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Release 6.0 A321 Structural Repair Manual

Task 51-77-11-911-022
Installation of Vacuum Bag and Heating Equipment
Weight Variant Number: A321-100 WV000, A321-100 WV002, A321-100 WV003, A321-100 WV004, A321-100 WV005, A321-100
WV006, A321-100 WV007, A321-100 WV008, A321-200 WV000, A321-200 WV001, A321-200 WV002, A321-200 WV003, A321-200
WV004, A321-200 WV005, A321-200 WV006, A321-200 WV007, A321-200 WV008, A321-200 WV009, A321-200 WV010, A321-200
WV011
Effective on: ALL

WARNING: OBEY THE MANUFACTURER'S INSTRUCTIONS WHEN YOU USE CLEANING AGENTS, ADHESIVES, SEALANTS AND PAINTS.
THESE MATERIALS ARE DANGEROUS.
WARNING: WEAR THE CORRECT PROTECTIVE GLOVES AND FILTER MASK WHEN YOU CUT, ABRADE OR DRILL COMPOSITE
MATERIALS. THE DUST FROM COMPOSITE MATERIALS CAN GET INTO YOUR LUNGS OR ON TO YOUR SKIN AND CAN BE
THE CAUSE OF INJURY AND SKIN IRRITATION.
WARNING: CARBON DUST IS ELECTRICALLY CONDUCTIVE AND CAN CAUSE AN EXPLOSION. WHEN YOU WORK WITH CFRP
COMPOSITE MATERIALS IMMEDIATELY REMOVE DUST WITH A VACUUM CLEANER.
WARNING: USE AN ISOLATION TRANSFORMER WHEN YOU USE MAINS ELECTRIC POWER ON THE AIRCRAFT. YOU MUST ONLY USE
POWER TOOLS AND EQUIPMENT THAT ARE EXPLOSION PROOF.
NOTE: There are risks to you and other persons when you work with composite repair materials. To prevent any risks, read and obey
the warnings given above.
1. Task Supporting Data

A. General

(1) The information in this topic is about the general procedures for the preparation of the
repair areas and the repair materials. General data for the procedures are included. The
applicable material data is also provided.

B. When you make permanent repairs the material must, as a general rule, match the original material as
follows:

‡ only carbon fiber material to repair carbon fiber structures,

‡ only glassfiber material to repair glassfiber and aramid fiber structures.

C. The contents of this task is applicable for Installation of Vacuum Bag and Heating Equipment:

D. Area of Applicability

E. Weight Variant Applicability

F. Limits/Restrictions

G. Repair Category

H. Inspections

I. Job Set Up Information

(1) Material References

(2) References

2. Repair Procedure

A. For curing of repair plies Refer to Figures 002 Lay Up for Cure with Heating Blanket and 003 Lay Up for Repair Cure with
Radiant Heat
NOTE: Refer to Chapter 51-77-11 Code 911 NUM 002 for information concerning the auxiliary materials required.

(1) Place a layer of peel ply over the repair plies. The peel ply must extend 12 mm (0.47 in.) beyond the
edge of the repair.

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(2) Apply vacuum bag sealant tape around the periphery of the repair area, preferably 150 mm (5.91 in.)
beyond the largest repair ply.

(3) Position thermocouples evenly spaced around the edge of the repair area. The recommended spacing for
satisfactory temperature monitoring of a repair is 150 mm (6. in.) and the maximum spacing must not
exceed 300 mm (12. in.) Refer to Figure 001 Installation of Thermocouples for Skin Repair . The
thermocouples are placed 3 mm (0.12 in.) from the edge of the repair. Use a minimum of three
thermocouples. Do not allow thermocouples to cross and locate them perpendicular to the edge of repair
shape.
NOTE: In known areas of structural heat sink it is essential that additional thermocouples are placed
in position. That will confirm that the cure temperature has been achieved.
NOTE: If thermocouples are in contact with a metallic caul plate, the ends must be electrically
insulated with high temperature flash breaker tape. The caul plate can prevent thermocouples
imprinting into the repair, if they are placed between the heat blanket and the caul plate.
Some trials will be necessary to determine the correlation between the highest temperature
recorded on the blanket side of the caul plate, compared to the lower temperature on the
repair side.
NOTE: The highest temperature recorded from the thermocouples is used to control the heating
process to avoid temperature overshoot. The lowest temperature recorded is used to
determine the cure time.

