DOC AIRBUS | AMM A320FRepairs of Cabin Polycarbonate Composite-Components with Honeycomb Core
TASK 25-00-00-340-007-A
Repairs of Cabin Polycarbonate Composite-Components with Honeycomb Core
Self explanatory
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment
B. Consumable Materials
C. Referenced Information
3. Job Set-up
Subtask 25-00-00-861-062-A Subtask 25-00-00-020-065-A
Subtask 25-00-00-340-060-A
Subtask 25-00-00-942-068-A
[Rev.10 from 2021]
2026.03.31 23:27:36 UTC
Repairs of Cabin Polycarbonate Composite-Components with Honeycomb Core
WARNING:
BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.
1. Reason for the JobSelf explanatory
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment
| REFERENCE | QTY | DESIGNATION |
|---|---|---|
| No specific | 1 | CLOTH-EMERY (GRADE 320 - 400) |
| No specific | 1 | CUTTER - THIN BLADE |
| No specific | 1 | DRILL DIA 3 MM (0.118 IN) |
| No specific | 1 | PLATE - BASE, RUBBER |
| REFERENCE | DESIGNATION |
|---|---|
| (Material No.05FCE1) | Polyurethane Adhesive-Equipment & Furnishing Two parts - |
| (Material No.08BBD1) | Non Aqueous Cleaner-- Isopropyl Alcohol - |
| (Material No.13ABC1) | Dry glass fabric-4H Satin 105 gsm - 120 style SRM Type 2 - |
| (Material No.13SBB1) | Honeycomb core-Aramide - hexagonal 1/8 - 3.0 - |
| (Material No.13TBC1) | Rigid Foam-Closed Cell Density 75 kg/m3 - |
| (Material No.14SBA1) | Textile-Lint free Cotton - |
| No specific | separating foil |
| REFERENCE | DESIGNATION |
|---|---|
| TASK 24-42-00-861-001-A | Energize the Ground Service Network from the External Power |
| TASK 24-42-00-862-001-A | De-energize the Ground Service Network Supplied from the External Power |
| TASK 25-20-00-370-006-A | Repair of the Paint Coat on Components |
Polycarbonate Composite ComponentsSubtask 25-00-00-861-062-A Subtask 25-00-00-020-065-A
B. If necessary, remove the component you will repair from the aircraft (refer to the related AMM chapter).
4. ProcedureSubtask 25-00-00-340-060-A
A. Repair of Polycarbonate Composite Components with Honeycomb Core
(1) Make sure that:
(a) The clearance to edges is:
(a) Carefully make the crack in the polycarbonate surface layer larger. The maximum width of the crack must be equal to the component thickness.
(b) Stop-drill the ends of the crack with a DRILL DIA 3 MM (0.118 IN).
(c) Remove the damage that went through the component with a CUTTER - THIN BLADE.
(d) Make the repair area smooth with a CLOTH-EMERY (GRADE 320 - 400).
(e) Clean the repair area with Non Aqueous Cleaner-- Isopropyl Alcohol - (Material No.08BBD1) and a Textile-Lint free Cotton - (Material No.14SBA1) .
(3) Repair the damage that is less than 10 mm (0.4 in.) in diameter at upper surface and at core material on flat and rounded components:
(a) Apply the separating foil (4) to the front face of the component (3).
(b) Put the component (3), front face down, on a PLATE - BASE, RUBBER (5).
(c) Fill the damaged area with Polyurethane Adhesive-Equipment & Furnishing Two parts - (Material No.05FCE1) .
(d) Let the adhesive cure as specified by the manufacturer.
(e) Remove the separating foil (4) from the component (3).
(f) Fill the areas that are not smooth with Polyurethane Adhesive-Equipment & Furnishing Two parts - (Material No.05FCE1) .
(g) Let the adhesive cure as specified by the manufacturer.
(h) If necessary, make the repair smooth with a CLOTH-EMERY (GRADE 320 - 400).
