GULFSTREAM G650ER

STRUCTURAL REPAIR MANUAL

GLOSSARY OF STRUCTURAL TERMS — GENERAL

1. Glossary of Terms
Accelerator - A substance that hastens a chemical reaction or the solidification in the case of
thermosetting resins.
Acetone - A volatile, flammable liquid used as a cleaning solvent.
Adhered - A body that is held to another body, usually by an adhesive. A detail or part prepared for
bonding.
Adhesion - The state in which two surfaces are held together at an interface by mechanical and / or
chemical forces.
Adhesion failure - The failure of sealant to stick to surface to which it has been applied.
Adhesion promoter - A cleaning / surface preparation which improves adhesion to surface of sealants,
adhesives, coatings and metals.
Adhesive - A paste type substance, which when applied to two mating surfaces is capable of holding
them together by surface attachment.
Advanced composites - Composite materials applicable to aerospace construction and made by
imbedding high strength, high modulus fibers within a resin. Fiberglass is not considered an advanced
composite due to its low modulus fibers.
Alodine® - A trade name for chemical conversion coating.
Application life - The time available for sealant application after mixing or after thawing a premixed and
frozen cartridge of sealant. Sealant applied after stated application time is exceeded, tends not to wet
surface well and thus not form a good bond.
Assembly time - Also called squeeze-out time. A term used in reference to faying surface sealants. The
time after a sealant is mixed, before faying surfaces, to which sealant was applied, shall be closed or
squeezed out. If time is exceeded, cure will have progressed too far.
Autoclave - A pressure vessel either heated or capable of containing heated tools used to cure
composite structures. Most autoclaves, for this purpose, have connections for applying vacuum and
for monitoring temperatures and pressures within the vessel. Pressurizing is accomplished by means
of a gas, either relatively inert such as nitrogen or carbon dioxide or compressed air. Nitrogen and
carbon dioxide are favored for high temperature applications to avoid fires.
B stage - An intermediate cure stage in the reaction of certain thermosetting resins. The resin in an
uncured preimprenated (prepreg) is usually in this stage.
Barcol hardness - A hardness test used on composite laminates / repairs to determine degree of
hardness on cured material. Also used to determine hardness of aluminum.
Batch / Lot - A quantity of material formed during same process and having identical characteristics
throughout.
Bleeder - A nonstructural layer of material used in manufacturing of composite parts to allow escape of
excess gases and resins during cure. The bleeder is removed after curing process and is not part of
final product.
Blisters - Bubble like imperfections found in coating. Blisters are typically caused by contamination due
to improper or insufficient surface preparation, excessive use of thinner or accelerators, material
incompatibility and excessive film thickness.