(4) Place a layer of perforated parting film over the peel ply. The perforated film must extend 50 mm (1.97
in.) beyond the edge of the peel ply. Smooth the film to remove any wrinkles.

(5) Position a bleeder ply over the perforated parting film and extending 50 mm (1.97 in.) beyond the film
edge.
NOTE: When the heat source is an electric heating blanket, the bleeder ply must extend 50 mm
(1.97 in.) beyond the edge of the blanket.
NOTE: All joints in the bleeder plies must be butt joints, without overlaps or gaps, when the part is
covered.

(6) Position a layer of non-perforated parting film over the bleeder ply. Cut the non-perforated film so that
its edges are even with the edges of the perforated parting film.

CAUTION: PRESSURE ON THE REPAIR WILL BE LESS THAN UNIFORM IF THE OPTIONAL CAUL PLATE
DOES NOT CONFORM TO THE CONTOURS OF THE REPAIR. THIS MAY CAUSE VOIDS OR HIGH
RESIN CONTENT AREAS IN THE REPAIR PLIES.

(7) When a caul plate (optional) is to be used to cover the repair, first place a piece of glass fiber fabric over
the non-perforated parting film to act as a breather. Cut the breather plies so that they extend to the
edges of the bleeder plies. Position the metal caul plate.

(8) When the optional caul plate is not going to be used, position a piece of glass fiber fabric (breather
material) over the non-perforated parting film. Cut the breather material so that the edges extend to the
bleeder plies. Ensure that the breather material is in contact with the bleeder plies at the edges.
NOTE: The breather material will maximize heat transfer.

(9) Using an heating blanket as a heat source, refer to Figure 002 Lay Up for Cure with Heating Blanket .

CAUTION: REFER TO THE RELEVANT TASK FOR THE CALIBRATION AND CHECK OF THE
HEATING BLANKETS.

(a) Position the heating blanket over the top layer of breather material. Ensure that the blanket
extends for a minimum of 50 mm (1.97 in.) beyond the material to be cured.

(b) Add a further four or five layers of breather material over the blanket. This is to insulate and
prevent damage to the bagging film.
NOTE: An optional thermocouple can be positioned at the center of the blanket. This
will allow the temperature of the blanket to be monitored and prevent the
blanket from being overheated.

(c) Install two probes through openings cut in the vacuum bag, the probes should be on
opposite sides. The probes are placed on a pad of breather material situated near the edge

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of the upper breather layer. Do not place the probes on the repair area.

(d) Position the vacuum bag over the stacked materials, smooth out any wrinkles. Press the
edge of the vacuum bag on to the sealant tape in order to secure an air tight seal. Place
tucks in the vacuum bag to allow for gap material stretching and abrupt transitional or
contour changes.

CAUTION: CHECK THE VACUUM BAG FOR LEAKS.

(e) Apply a vacuum source to the vacuum bag and evacuate the space in the vacuum bag.
Smooth the bag by hand pressure as the air is removed.
Apply full vacuum to get a minimum of 0.75 bar (10.9 psi) or 560 mm Hg (22 inch Hg) and
wait for several minutes after the readings have stabilized.
Disconnect the vacuum source and re-seal if required. The maximum vacuum pressure drop
is to be less than 0.16 bar (2.3 psi) or 130 mm Hg (5 inch Hg) over 5 minutes.
Re-apply full vacuum. A minimum vacuum of 0.75 bar (10.9 psi) or 560 mm Hg (22 inch
Hg) is required for the curing process.