(4) Repair the damage that is 10 mm (0.4 in.) or larger in diameter at upper surface and at core material on flat components:
(a) Make sure that the minimum distance from the edge of the stiffener (8) to the damaged area is 20 times the component thickness.
(b) Make a repair plug (7) from the applicable polycarbonate material.
(c) Make a stiffener (8) from the applicable polycarbonate material.
1 If the component is rounded, make a stiffener (8) from Dry glass fabric-4H Satin 105 gsm - 120 style SRM Type 2 - (Material No.13ABC1) .
(d) Make a stiffener (1) from Dry glass fabric-4H Satin 105 gsm - 120 style SRM Type 2 - (Material No.13ABC1) .
1 If the rear side of the component is made of polycarbonate material, make a stiffener (1) from the same material. Chamfer the edges of the polycarbonate stiffener to 45 degrees.
(e) Make an insert (9) of13TBC1 Rigid Foam-Closed Cell Density 75 kg/m3 - 13SBB1 Honeycomb core-Aramide - hexagonal 1/8 - 3.0 -
(f) Chamfer the edges of the polycarbonate surface layer (6) to 45 degrees.
(g) Chamfer the edges of the repair plug (7) to 45 degrees.
(h) Apply the separating foil (4) to the front face of the component (3).
(i) Put the component (3), front face down, on a PLATE - BASE, RUBBER (5).
(j) Bond the repair plug (7) to the component (3) with Polyurethane Adhesive-Equipment & Furnishing Two parts - (Material No.05FCE1) .
(k) Apply Polyurethane Adhesive-Equipment & Furnishing Two parts - (Material No.05FCE1) to the repair area, stiffener (8), insert (9) and honeycomb and put them together.
(l) Let the adhesive cure as specified by the manufacturer.
(m) Make the repair smooth with a CLOTH-EMERY (GRADE 320 - 400).
(n) Clean the repair area with Non Aqueous Cleaner-- Isopropyl Alcohol - (Material No.08BBD1) and a Textile-Lint free Cotton - (Material No.14SBA1) .
(o) Apply Polyurethane Adhesive-Equipment & Furnishing Two parts - (Material No.05FCE1) to the repair area.
(p) Attach the stiffener (1) to the repair area.
1 Make sure that:
(r) Fill the areas that are not smooth with Polyurethane Adhesive-Equipment & Furnishing Two parts - (Material No.05FCE1) .
(s) Let the adhesive cure as specified by the manufacturer.
(t) If necessary, make the area of the repair smooth with a CLOTH-EMERY (GRADE 320 - 400).
(5) If necessary, apply a top layer (Ref. AMM TASK 25-20-00-370-006).
Subtask 25-00-00-420-062-A (1) Make sure that:
(a) The clearance to edges is:
- More than 300 times of Dry glass fabric-4H Satin 105 gsm - 120 style SRM Type 2 - (Material No.13ABC1) thickness
or - More than 100 times of damaged polycarbonate-surface layer-thickness.
- More than 800 times of Dry glass fabric-4H Satin 105 gsm - 120 style SRM Type 2 - (Material No.13ABC1) thickness
or - More than 250 times of damaged polycarbonate-surface layer-thickness.
- More than 500 times of Dry glass fabric-4H Satin 105 gsm - 120 style SRM Type 2 - (Material No.13ABC1) thickness
or - More than 150 times of damaged polycarbonate-surface layer-thickness.
(a) Carefully make the crack in the polycarbonate surface layer larger. The maximum width of the crack must be equal to the component thickness.
(b) Stop-drill the ends of the crack with a DRILL DIA 3 MM (0.118 IN).
(c) Remove the damage that went through the component with a CUTTER - THIN BLADE.
(d) Make the repair area smooth with a CLOTH-EMERY (GRADE 320 - 400).
(e) Clean the repair area with Non Aqueous Cleaner-- Isopropyl Alcohol - (Material No.08BBD1) and a Textile-Lint free Cotton - (Material No.14SBA1) .