51-06-00
Page 1
August 15/14
 GULFSTREAM G650ER
STRUCTURAL REPAIR MANUAL

Bond - A bond is any fixed union, existing between two metallic objects, that results in electrical
conduction between the objects having a resistance value equal to or less than specified in this
document. Such union results from either physical contact or the addition of a firm electrical
connection between conductive surfaces of the objects. The physical characteristics of the bond shall
meet the requirements of this document.
Bonding - Aircraft electrical bonding is the process of obtaining the specified electrical conductivity
between the bonded surfaces.
Bonding connectors - A bonding connector provides the specified electrical conductivity and physical
characteristics between metallic parts in an aircraft which would not otherwise be in sufficient electrical
contact. Examples of bonding connectors are bonding straps and bonding jumpers.
Blushing - White cloudy appearance of surface film.
Breakout - Fiber separation or break of surface plies during drilling, machining, etc.
Breather - A nonstructural layer of material used in manufacturing of composite and metal bonded parts
to provide venting and pressure uniformity under a vacuum bag. Distinguished from bleeder in resin
absorption because is not usually expected.
Bridging - A condition where one or more plies of prepreg material span a radius, step or chamfered
edge of core without full contact.
Broad goods - Uncured impregnated materials wider than 12 inches. These include woven fabrics and
tapes made either in one operation or by combining several narrow widths.
Catalyst - A substance that changes velocity of a chemical reaction (curing rate) and may be recovered
essentially unaltered in form or amount at end of reaction. See definition for Hardener and Inhibitor.
Caul plates / Blocks - Smooth plates, usually metal, used to equal out clamp up or pressure force and
temperature gradient and to assist in obtaining a smooth surface.
Center to center - The distance between center line of two fastener holes.
Chime - The top rim of a primer / paint can which lid press fits into upon closure.
Chipped area - Any area of missing fibers.
Co-cure - The process of curing several different materials in a single step.
Cohesive strength - The strength of adhesive to itself.
Coin tap - An inspection method used to sound out voids, unbonds and delaminations. The preferred
materials for tapping are copper or brass. Also called tap testing.
Cold bonded repair - A repair using adhesives that may be cured at room temperature or less than
180°F (82°C).
Compaction - The application of a temporary vacuum bag and vacuum to remove trapped air and
compact lay up prior to regular cure cycle.
Composite material - A combination of two or more materials (reinforcement elements, fillers and
composite matrix binder) differing in form or composition on a macro scale (large scale). The
constituents retain their identities; that is, they do not dissolve or merge completely into one another
although they act in concert. Normally, the components may be physically identified and exhibit an
interface between one another. Some examples would be mud and straw mixture used to construct
shelters and laminated wood.
Compaction - The application of a temporary vacuum bag and vacuum to remove trapped air and
compact lay up prior to regular cure cycle.

51-06-00
Page 2
August 15/14
 GULFSTREAM G650ER
STRUCTURAL REPAIR MANUAL

Composite material - A combination of two or more materials (reinforcement elements, fillers and
composite matrix binder) differing in form or composition on a macro scale (large scale). The
constituents retain their identities; that is, they do not dissolve or merge completely into one another
although they act in concert. Normally, the components may be physically identified and exhibit an
interface between one another. Some examples would be mud and straw mixture used to construct
shelters and laminated wood.
Condense core cells - Refers to honeycomb core materials. The core cells are pushed together to form
a denser (packed) cell column. See Figure 1.
Conducting surfaces or objects - All objects having a resistivity which does not exceed one megohm-
centimeter, for the purposes of this manual.
Core - The central member between two skins, providing a rigid lightweight assembly. Core material
may be made from wood, foam, aluminum or nomex strips. See Core, Honeycomb and Nomex.
Core, honeycomb - A generally hexagonal shaped cell whose wall may be made from a variety of
materials. See Figure 1 for graphical definition of basic core terminology.
Core orientation - Also called ribbon direction. See definition for Core, Honeycomb.
Core separation - A partial or complete breaking of core node bond. See definition for Core,
Honeycomb and Node Bond.
Core splicing - The joining of segments of core by driving them together or bonding them together.
Cracking - Visible cracks through film surface.
Cratering - Round thin spots or voids with V or U cross sections.
Crazing - Region of ultra fine resin cracks, which extend under the surface of a resin or plastic material.
Appearance is usually as a white band. Often found when fiberglass is drilled without using a backup
plate.
Cross-linking - The setting up of chemical links or bridges between two or more chains of polymer
molecules. Chemical additives used as cross-linkers impart higher stress and modulus and reduced
strain capability to cured resin systems.
Crush / Depressed core - A collapse or compression of core column.
Cure - The physical change in primer compound from a soft, easily removable coating to a hard,
strongly bonded condition.
Cure cycle - The time / temperature / pressure cycle used to cure a thermosetting resin system.
Cure time - The actual time at which resin completes its cure (cross-linking). The cure time does not
start until the repair part has reached designated temperature.
Debond - A deliberate separation of a bonded joint or interface, usually for repair or rework purposes.
Delamination - Separation of layers of material in a laminate, either local or covering a wide area. It
may occur during cure or subsequent life.
Density - Weight per until volume. For honeycomb core it is expressed in pounds per cubic foot.
Dimensional stability - Ability of a plastic part to retain precise shape to which it was molded, cast or
otherwise fabricated.
Disbond - An area within a bonded interface between two adherends in which an adhesion failure or
separation has occurred.
Dusting - Grainy coating caused by overspray or by insufficient amounts of primer material due to low
fluid pressure during application.

