Key Processing Issues for Bonded Repairs 2004-01-2816

Many questions have been directed in recent years to aircraft structural repair communities concerning bonded repairs. Areas of concern have primarily focused on surface preparation issues with the various types of composite and metallic structure, cure profiles, and quality assurance requirements. These questions have come from a variety of sources – within the OEM, from outside suppliers and from customers, both military and commercial. Some questions are asked in an effort to reduce the “down time” on an aircraft associated with these repairs. Others because of frequent “re-repairs” due to poor bond quality from a previous repair. Future design concepts are focusing on more “one-piece” types of structure that will rely on structural, durable repairs that can be performed with a minimal amount of facilities required. Based on the frequency and scope of past inquiries, a summary of recommendations and requirements is needed to preserve the integrity and possibly increase acceptance of bonded repairs in aerospace applications.