 51-77-11 Code 911 NUM 012
, Paragraph.2.C for details of the equipment, calibration and installation.
When vacuum bags are to be used refer to Chapter 51-77-11 Code 911 NUM 022 .
When a vacuum bag is not applicable use grip pins, clamps, weights or other
suitable devices but only to attach pre-cured or metallic doublers.

NOTE: When using a vacuum bag maintain a minimum vacuum pressure of 0.75 bar
(10.9 psi) or 560 mm Hg (22 inch Hg) in the vacuum bag. The vacuum pressure
must be recorded.

(1) Let the adhesive/resin gel at room temperature (Refer to Chapter 51-77-11 Code
911 NUM 006 , Paragraph .2.E and Chapter 51-77-11 Code 911 NUM 031 ).
NOTE: The gel time of the adhesive / resin must be strictly controlled before
applying. Failure to let the adhesive gel can result in an unwanted
adhesive flow when the heat is applied. This will lead to a defective
repair, regarding bonding thickness or porosity.

CAUTION: DURING THIS STEP THE TEMPERATURE MUST BE STRICTLY

CONTROLLED.

(2) Increase the temperature to that specified in the repair procedure (Refer to
Chapter 51-77-11 Code 911 NUM 031 ). The rate of increase of the temperature
must be between 1° C to 3° C (2° F to 6° F).

(3) Let the repair cure at the temperature and time specified in the repair procedure
(Refer to Chapter 51-77-11 Code 911 NUM 031 ).

(a) For core replacement

The curing temperature shall be carefully monitored by means of the
thermocouples installed at the bottom of the honeycomb core in
contact with the adhesive film (Refer to Chapter 51-77-11 Code 911
NUM 022 , Paragraph 2.B).
When heat can only be applied from one side of the repair, it can be
necessary to increase the output from the heating blanket in order to
achieve the curing temperature at the bottom of the honeycomb core.
The thermocouples installed on the sink around the core plug (Refer
to Chapter 51-77-11 Code 911 NUM 022 ) are used to avoid
temperature overshoot. That means, the skin temperature shall not
exceed 95 °C (203 °F) for 120 °C (250 °F) manufactured structures
and 150 °C (302 °F) for 180 °C (350 °F) manufactured structures.
Sufficient layers of breather material shall be positioned around the
edge of the core replacement area to fulfil these requirements (Refer
to Chapter 51-77-11 Code 911 NUM 022 , Paragraph 2.B).
If there is access to both sides of the repair, heating equipment shall
be installed on both sides.

(b) For curing of repair plies and doubler installation with adhesive paste
or resin.
Temperature shall be carefully controlled by means of the
thermocouples suitable positioned around the repair (Refer to
Chapter 51-77-11 Code 911 NUM 022 , Paragraph 2.A). The lowest
temperature recorded shall meet the curing temperature, as specified
by the repair procedure. The highest temperature recorded is used to
control the heating process to avoid temperature overshoot.

(4) In the event of a complete loss of heat input or vacuum pressure, due either to
bag / sealing failures or equipment failure during the repair, the procedure given
in Figure 001 Accelerated Cure by Heating and Hot Bonding Cure - Actions
Following Loss of Vacuum or Heating Failure during Cure Cycle must be followed.

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(5) Check the heat application and vacuum record data before the next step of repair
procedure (Refer to Chapter 51-77-10 Code 911 NUM 004 ).
Figure 001 Accelerated Cure by Heating and Hot Bonding Cure - Actions
Following Loss of Vacuum or Heating Failure during Cure Cycle

B. Hot Bonding Repair

NOTE: Refer to Figure 002 Example of 120 °C (250 °F) Cure Cycle for an example of a
typical hot bonding cure cycle.
NOTE: For this procedure either use a heating blanket and a vacuum bag or oven and a
vacuum bag. For the installation of the vacuum bag refer to Chapter 51-77-11
Code 911 NUM 022 .
NOTE: When a heating blanket is to be used, refer to Chapter 51-77-11 Code 911 NUM
003 for details of the equipment calibration and check. Refer to Chapter 51-77-11
Code 911 NUM 003 , Paragraph 2.B for the calibration of thermocouples.

(1) Note the limits of the repair thickness given in the related repair scheme.

(2) Maintain a minimum vacuum pressure of 0.75 bar (10.9 psi) or 560 mm Hg (22
inch Hg) inside the vacuum bag. The vacuum pressure must be recorded.

(3) Increase the temperature to that specified in the repair procedure (Refer to
Chapter 51-77-11 Code 911 NUM 031 ). The rate of increase of the temperature
must not be more than 3 °C (6 °F) per minute.

(4) Let the repair cure at the temperature and time specified in the repair procedure
(Refer to Chapter 51-77-11 Code 911 NUM 031 ).

(a) For core replacement

The curing temperature shall be carefully monitored by means of the
thermocouples installed at the bottom of the honeycomb core in
contact with the adhesive film (Refer to Chapter 51-77-11 Code 911
NUM 022 , Paragraph 2.B).
When heat can only be applied from one side of the repair, it can be
necessary to increase the output from the heating blanket in order to
achieve the curing temperature at the bottom of the honeycomb core.
The thermocouples installed on the sink around the core plug (Refer
to Chapter 51-77-11 Code 911 NUM 022 ) are used to avoid
temperature overshoot. That means, the skin temperature shall not
exceed 95 °C (203 °F) for 120 °C (250 °F) manufactured structures
and 150 °C (302 °F) for 180 °C (350 °F) manufactured structures.
Sufficient layers of breather material shall be positioned around the
edge of the core replacement area to fulfil these requirements (Refer
to Chapter 51-77-11 Code 911 NUM 022 , Paragraph 2.B).
If there is access to both sides of the repair, heating equipment shall
be installed on both sides. When heating from both sides, with a core
thicker than 45 mm (1.77 in), then use nominal cure time plus 15
minutes (-0, + 15 minutes).

(b) For curing of repair plies and doubler installation with adhesive film
Temperature shall be carefully controlled by means of the
thermocouples suitable positioned around the repair (Refer to
Chapter 51-77-11 Code 911 NUM 022 , Paragraph 2.A). The lowest
temperature recorded shall meet the curing temperature, as specified
by the repair procedure. The highest temperature recorded is used to
control the heating process to avoid temperature overshoot.

(5) In the event of a complete loss of heat input or vacuum pressure, due either to
bag / sealing failures or equipment failure during the repair, the procedure given
in Figure 001 Accelerated Cure by Heating and Hot Bonding Cure - Actions
Following Loss of Vacuum or Heating Failure during Cure Cycle must be followed.

(6) Check the heat application and vacuum record data before the next step of repair
procedure (Refer to Chapter 51-77-10 Code 911 NUM 004 ).

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Figure 002 Example of 120 °C (250 °F) Cure Cycle

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Release 6.0 A321 Structural Repair Manual

Figure 001 Accelerated Cure by Heating and Hot Bonding Cure - Actions Following Loss of Vacuum or Heating Sheet Rev Date:
Failure during Cure Cycle (Sheet 01) / 51-77-11-991-001 12/03/2019

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Figure 002 Example of 120 °C (250 °F) Cure Cycle   (Sheet 01) / 51-77-11-991-002 Sheet Rev Date: 12/03/2019

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