51-06-00
Page 3
August 15/14
 GULFSTREAM G650ER
STRUCTURAL REPAIR MANUAL

Empennage - The horizontal and vertical stabilizers plus all control surfaces of horizontal and vertical
stabilizer.
EOP - Abbreviation for Edge of Part.
Epoxy resin - A common thermosetting resin which exhibits exceptionally good adhesion, low cure
shrinkage and low water absorption properties.
Exotherm - The liberation or giving off of heat during curing of a plastic product.
Fabric, woven - A material constructed by interlacing yarns, fibers or filaments, to form such fabric
patterns as plain, harness satin or leno weaves.
Fair - To shape and smooth uncured sealant using a fairing tool.
Fairing tool - A tool used to shape sealant to configuration.
Faying surface seal - The application of sealant between mating surfaces or parts; usually applied to
detail parts at time of installation used for corrosion control or to seal a pressure boundary.
Fiberglass - Glass fibers fused by heating and cooled to a rigid form without crystallizing. The most
common types of fiberglass in structural composites are E-glass (electrical grade) and S-glass (high
strength grade).
Filler ply - Additional plies used to minimize surface depression or to build up an edge band thickness.
Fillers - A relatively inert material added to a resin system to control viscosity, weight, thermal
properties, shrinkage and exothermic heat, increase pot life, strength and ease of application.
Fillet seal - A seal applied (to pressure side of a seal boundary) as a continuous bead of sealant along
edges of faying surfaces (seams) between installed parts used for corrosion control or seal a pressure
boundary.
Fill yarn or Fill thread - The transverse threads or fibers in a woven fabric. Those fibers running
perpendicular to warp. Also called weft.
Film adhesive - A synthetic resin adhesive, usually of thermosetting type, in the form of a thin dry film
with or without a paper or glass scrim cloth.
Finish - Treatment of filaments to aid processing or provide improved physical or mechanical
properties. Finishes often contain ingredients which provide lubricity to filament surface, preventing
abrasive damage during handling and a binder which promotes strand integrity and aids packing of the
filaments.
Fisheyes - Bubbles at or below coating surface.
Flash off - Refers to volatile solvent and water evaporation from primer material.
Flex core® - Trademark of Hexcel Corporation for a core cell design that allows core to accept contour
variations. See Figure 1.
Foam adhesive - Adhesives that have chemicals added that will generate inert gases on heating,
causing resin to assume a cellular structure.
Frayed area - Any area of loose fibers.
Full cure time - The time required for a sealant to polymerize and develop its full physical / mechanical
properties as required by governing specification.
Graphite fiber - A carbonized fiber with high modulus strength. When combined with epoxy resin and
laminated, a high strength to weight ratio is achieved.
Hand lay up - The process of assembling a component by orienting and positioning individual plies or
groups of plies by hand. Parts manufactured by this method may be in a vacuum bag, oven, press,
autoclave, heat blanket, etc.

51-06-00
Page 4
August 15/14
 GULFSTREAM G650ER
STRUCTURAL REPAIR MANUAL

Hardener - A substance or mixture of substances (curing agent) added to an adhesive or plastic

