Composite System Auditing

C.A.S.E.
 Introduction
 Timothy J. Willyard
 Quality Engineer Specialist
 NORDAM Repair Division
 C.A.S.E. Instructor ARSS

 C.A.S.E. Level IV Auditor ARSS

 C.A.S.E VP, Training Co-Chair, ARSS Vice-Chair

 AS9100:2009 Rev C Lead Auditor

 A & P License

 6 years???
 Introduction Continued
 Please tell us your
 Name,

 Company,

 Title, and

 Composite Audit experience

 Topics of Discussion
 Vendors
 Transporting
 Receiving Inspection
 Storage
 Work Record (Traveler)
 Metal Processing
 Bond Room
 Lay-up process
 Consumables
 Portable Bonder & Autoclave Process
 Process verification
 The Goal
 Check List Development
 Composite
 What is a “Composite”?
 A "composite" is when two or more different materials
are combined together to create a superior and
unique material.
 The history of composites dates back to ancient
times for construction applications; straw was mixed
with mud to form a building material known as adobe
 Vendors
 Material Manufacture
 Authorized Distributor
 Second use Supplier (remaining material)
 Per aircraft OEM part specifications

 Per customer specifications

 Per vendor developed / FAA acceptable

 Per material manufacture specifications

 Transporting
 Monitor Material Transport
 Objective evidence

• Temperature recorder
 Material Identification
 Material Certs.

 Material Label

 Shipper
 Receiving Inspection
 Review Purchase Order requirements
 Per Material Manufacture specifications

 Per Aircraft OEM specifications

 Verify material traceability

 Roll, Batch, and Lot numbers
 Receiving Inspection
 Verify C.O.A. Certificate of Analysis
• Material test values
• Compliant material
 C.O.C. Certificate of Conformance

• Compliant process
 Review temperature recorder graph/chart
 Two per shipment

• Out time may have to be reduced

 Certificate of Analysis
Provides test values
 Temperature Recorder
 Digital temperature recorders with each shipment
 Temperature Recorder/Chart
 Analog temperature recorder/chart
 Temperature Recorder Chart
 Digital temperature graph
 Temperature Recorder Chart
 Digital temperature printout
 Storage
 Review storage requirements
 Per material manufacture specifications

 Per vendor developed / FAA acceptable

 Material supported by tube ends, not contacting

the floor
 Material segregation

• Acceptable from rejected

 AC 43-214 7. c (1)
 (1) Material must be supported by the ends of the support tube,
or in its original shipping container, to prevent flat spots on the
material. Stacking of rolls on top of one another is not allowed.
 Material
 Support material by the tube
 Storage
 Review storage requirements
 Review temperature chart

• Current and historical

 High temperature alarms

 Low temperature alarms

 Loss of power alarms

 Freezer
 0° Freezer
 Material log
 Review material history
 Per material manufacture specifications

 Per vendor developed / FAA acceptable

 Material traceability information

 Time in and out of the freezer, tracking

 Minimum of 8 hrs. for 0° & minimum 6 hrs. for 40°

• No moisture on bag prior to opening the

material bag
• Ambient air temp affects the material’s thaw
rate.
• Warm to touch
 Work Record (Traveler)
 Bonding
 Work instructions

 Maintain traceability

 Per aircraft OEM part specifications

• Per Air Carrier’s CAMP

 Vendor developed / FAA accepted
 Metal Processing
 Skins, core, and details
 Per aircraft OEM part specifications

 Per customer specifications

 Per vendor developed / FAA acceptable

 Per material manufacture specifications

 Operation instructions

• Phosphoric Acid Anodize (PAA) capabilities

 Calibrated timer

 Carriage system, doesn’t drip oil/grease

 Solution testing

• Acid, Alkaline, Rinse water

• Process verification records
 Clean Line
 Material staging area
 Clean Line
 Metal processing Line
 Clean Line Controls
 Phosphoric Acid Anodize controls
 Clean Room
 Positive air pressure
 Temperature and humidity controlled
 Filtered air
 Filters changed regularly

 No Internal combustion powered engines

hydrocarbons!
 Electric only

 No release agents
 No food or drink
 Lab coats, gloves, hand lotions, etc.
 Clean Room
 Cleanroom, Contamination Containment Area, CCA
 Positive pressure with air filtration
 Clean Room
 Cleanroom, Contamination Containment Area
 Material
 Support material by the tube
 Monitor Clean Room
Temperature & Humidity chart
Dust Particle collector (black tube & funnel)
 Clean Room
 Cleanroom, Contamination Containment Area
 Clean Room
 Cleanroom, Contamination Containment Area
 Forklift
 No Hydrocarbons in clean room
 Clean Room
 No un-cured or excessive release agents on tools
 No dust on tool surface or frame
 No hand creams
 Gloves must be worn when working with Metal and
adhesives
 Materials must be cut on a urethane surface
 No cardboard, wood, or metal; no scissors.