(3) Repair the damage that is less than 10 mm (0.4 in.) in diameter at upper surface and at core material on flat and rounded components:
(a) Apply the separating foil (4) to the front face of the component (3).
(b) Put the component (3), front face down, on a PLATE - BASE, RUBBER (5).
(c) Fill the damaged area with Polyurethane Adhesive-Equipment & Furnishing Two parts - (Material No.05FCE1) .
(d) Let the adhesive cure as specified by the manufacturer.
(e) Remove the separating foil (4) from the component (3).
(f) Fill the areas that are not smooth with Polyurethane Adhesive-Equipment & Furnishing Two parts - (Material No.05FCE1) .
(g) Let the adhesive cure as specified by the manufacturer.
(h) If necessary, make the repair smooth with a CLOTH-EMERY (GRADE 320 - 400).
(4) Repair the damage that is 10 mm (0.4 in.) or larger in diameter at upper surface and at core material on flat components:
(a) Make sure that the minimum distance from the edge of the stiffener (8) to the damaged area is 20 times the component thickness.
(b) Make a repair plug (7) from the applicable polycarbonate material.
(c) Make a stiffener (8) from the applicable polycarbonate material.
1 If the component is rounded, make a stiffener (8) from Dry glass fabric-4H Satin 105 gsm - 120 style SRM Type 2 - (Material No.13ABC1) .
(d) Make a stiffener (1) from Dry glass fabric-4H Satin 105 gsm - 120 style SRM Type 2 - (Material No.13ABC1) .
1 If the rear side of the component is made of polycarbonate material, make a stiffener (1) from the same material. Chamfer the edges of the polycarbonate stiffener to 45 degrees.
(e) Make an insert (9) of
(f) Chamfer the edges of the polycarbonate surface layer (6) to 45 degrees.
(g) Chamfer the edges of the repair plug (7) to 45 degrees.
(h) Apply the separating foil (4) to the front face of the component (3).
(i) Put the component (3), front face down, on a PLATE - BASE, RUBBER (5).
(j) Bond the repair plug (7) to the component (3) with Polyurethane Adhesive-Equipment & Furnishing Two parts - (Material No.05FCE1) .
(k) Apply Polyurethane Adhesive-Equipment & Furnishing Two parts - (Material No.05FCE1) to the repair area, stiffener (8), insert (9) and honeycomb and put them together.
(l) Let the adhesive cure as specified by the manufacturer.
(m) Make the repair smooth with a CLOTH-EMERY (GRADE 320 - 400).
(n) Clean the repair area with Non Aqueous Cleaner-- Isopropyl Alcohol - (Material No.08BBD1) and a Textile-Lint free Cotton - (Material No.14SBA1) .
(o) Apply Polyurethane Adhesive-Equipment & Furnishing Two parts - (Material No.05FCE1) to the repair area.
(p) Attach the stiffener (1) to the repair area.
1 Make sure that:
- The total thickness of Dry glass fabric-4H Satin 105 gsm - 120 style SRM Type 2 - (Material No.13ABC1) (1) is equal to the initial polycarbonate layer (2).
- The minimum distance from the edge of the stiffener (1) to the insert (9) is 40 times the thickness of the polycarbonate layer (2).
(r) Fill the areas that are not smooth with Polyurethane Adhesive-Equipment & Furnishing Two parts - (Material No.05FCE1) .
(s) Let the adhesive cure as specified by the manufacturer.
(t) If necessary, make the area of the repair smooth with a CLOTH-EMERY (GRADE 320 - 400).
(5) If necessary, apply a top layer (Ref. AMM TASK 25-20-00-370-006).
B. If you removed the component to do the repair, install the component in the aircraft (refer to the related AMM chapter).
5. Close-upSubtask 25-00-00-942-068-A
A. Close-up
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Remove the ground support and maintenance equipment, the special and standard tools and all other items.
Subtask 25-00-00-862-062-A (1) Make sure that the work area is clean and clear of tools and other items.
(2) Remove the ground support and maintenance equipment, the special and standard tools and all other items.