NOTE: Insulating material can be placed over the vacuum bag during the heating up
and hold phase to reduce heat loss.

(10) Using an infrared lamp or other radiant heat equipment, Refer to Figure 003 Lay Up for Repair Cure with
Radiant Heat .

CAUTION: REFER TO THE RELEVANT TASK FOR THE CALIBRATION OF THE RADIANT HEAT
EQUIPMENT.

(a) The vacuum bagging procedure to be used when using an infrared lamp or other radiant
heat equipment, is the same as that given in Paragraph 2.A.(9) above. Except that the
following items are not used:

‡ heating blanket

‡ the additional breather layers over the heating blanket

‡ the insulation material over the vacuum bag

(b) Install an additional thermocouple below the uppermost breather ply.

(c) Install a piece of dry carbon fabric over the uppermost breather ply.
Figure 001 Installation of Thermocouples for Skin Repair
Figure 002 Lay Up for Cure with Heating Blanket
Figure 003 Lay Up for Repair Cure with Radiant Heat

B. For core replacement - heating from one side Refer to Figure 004 Lay Up for Core Replacement with Heating Blanket -
Heating from one Side
NOTE: Refer to Chapter 51-77-11 Code 911 NUM 002 for information concerning the auxiliary materials required.

(1) Apply vacuum bag sealant tape around the periphery of the core replacement area, preferably 150 mm (5.91 in.)
beyond the largest repair ply.

(2) Position thermocouples as follows:

(a) In the repair area where the core plug is to be installed. The number of thermocouples to be used will be
JRYHUQHGE\WKHDUHD)RUDUHDVJUHDWHUWKDQPPðLQðGLYLGHWKHUHSDLULQWRHTXDODUHDVDQG
position thermocouples in the center of each of these areas in accordance with the following table:

REPAIR AREAS NUMBER OF THERMOCOUPLES

XSWRPPðLQð one

PPðLQðWRPPðLQð two

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REPAIR AREAS NUMBER OF THERMOCOUPLES

PPðLQðWRPPðLQð three

PPðLQðWRPPðLQð four

The thermocouple shall be have a turnover of at least 20 mm (0.787 in.), the whole of which shall make
intimate contact with the adhesive layer at the bottom of the plug.
NOTE: After the curing process is completed, it will be necessary to cut these thermocouples as close to the
surface of the honeycomb as possible without damaging the honeycomb.

(b) A minimum of two thermocouples shall be positioned on the skin around the core plug not more than 3 mm
(0.118 in.) from the edge of the core plug.
NOTE: In known areas of structural heat sink it is essential that additional thermocouples are placed in position to
confirm that the cure temperature has been achieved.

(3) Position a strip of high temperature resistant tape over the area of the core plug splice.

(4) Position a layer of perforated parting film over the core replacement area. The film must extend 75 mm (2.95 in.)
beyond the edge of the replacement area. Smooth out any wrinkles.
NOTE: 8VHDSHUIRUDWHGSDUWLQJILOPZLWKDPLQLPXPXVHWHPSHUDWXUHRIƒ&ƒ)UHIHUWRChapter
51-77-11 Code 911 NUM 002 , Paragraph 2.A.

(5) Position several layers of breather material around the edge of the core replacement area. This is to insulate the
original structure in the repair area.
NOTE: Use either (preferred) 20 plies of fiberglass cloth style 181 or 7781 or 1581, refer to Chapter 51-77-11
Code 911 NUM 002 , Paragraph 2.A.
or
5 plies minimum of polyester felt with a fiberglass cloth on top, refer to Chapter 51-77-11 Code 911
NUM 002 , Paragraph 2.A. Use new breather for each cure cycle.

(6) Position a piece of glass fiber fabric over the perforated parting film to act as a breather material. Ensure that the
breather layer makes contact with the edge breather.

(7) Using a heating blanket as a heat source.

CAUTION: REFER TO THE RELEVANT TASK FOR THE CALIBRATION AND CHECK OF THE HEATING
BLANKETS.