 No drilling / grinding
 Bonding Specifications
 Laminate
 Material manufacture specification

• BMS8-79, 250° Prepreg Fiberglass

 Aircraft OEM part specification

• BMS5317, Bonding process general

 Metal bond
 Material manufacture specification

• BMS5-101, 250° Adhesive

 Aircraft OEM part specification

• BMS5514, Bonding process general

 Vendor developed / FAA acceptable
 757 Spoiler
 Notice layers and direction of carbon fiber / “graphite”
 Lay-up Process
 Contained in work record (Traveler)
 or by referenced specification

• On hand or available in work area

 Cover part prior to exiting cleanroom/CCA
 Consumable materials
 Release cloth

 Manifold material

 Bagging material

 All materials must be per process specification

 Lay-up Process
 Bagging (general)
 Vacuum leak = 1”Hg a minute

 10”Hg max – High vacuum, 30Hg or less

• Metal to metal
• Laminates without honeycomb core
 5”Hg max – low vacuum, 15”Hg or less

• Laminates with honeycomb core

 Blocker Door
 Blocker Door ready for vacuum bagging process
 Breather Material
 Allows the evacuation of air from a vacuum bag
 Valve
 Valve for removing air from the vacuum bag
 Trans Cowl
 Cowling ready for cure in the autoclave
 Portable Bonder Topics of
Discussion
 Types of Portable Bonders
 Specifications
 Operation
 Planning
 Calibration
 Process
 Hot Bonder
 Portable Hot Bonder
 Portable Bonder Types
 Heat Lamps
 Heat pads
 Portable Bond System
 Portable Bonder Specifications
 Portable Bond System
 Per aircraft OEM part specifications

 Per customer specifications

 Per vendor developed / FAA acceptable

 Per material manufacture specifications

 Portable Bonder Operation
 Operation instructions
 Per Manufactures specifications

 Per Material Manufacture specifications

 Per Aircraft OEM part specifications

 Per vendor developed / FAA acceptable

Portable Bonder Calibration
 Transducers
 Chart recorder
• Vacuum, Temp
 Gages
• Vacuum, Temp
 Software validation
 TC wire verification
 Heat Pad survey
 Heat Lamp verification
 Portable Bonder Process
 Set-up Bonder
 Verify vacuum Bag (general)

• Vacuum valves & TC wires

 Vacuum leak = 1”Hg a minute

 10”Hg max or 5”Hg max

 Cure observation
 Monitor cure parameters

• Bonder output; Temp and Vacuum every 5 to

10 minutes
• Part reading; Temp and Vacuum every 5 to 10
minutes
 Portable Bonder Process
 End cure cycle
 10”Hg max or 5”Hg max

 Part less than 140°

 Bonder Process Verification
 Cure verification
 Chart review

 Ramp rates & Soak times

 Temp and Vacuum readings

• Bonder output and part

 Process coupon destructive test

• Typically not required

◊ Laminates: ◊ Metal bond:
– Compression - Lap shear
– Flatwise tensile - Drum peel
 Test Coupon
 Lab request to track destructive test results
 Bonder Process Verification
 Work record review
 Verify material traceability & expiration dates

 Verify mechanic process sign-off & date

• Verify mechanic’s training record

 Autoclave Topics of Discussion
 Specifications
 Operation
 Planning
 Calibration
 Process
 Emergency Methods
 Equipment Safety
 Autoclave
Autoclave 60’ X 10’ 450° 100psi maximum
 Autoclave Controls
 Manual & Computerized
 Oven
 Oven
 Oven Controls
 Manual & Computerized
 Autoclave Specifications
 D38558-1
 Mechanical and Vessel design

 D38558-2
 Instrumentation and Control

 D38558-3
 Codes and Industry standards
 Autoclave Operation
 D6-49327
 Identify equipment and operating requirements of autoclaves
 Operation instructions
 Per Material Manufacture specifications

 Per Aircraft OEM part specifications

 Developed internally, FAA Acceptable

 Autoclave Calibration
 Transducers
 Chart recorder
• PSI, Vacuum, Temp
 Gages
• PSI, Vacuum, Temp
 Software validation
 Heat survey
 Autoclave Process
 Loading autoclave
 Verify vacuum Bag (general)

 Vacuum valves & TC wires

 Vacuum leak = 1”Hg a minute

 10”Hg max

 Cure observation
 Monitor cure parameters

• Clave; Temp, PSI every 10 minutes

• Parts; Temp and Vacuum every 10 minutes
 Autoclave Process
 Unloading autoclave
 Zero PSI

 Autoclave & Parts less than 140°

 Autoclave Emergency Methods
 Procedures for
 Fire

• Maintain pressure, reduce air temp, extinguish fire.