composition to promote or control curing reaction by taking part in it.
Heat sink - A device or material that will absorb or transfer heat away from a critical element or part.
Bulk graphite is often used as a heat sink.
Holiday - During touch up application by brush method, skipped or missed areas caused by application
of insufficient amount of primer material or insufficient spreading.
Honeycomb - See definition for Core, Honeycomb.
Hot bonded repair - A repair requiring a cure temperature of 180°F (82°C) or greater.
Hybridize - A laminate containing two or more material types designed to obtain properties not readily
available from a single material or to reduce use of higher cost materials. One or more compatible
resin systems may be used.
Hygroscopic - Having property of absorbing and retaining an appreciable quantity of moisture (water
vapor).
Inclusion - A physical and mechanical foreign object within a material or part.
Inhibitor - A substance which slows chemical reaction. Inhibitors are sometimes used in resins to
prolong storage (shelf) life and pot life.
Integral fuel tank - A load carrying structure of an aircraft that has been sealed to provide for fuel
containment.
Interlaminar - Pertaining to or describing a condition occurring between two or more plies of a laminate.
Isotropic - Having uniform properties in all directions. Composite materials are rarely isotropic.
Joggle - A machined or formed displacement in a structural member to accommodate fit up of an
adjacent member (prepack sealing is generally required).
Lamina - A single ply or layer in a laminate made up of a series of layers.
Laminae - Plural of lamina.
Laminate - Laminae that are united together, usually by application of heat and pressure.
Lap joint - A joint made by placing one adherend partly over another and bonding overlapped portions.
L direction - Alternate way of saying ribbon direction. See Ribbon Direction.
Litmus paper - An indicator for determining acidity and basicity.
Material Safety Data Sheets (MSDS) - Vendor supplied data showing hazardous and toxic
components in a product and maximum exposure levels allowed for the user.
Matrix - The resin system or polymer material in which the fiber system of a composite is imbedded.
Thermosetting resins, thermoplastic, metals, ceramics and glasses may be used.
Methyl Ethyl Ketone (MEK) - A flammable liquid used as a cleaning solvent.
Methyl Propyl Ketone (MPK) - A flammable liquid used as a cleaning solvent.
Microballoons - Very small phenolic spheres mixed with resin to make a lower viscosity, lower density
material.
Milled glass fiber - Short fiber prepared by hammer milling (or other process) used as an inexpensive
filler.
Modulus of elasticity - The ratio of a unit stress to a unit strain or deformation of a material that is
elastically deformed. A direct indication of materials stiffness.

51-06-00
Page 5
August 15/14
 GULFSTREAM G650ER
STRUCTURAL REPAIR MANUAL

Mold - To shape parts or finished articles by heating a plastic composition under pressure. The cavity or
matrix into which plastic composition is placed and form which it takes its form; sometimes called
impression.
Mold release agent - A lubricant or anti-adhesion agent used to coat a mold cavity or a mold to prevent
a molded piece from adhering to it thus facilitating its removal.
Node bond - The connected portion of adjacent ribbons of honeycomb core. See Core, Honeycomb.
Nomex® - Trademark of an aramid fiber used in manufacture of composite materials.
Orange peel - Pebble like, grainy surface texture.
Organic - Pertaining to chemistry of carbon compounds, not including carbonates or oxides of carbon.
Outside Mold Line (OML) - The outside surface of aircraft skin.
Out time - The time that a product retains its physical and mechanical properties when exposed to room
temperature.
Overcoat - Application of a sealant to a fastener (head or opposite end) that protects fastener from
corrosion.
Pallbearers gloves - The white, lint, free cotton gloves worn during all bonding, prebonding and
adhesive handling operations.
Pasa jel / liquid 105 - Acid paste used for cleaning aluminum.
Paste adhesive - Adhesives in container form, usually two part mixes, applied with brush or spatula, air
or heat cured. Paste adhesive are also available in one and three part mixes.
Peel ply - A sacrificial (removal) ply of material. The primary purpose of peel ply is to protect bonding
surfaces from contamination and damage and to prevent delamination during drilling operations.
Phenolic - A thermosetting resin produced by condensation of an aromatic alcohol with an aldehyde
used in high temperature applications with various fillers and reinforcements.
Pin holing - Small pore like flaws in a coating that extend entirely through applied film and have general
appearance of pin pricks when viewed by reflected light.
Plastic - A plastic is any one of a large and varied group of materials which consist of or contains as an
essential ingredient an organic substance of large molecular weight and while solid in the finished
state, at some stage in its manufacturing has been or may be formed into various shapes by flowing,
usually through application of heat and pressure singularly or together.
Ply wrinkles - A condition where one or more laminate plies are permanently formed into a ridge,
depression or fold.
Pot life - Length of time a catalyzed resin system retains a viscosity low enough to be used in
processing.
Prepreg - Describes a reinforcement (fiberglass, graphite) which has been preimpregnated with a liquid
thermosetting resin and cured to B stage.
Process record - A record of materials and processes used to make repair. This record may be very
important in determining acceptability of a repair when process control specimens are lost, incorrectly
made, etc.
Pull through - Rapid exit of drill bit from drilled material. When drill bit begins to exit material, the
material is no longer able to resist feed rate (pushing force) of the operator. Prevention requires the
operator to reduce feed rate just prior to drill bit exiting. Delamination and / or unbonds may result from
pull through.
Putty - A highly viscous, dough like mixture of a fluid adhesive and fine solid material in suspension.