(a) Position the heating blanket over the top layer of breather material. Ensure that the blanket extends
for a minimum of 100 mm (4.0 in.) beyond the material to be cured.

(b) Add a further four or five layers of breather material over the blanket. This is to insulate and prevent
damage to the bagging film.
NOTE: An optional thermocouple can be positioned at the center of the blanket. This will allow
the temperature of the blanket to be monitored and prevent the blanket from being
overheated.

(c) Install two probes through opening cuts in the vacuum bag. The probes should be on opposite sides
and placed on a pad of breather material situated near the edge of the upper breather layer. Do not
put the probes on the repair area.
NOTE: One probe is connected to the vacuum source, the other probe is connected to a vacuum
gage.

(d) Position the vacuum bag over the stacked materials, smooth out any wrinkles. Press the edge of the
vacuum bag on to the sealant tape in order to secure an air tight seal. Place tucks in the vacuum
bag to allow for gap material stretching and abrupt transitional or contour changes.

CAUTION: CHECK THE VACUUM BAG FOR LEAKS.

(e) Apply a vacuum source to the vacuum bag and evacuate the space in the vacuum bag, smooth the

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bag by hand pressure as the air is removed.
Apply full vacuum to get a minimum of 0.75 bar (10.9 psi) or 560 mm Hg (22 inch Hg) and wait for
several minutes after the readings have stabilized.
Disconnect the vacuum source and re-seal if required. The maximum vacuum pressure drop is to be
less than 0.16 bar (2.3 psi) or 130 mm Hg (5 inch Hg) over 5 minutes.
Re-apply full vacuum, a minimum vacuum of 0.75 bar (10.9 psi) or 560 mm Hg (22 inch Hg) is
required for the curing process.

NOTE: Insulating material can be placed over the vacuum bag during the heating up and hold
phase to reduce heat loss.
Figure 004 Lay Up for Core Replacement with Heating Blanket - Heating from one Side

C. For core replacement - heating from both sides Refer to Figure 005 Lay Up for Core Replacement with Heating Blanket -
Heating from both Sides
NOTE: Refer to Chapter 51-77-11 Code 911 NUM 002 for information concerning the auxiliary materials required.

(1) Apply vacuum bag sealant tape around the periphery of the core replacement area, preferably 150 mm (5.91 in.)
beyond the largest repair ply.

(2) Put the thermocouples as follows in position:

(a) In the repair area where the core plug is to be installed. The number of thermocouples to be used will be
JRYHUQHGE\WKHDUHD)RUDUHDVJUHDWHUWKDQPPðLQðGLYLGHWKHUHSDLULQWRHTXDODUHDVDQGSXW
thermocouples in the center of each of these areas in position in accordance with the following table:

REPAIR AREAS NUMBER OF THERMOCOUPLES

XSWRPPðLQð one

PPðLQðWRPPðLQð two

PPðLQðWRPPðLQð three

PPðLQðWRPPðLQð four

The thermocouple shall be have a turnover of at least 20 mm (0.787 in.), the whole of which shall make
intimate contact with the adhesive layer at the bottom of the plug.
NOTE: After the curing process is completed, it will be necessary to cut these thermocouples as close to the
surface of the honeycomb as possible without damaging the honeycomb.

(b) A minimum of two thermocouples shall be positioned on the external skin around the core plug not more
than 3 mm (0.12 in.) from the edge of the core plug. A minimum of 2 thermocouples shall be positioned on
the opposite skin, one thermocouple located at the center of the repaired area. To prevent excessive mark off
do not cross the thermocouples.
NOTE: In known areas of structural heat sink it is essential that additional thermocouples are placed in
position to confirm that the cure temperature has been achieved.

(3) Put a strip of high temperature resistant tape in position over the area of the core plug splice.

(4) Put a layer of perforated parting film over the core replacement area in position. The film must extend 75 mm (3.0
in.) beyond the edge of the replacement core. Smooth out any wrinkles.