 Excessive temp
 Excessive pressure
 Blown vacuum bag
 Loss of power

 Any of the above events require Engineering

evaluation/disposition of the part
 Autoclave Equipment Safety
 Safety devices
 Man in clave switch

 Oxygen sensors

 Over pressurization alarm

 High temperature Alarm

 Prevent fires with the use an inert gas;

• e.g. Nitrogen
 Autoclave Equipment Safety
 Cyclic fatigue and corrosion
 NDI methods ET, UT, MT

 Door interlock mechanism

 Pressure vessel laws

 ASME Pressure Vessel Code

 State Pressure Vessel Code

 Autoclave Process Verification
 Cure verification
 Chart review

 Ramp rates & Soak times

 Temp, PSI, and Vacuum readings

• Both autoclave and parts

 Autoclave Process Verification
 Cure verification
 Process coupon destructive test

• Laminates: Metal bond:

– Compression - Lap shear
– Flatwise tensile - Drum peel
 Work record review
 Verify material traceability & expiration dates

 Verify mechanic process sign-off & date

• Verify mechanic’s training record

 What is the goal?
 Confidence in the process
 Process control

 Process repeatability

 Acceptable parts
 Safety! Is the Goal
 The bonding process is critical to flight safety!
 Regulatory compliance
 FAR 145, Repair Station
 FAR 145.61, Limited Rating
 FAR 145.151, Personnel Requirements
 Customer specific requirements
 FAR 145.205.a, Continuous Airworthiness Requirements
 AC 145-6, Repair Stations for Composite and
Bonded Aircraft Structure
 Order 8110.54, Instructions for Continued
Airworthiness
 Audit Check List
 Develop a list that addresses the following,
 Verify vendors / suppliers are approved

 Verify receiving inspection

• Purchase order, COA, Temp recorder chart

 Verify material storage

• Material Identification, segregation

• Temperature charts, Alarms
• Handling of material
 Metal processing

• List what process Specification is used

• Titration test, acid, alkaline, and rinse water
 Audit Check List Continued
 Clean room
• Housekeeping (no dust & no trash)
• Good lighting
• Filtered, Positive air pressure
• Look for contaminates
• Electric motors only (No Hydrocarbons)
• Bond tools clean
• No drilling / grinding
• Gloves worn (Metal Bond and Adhesives)
 Audit Check List Continued
 Portable Bonder Process
• Per Material Manufacture specifications
• Per Aircraft OEM part specifications
• Per Customers specifications
• Per Vendor developed data (FAA acceptable)
• Review charts
– Ramp and Cure times
– Temp and Vacuum levels
 Audit Check List Continued
 Autoclave Process
• Per Material Manufacture specifications
• Per Aircraft OEM part specifications
• Per Customers specifications
• Per Vendor developed data (FAA acceptable)
• Review charts
– Ramp & Cure times
– PSI, Temp, and Vacuum levels
 Audit Check List Continued
 Work record review
 Review customer requirements (repair order)

 Verify instructions are per applicable data

 Verify material traceability & expiration dates

 Verify mechanic process sign-off & date

 Verify mechanic training record

 Verify equipment used

 Audit Check List Continued
 Process verification
• Sonic test (NDT)
• Coupon destructive testing
– Laminates
» Compression
» Flatwise tensile
– Metal bond
» Lap shear
» Drum peel
 Audit Check List Recap
 Verify vendors/suppliers
 Verify receiving inspection
 Verify calibration of instruments and gages
 Verify that Equipment Safety devices - functional
 Verify work record for compliance and completion
 Verify final inspection
 Verify employee training records
• Observe process in action
• Interview process technicians
• Obtain objective evidence
 Photos
 The following slides should aid your visual
identification/ recognition during an audit of a
composite bonding facility.
 Prime Both
 Adhesive primer booth
 Monitor Prime Booth
 Temperature & Humidity chart
 Tool & Part Numbers
 Tool identification and Part identification
 Tool Verification
 Traceability for tool manufacture and calibration/verification
 Flammability
 Proper storage of flammable materials
 Summarize & Review
 What have you learned?
 The basics about composite bonding

 Rely on your auditing skills

 Review their process for adequacy

• Per Air Carrier’s CAMP

 Verify their process for compliance
 Questions?
 What haven't you learned?
 Anyone, anyone?
 Thank you
Thank you for your participation.
Contact information

 Timothy J. Willyard
 twillyard@nordam.com

 918-878-6042 office

 918-815-4282 mobil

 918-878-6618 fax