Composite Materials & Repair Flashcards
7 cards from real ACS practice questions. Tap to flip, then mark Knew It or Still Learning — missed cards come back until you master them.
Read the first 7 Composite Materials & Repair flashcards as text
Moisture contamination in a composite honeycomb panel is MOST commonly found using which inspection technique?
Answer: Infrared thermography or radiographic (X-ray) inspection
Infrared thermography detects temperature differences caused by water-filled cells, and X-ray radiography can reveal water pooling patterns inside honeycomb cells.
When performing a flush repair on a composite skin, the stepped preparation method differs from a scarf by:
Answer: Removing material in discrete flat steps equal to one ply thickness each rather than a continuous taper
A stepped repair removes each ply in a flat step (typically 0.5–1 inch per step), while a scarf creates a continuous angular taper through the laminate thickness.
Which safety precaution is MOST critical when sanding or grinding carbon fiber composites?
Answer: Using respiratory protection (P100 respirator) and skin coverage to prevent inhalation and irritation
Carbon fiber dust is a respirable particulate and a skin irritant; NIOSH-approved P100 respirators and protective clothing are required during any dry sanding or grinding.
A co-cure composite repair differs from a secondary bonded repair in that:
Answer: Co-cure cures the repair plies and the bond to the parent structure simultaneously in one step
In co-cure, uncured repair plies are placed directly on the prepared parent surface and cured together, forming the bond and curing the laminate in a single heat cycle.
When the repair data in the Structural Repair Manual (SRM) does not cover the type or size of damage found, the technician must:
Answer: Contact the aircraft manufacturer's engineering department for a specific repair disposition
When damage exceeds SRM limits or the damage type is not covered, FAA regulations require contacting the Type Certificate holder (manufacturer) for engineering approval of the repair.
What is the MAIN reason that cure pressure is applied during composite repair?
Answer: To consolidate plies, remove voids, and ensure intimate fiber-to-matrix contact
Applied pressure (via vacuum bag or autoclave) compacts the fiber layers, expels entrapped air and excess resin, and ensures full consolidation for maximum structural properties.
After completing a composite skin repair, what is the FIRST post-cure inspection step before returning the aircraft to service?
Answer: Perform a tap test and visual inspection of the repair area to verify consolidation and surface quality
A post-cure tap test and visual inspection verify that the repair is void-free, properly consolidated, and bonded before any finish work or return-to-service is authorized.