(5) Put a layer of glass fiber fabric as breather material in position over the perforated parting film. If an edge
breather is used, make sure that the layer of breather material makes contact with the edge breather.
NOTE: Optional: Put a thin caul plate on top of the parting film in correct position, with same dimensions as
the heating blanket.

(6) Use a heating blanket as a heat source.

CAUTION: REFER TO THE RELEVANT TASK FOR THE CALIBRATION AND CHECK OF THE HEATING
BLANKETS.

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(a) Put the heating blanket over the top layer of breather material in position. Make sure that the
blanket extends for a minimum of 100 mm (4.0 in.) beyond the material to be cured.

(b) Put one piece of breather material over the heating blanket. Make sure that the layer of breather
material makes contact with the edge breather.
NOTE: An optional thermocouple can be positioned at the center of the heating blanket. This, to
monitor the temperature of the blanket and prevent the blanket from being overheated.

(c) Install two probes through opening cuts in the vacuum bag. The probes should be on opposite sides
and placed on a pad of breather material, situated near the edge of the upper breather layer. Do not
put the probes on the repair area.
NOTE: One probe is connected to the vacuum source, the other probe is connected to a vacuum
gage.

(d) Put the vacuum bag over the stacked materials in position and smooth out any wrinkles. Press the
edge of the vacuum bag on to the sealant tape in order to secure an air tight seal. Place tucks in the
vacuum bag to allow for gap material stretching and abrupt transitional or contour changes.

(e) Put the heating blanket over the opposite (bottom) skin in position. Make sure that the blanket
extends for a minimum of 50 mm (2 in.) beyond the material to be cured.

(f) To avoid the distortion of thin skins support the bottom skin.

(g) Put a piece of breather material over the heating blanket in position. Make sure that the layer of
breather material makes contact with the edge breather.

(h) Install two probes through opening cuts in the vacuum bag. The probes should be on opposite sides
and placed on a pad of breather material, situated near the edge of the upper breather layer. Do not
put the probes on the repair area.
NOTE: One probe is connected to the vacuum source, the other probe is connected to a vacuum
gage.

(i) Put the vacuum bag over the stacked materials in position and smooth out any wrinkles. Press the
edge of the vacuum bag on to the sealant tape in order to secure an air tight seal. Place tucks in the
vacuum bag to allow for gap material stretching and abrupt transitional or contour changes.

(j) Apply a vacuum source to the vacuum bag installed over the repaired area and evacuate the space in
the bag. Smooth the bag by hand pressure as the air is removed. Apply 0.5 bar (7.3 psi) to 0.6 bar
(8.7 psi) with vacuum 400-500 mm Hg (15.75 -19.7 inch Hg) during the curing cycle.
NOTE: Insulating material can be placed over the vacuum bag during the heating up and hold
phase to reduce heat loss.

(k) Apply a vacuum source to the opposite (bottom) vacuum bag and evacuate the space in the bag.
Smooth the bag by hand pressure as the air is removed. Pull full vacuum.
Figure 005 Lay Up for Core Replacement with Heating Blanket - Heating from both Sides

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Figure 001 Installation of Thermocouples for Skin Repair (Sheet 01) / 51-77-11-991-001 Sheet Rev Date: 12/03/2019

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Figure 002 Lay Up for Cure with Heating Blanket (Sheet 01) / 51-77-11-991-002 Sheet Rev Date: 12/03/2019

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Figure 003 Lay Up for Repair Cure with Radiant Heat (Sheet 01) / 51-77-11-991-003 Sheet Rev Date: 12/03/2019

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Figure 004 Lay Up for Core Replacement with Heating Blanket - Heating from one Side (Sheet 01) / 51- Sheet Rev Date:
77-11-991-004 12/03/2019

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Figure 005 Lay Up for Core Replacement with Heating Blanket - Heating from both Sides (Sheet 01) / Sheet Rev Date:
51-77-11-991-005 12/03/2019

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