51-06-00
Page 6
August 15/14
 GULFSTREAM G650ER
STRUCTURAL REPAIR MANUAL

Pyrometer - An instrument for measuring (reading) temperatures. It employs use of thermocouple

wires.
Reentrant edge - The edge of sealant (bonded to sealant or other surface) which represents an angle
of less than 90° to sloshing fuel, that could cause adhesive failure.
Reinforced plastic - Plastic compositions containing materials such as fiberglass, Kevlar, boron,
graphite, etc., to produce structural qualities superior to base resin.
Resin - A synthetic polymer resulting from a chemical reaction of two or more substances. Resins are
used in manufacture of plastics, sealants, rubbers, etc.
Resin content - The amount of matrix present in a composite either by percent weight or percent
volume.
Resin richness - An area of excess resin, usually occurring at radii, steps and chamfered edge of core.
Resin ridge - A sharp buildup of resin on surface of a part.
Resin starved - An area lacking in resin.
Ribbon direction - The direction on one continuous ribbon of material, applied to honeycomb
materials. See definition for Core, Honeycomb.
Room temperature - The temperature range between 65°F (18°C) and 85°F (29°C).
Runs or sags - Nonuniform downward flow of wet paint film that occurs between times of application
and setting, resulting in an uneven coating having a thick lower edge.
Sandwich construction - An assembly consisting of relatively dense, high strength skins (facings)
bonded to a less dense intermediate material (core). High strength to weight ratios are obtained with
this type of construction.
Scarf joint - A joint made by cutting away similar angular segments of two adherents and bonding
adherents with cut areas fitted together.
Scrim cloth - An open weave material usually made from fiberglass, nylon or polyester, used as an
adhesive support during bonding operation to prevent excessive adhesive squeeze out. Note that
most film adhesive will have some form of a scrim cloth within the resin matrix.
Seal - The process of isolation or making leak tight.
Sealant - Any compound, typically elastomeric, applied, so that it will form a seal to accommodate
flexure and temperature variations.
Sealing symbology system - Standard sealing symbols defined in Air Force Design handbook.
Selvage - A special woven edge which prevents fabric from unraveling. The warp direction of a fabric is
parallel to this edge.
Shelf life - The time span in which a plastics product will remain acceptable for use. Temperature during
storage is a prime factor of shelf life. Sometimes called storage life.
Shore A - A mechanical means of defining hardness (0 - 100) of an elastomer. Equivalent to Rex gage
readings.
Solvent - A liquid substance with solubilizing properties.
Solvent pop - Blisters in coating surface caused by trapped solvents, which is further aggravated by
force drying or uneven heating.
Squeeze out - The extruding of faying surface sealant as a result of applying clamping pressure in
assembly. The squeeze out should exhibit a continuous bead around mating parts.

