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sandwich construction with damage
to the core. There is no damage
to the opposite laminate surface.
Sandwich penetration. This is
damage to both sides of sandwich
construction. Both laminate surfaces
are punctured and foam core
is exposed.
Repair classification
Now that we know what type
of damage we have, we need to
determine what type of repair
we are looking at. Cirrus breaks
repairs down into four categories:
cosmetic repair, minor repair,
major repair, and restricted repair.
Cosmetic repair. Cirrus classifies
a cosmetic repair as that
which is designed to repair localized
surface defects to the original
profile and to prevent UV damage
and moisture ingress. Cosmetic
repairs relate to minor defects
which have no significant effect
on the structural strength of the
structure.
Minor repair. Cirrus defines
minor and major repairs the same
as the FARs do. So, a minor repair
would be a repair that is not a
major repair.
Major repair. A major repair is
a repair, that if done improperly
might appreciably affect weight,
balance, structural strength, performance,
powerplant operation,
flight characteristics, or other
qualities affecting airworthiness;
or a repair that is not done
according to accepted practices
or cannot be done by elementary
operations.
Cirrus allows major repairs
in the field if the repair
area does not fall into a norepair
zone, and it does not
require non-standard repair
procedures. In addition,
field repair is allowed if the
repair is specifically covered
in the maintenance manual.
All other major repairs need
Cirrus Design engineering
disposition.
Restricted. Any repairs
that occur in no-repair zones
as listed in the maintenance
manual are restricted. The
mechanic needs to contact
Cirrus Design for disposition.
Once we have gotten to
this point, we know whether
or not a repair is allowed in
the area we are looking at.
We can then begin the repair
process. There are too many
possible repair scenarios to
cover in the limited space
here, but we can cover some
essential tips when performing
the repair.
Repair environment
One thing you need to be
aware of is the repair environment.
For cosmetic repairs, the
environment is not as critical.
However, Cirrus has stringent
environment requirements for
minor and major repairs.
From our own safety perspective,
we want to make sure the
repair is carried out in an area
that has adequate ventilation.
We also need to ensure that
we are performing the repair in a
controlled environment to ensure
proper integrity of the repair and
avoid any contamination issues.
See the Repair Environment sidebar
on this page for some guidelines
on proper composite repair
environment.
Ply orientation
When looking at a repair, we
need to know the ply lay-up. The
zone diagrams in chapter 51 of
the maintenance manual provide
that information. The charts contain
information such as ply count
and warp clocks. They show the
zero-degree reference for each
section of the airframe.
Here is a tip for determining ply
count. If you’re looking at a solid
laminate and don’t know the ply
count, you can measure the thickness
to determine it. The thickness
of one ply is generally between
0.008 and 0.010 inch. So, if you
measure the total thickness of the
laminate and divide by 0.009, you
can determine the ply count.
Wet lay-up
Cirrus has established a wet
lay-up composite repair process.
No vacuum system is necessary.
Volinkaty says that the repair procedure
was chosen so that shops
were not forced to buy expensive
curing equipment. Instead, the
mechanic fabricates a tent to create
an envelope around the repair
area. A dryer is used with a thermostat
to control the cure cycle of
the repair.
Repair Environment
Cirrus offers the following guidelines for setting
up a proper composite repair environment:
• The area must be completely enclosed.
• Temperature and humidity must be controlled
so that the minimum temperature is
60 F (16 C) with a corresponding relative
humitidy not greater than 71 percent and
the maximum temperature is 75 F (24 C)
with a corresponding relative humidity not
greater than 46 percent.
• The area where surface cleaning of the
　
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