51-06-00
Page 7
August 15/14
 GULFSTREAM G650ER
STRUCTURAL REPAIR MANUAL

Squeeze-out life - The time allowed between sealant thaw or mix time and achieving clamp up torque
for assembly of two or more parts. Typically applied to fay and prepack seal applications.
Storage life - The length of time that sealant may be stored and retain its properties. It may be stored
in bulk, kit or mixed and frozen.
Supplier - An organization contracted to perform certain functions and / or processes for components
of a total end item.
Surface finish - A treatment applied to a surface which may include cleaning, etching and painting.
Syntactic foam - Composites made by mixing hollow microspheres of glass, epoxy, phenolic, etc., into
fluid resins (with additives and curing agents) to form a moldable, curable, lightweight fluid mass.
Tack free - A later stage of cure when material is no longer sticky.
Tack-free time - A period of time in cure of sealant when clean polyethylene film, pressed against
sealant and withdrawn at a right angle, will not stick to material.
Taper plies - A drop off or blending of individual plies in specific increments.
Thermocouple - A temperature detection device.
Thermoplastic material - Material capable of being repeatedly softened by an increase in temperature
and hardened by a decrease in temperature.
Thermosetting material - A resin or adhesive system which cures or solidifies due to action of heat,
catalysts, ultraviolet light, etc.
Thixotropic - Describes materials that are gel like at rest but fluid when agitated.
Unbond - An area within a bonded interface between two adherends in which the intended bonding
action failed to take place.
Unidirectional - A reinforced plastic laminate in which most of the fibers are oriented in the same
direction.
Void - Air or gas that has been trapped and cured into laminate caused by poor fit up, contamination of
materials.
Viscosity - Internal friction or resistance to flow of a liquid.
Warp - The lengthwise yarns of fiber reinforcements running parallel to selvage.
Water break free surface - A surface that is clean and water break free will retain a uniform, even sheet
of water on its surface that will not break up rapidly into beads or other accumulations of water,
obviously repelled from an adjacent area.
W direction - Axis of core that is transverse to ribbon direction. See definition for Core, Honeycomb and
Ribbon Direction.
Weft - Those fibers running perpendicular to warp. Also called fill.
Wet installation - The application of a sealant into fastener hole under fastener head to both sides of
all washers and between nut and their mating surfaces to prevent leakage and provide corrosion
protection.
Wrinkles - Formation of a fold, crease or ridge pattern.
Yarn - A group of twisted filaments, fibers or strands, either natural or manufactured, to form a
continuous length that is suitable for use in weaving into textile materials.

51-06-00
Page 8
August 15/14
 GULFSTREAM G650ER
STRUCTURAL REPAIR MANUAL

W
CELL EDGE

CORE COLUMN
NODE

LEGEND
L = RIBBON OR LONGITUDINAL DIMENSION
W = DIMENSION TRANSVERSE (NORMAL) TO RIBBON DIRECTION
T = THICKNESS DIMENSION

HONEYCOMB CORE

TIL-014714A

Core Components
Figure 1 (Sheet 1 of 3)

51-06-00
Page 9
August 15/14
 GULFSTREAM G650ER
STRUCTURAL REPAIR MANUAL

LEGEND
L = RIBBON OR LONGITUDINAL DIMENSION
W = DIMENSION TRANSVERSE (NORMAL)
TO RIBBON DIRECTION
T = THICKNESS DIMENSION

CONDENSED CORE CELLS

TIL-014713A

Core Components
Figure 1 (Sheet 2 of 3)

51-06-00
Page 10
August 15/14
GULFSTREAM G650ER
STRUCTURAL REPAIR MANUAL

FLEXCORE DESIGN

TIL-014712A

Core Components
Figure 1 (Sheet 3 of 3)

51-06-00
Page 11
August 15/14
 GULFSTREAM G650ER
STRUCTURAL REPAIR MANUAL

THIS PAGE IS INTENTIONALLY LEFT BLANK

51-06-00
Page 12
August 15/14