Arke Boeing 787-8 Composite Structure Inspections Airline Perspective Erik Schoep Structures Engineer ArkeFly Contents 1. Introduction 2. B787 Structures Overview 3. B787 Specific Technologies: a. Ramp Damage Checker b. Quick Composite Repair c. Solid Laminate: Bonded Repair d. Solid Laminate: Bolted Titanium Repair 4. Scheduled Inspections: Aircraft Maintenance Program 5. Non-scheduled Inspections: Accidental Damage 6. Practical Examples a. Case 1: Low Energy Surface Damage b. Case 2: High Energy Impact 7. Questions? TUI Travel PLC - 2 Contents 1. Introduction 2. B787 Structures Overview 3. B787 Specific Techniques: a. Ramp Damage Checker b. Quick Composite Repair c. Solid Laminate: Bonded Repair d. Solid Laminate: Bolted Titanium Repair 4. Scheduled Inspections: Aircraft Maintenance Program 5. Non-scheduled Inspections: Accidental Damage 6. Practical Examples a. Case 1: Low Energy Surface Damage b. Case 2: High Energy Impact 7. Questions? TUI Travel PLC - 3 Introduction TUI Airlines: Arke (NL) JetairFly (B) Thomson Airways (UK) TUIFly (D) TUI Nordic (S) Type Arke TUI Airlines B737NG 5 85 B757 - 15 B767 3 (1) 9 B787-8 1 (3) 8 (13) E190 - 2 Total 9 119 TUI Travel PLC - 4 Contents 1. Introduction 2. B787 Structures Overview 3. B787 Specific Techniques: a. Ramp Damage Checker b. Quick Composite Repair c. Solid Laminate: Bonded Repair d. Solid Laminate: Bolted Titanium Repair 4. Scheduled Inspections: Aircraft Maintenance Program 5. Non-scheduled Inspections: Accidental Damage 6. Practical Examples a. Case 1: Low Energy Surface Damage b. Case 2: High Energy Impact 7. Questions? TUI Travel PLC - 5 Structures Overview TUI Travel PLC - 6 Structures Overview • • • CFRP Solid Laminate Material BMS 8-276 (various shapes) Typical fuselage skin thickness range ± 0,075” (crown area), ±10 plies ± 0,500” (at cutouts), ±70 plies aerodynamic surface (OML) P1 plain weave with phosphor bronze mesh P2 plain weave P3 UD tape P4 UD tape P5 UD tape P6 UD tape P(x) UD tape P(n) plain weave non-aerodynamic surface (IML) TUI Travel PLC - 7 Structures Overview TUI Travel PLC - 8 Structures Overview Skin and Stringers (Carbon Epoxy) TUI Travel PLC - 9 Contents 1. Introduction 2. B787 Structures Overview 3. B787 Specific Techniques: a. Ramp Damage Checker b. Quick Composite Repair c. Solid Laminate: Bonded Repair d. Solid Laminate: Bolted Titanium Repair 4. Scheduled Inspections: Aircraft Maintenance Program 5. Non-scheduled Inspections: Accidental Damage 6. Practical Examples a. Case 1: Low Energy Surface Damage b. Case 2: High Energy Impact 7. Questions? TUI Travel PLC - 10 Ramp Damage Checker TUI Travel PLC - 11 Ramp Damage Checker TUI Travel PLC - 12 Quick Composite Repair • • • • • • Category C repair: 24 months GVI every 90 days Provided in complete kit (approx. 10,000 USD) 6 different patches (carbon/glass fiber, various thicknesses) Repair lightning strike damage, dent, scratch, delamination Max. damage dimensions: 4,0x0,75 inch or diam. 2,0 inch (up to 5 plies) TUI Travel PLC - 13 Quick Composite Repair TUI Travel PLC - 14 Quick Composite Repair Post repair inspections: • Check temperature strip on anti-caul plate • Visual inspect squeeze out of adhesive at repair edge • Tap test for complete bonding Apply: • Aluminum foil patch • Reflective patch (white) TUI Travel PLC - 15 Solid Laminate: Bonded Repair • • • Category A repair on CFRP solid laminate skin Double Vacuum Debulk procedure Thermal survey TUI Travel PLC - 16 Solid Laminate: Bonded Repair Post repair inspections: • Ultrasonic inspection: A-scan or C-scan • Tap test acceptable in repairs of 4 repair plies or less Reject repair if: - Voids, disbonds, delaminations etc. larger than 0,5 inch (solid laminate) - Porosity <4% in area larger than 2 inch2 TUI Travel PLC - 17 Solid Laminate: Bolted Titanium Repair • • • • • Category B repair on CFRP solid laminate skin and stringers HFEC, LFEC, DET inspections: threshold 12,000 FC; interval 5,000 FC Titanium doubler installed with hi-loks and blind bolts Drilling procedure in composite/titanium structure (burn composite, damage substructure, fiber breakout) Borescope inspection of blind bolts TUI Travel PLC - 18 Contents 1. Introduction 2. B787 Structures Overview 3. B787 Specific Techniques: a. Ramp Damage Checker b. Quick Composite Repair c. Solid Laminate: Bonded Repair d. Solid Laminate: Bolted Titanium Repair 4. Scheduled Inspections: Aircraft Maintenance Program 5. Non-scheduled Inspections: Accidental Damage 6. Practical Examples a. Case 1: Low Energy Surface Damage b. Case 2: High Energy Impact 7. Questions? TUI Travel PLC - 19 Scheduled Inspections: Aircraft Maintenance Program B767-300 GE CF6 B787-8 GEnX A-check 850 FH (60 days) 2000 FH (130 days) Servicing/Lubrication C-check 8500 FH 3000 FC 2 YR 12000 FH 6000 FC 3 YR - external detailed in general of door cutout structures and door stops, - special inspections of vertical fin root bolts (i-Bolts) 13 tasks light access 12000 FC 6 YR - internal and external detailed inspections requiring numerous panel removals, - inspections focus on MLG, tail and fuselage support structure 27 tasks deep access 24000 FC 12 YR - internal and external detailed inspections including deep access of the interior of the cabin 92 tasks deep access Thresholds: 33,000 FC 44,000 FC FLS Supplemental Structural Inspections (PSE) In accordance with Damage Tolerance Rating (DTR) check forms - Detailed visual and NDT inspections Fatigue Inspections Thresholds: 25,000 FC 40,000 FC 50,000 FC In general: • Scheduled inspections (MPD) are detailed visual (borescope) (except PSE) • Optional to do external NDT instead of internal visual inspections TUI Travel PLC - 20 Scheduled Inspections: Aircraft Maintenance Program i-Bolt® Inspection Load Control Technologies, an Innovation Plus LLC company TUI Travel PLC - 21 Contents 1. Introduction 2. B787 Structures Overview 3. B787 Specific Techniques: a. Ramp Damage Checker b. Quick Composite Repair c. Solid Laminate: Bonded Repair d. Solid Laminate: Bolted Titanium Repair 4. Scheduled Inspections: Aircraft Maintenance Program 5. Non-scheduled Inspections: Accidental Damage 6. Practical Examples a. Case 1: Low Energy Surface Damage b. Case 2: High Energy Impact 7. Questions? TUI Travel PLC - 22 Non-scheduled inspections: Accidental Damage Barely Visible Impact Damage: - Small damages that may not be found during scheduled inspections (GVI) - Ultimate design strength required during service life - Validated by testing impact location TUI Travel PLC - 23 Non-scheduled inspections: Accidental Damage TUI Travel PLC - 24 Non-scheduled inspections: Accidental Damage High energy impact (e.g. GSE >3 km/h, birdstrike) 1. External visual and NDI inspection. 2. Only in case of external findings: Internal visual and NDI inspection. 3. Evaluate any findings in accordance with SRM. Low energy impact 1. Evaluate visual damage in accordance with SRM. 2. Ramp Damage Checker or NDI only if SRM requires. TUI Travel PLC - 25 Contents 1. Introduction 2. B787 Structures Overview 3. B787 Specific Techniques: a. Ramp Damage Checker b. Quick Composite Repair c. Solid Laminate: Bonded Repair d. Solid Laminate: Bolted Titanium Repair 4. Scheduled Inspections: Aircraft Maintenance Program 5. Non-scheduled Inspections: Accidental Damage 6. Practical Examples a. Case 1: Low Energy Surface Damage b. Case 2: High Energy Impact 7. Questions? TUI Travel PLC - 26 Practical Examples Case 1: Low energy surface damage Surface nick at forward cargo door cutout Beyond SRM allowable limits due to fastener proximity 12 x 12 mm, 4 plies deep Temp. repair (400 FC): apply aluminum foil tape Final repair: seal with resin TUI Travel PLC - 27 Practical Examples Case 2: High energy impact Cargo loader impact at aft cargo door cutout at outstation 1. During turnaround in Curaçao: a. Internal and external detailed visual inspection b. Ramp Damage Checker (external) 2. Internal and external C-scan inspection during scheduled maintenance within 10 FC. TUI Travel PLC - 28 Practical Examples Case 2: High energy impact Cargo loader impact at aft cargo door cutout at outstation TUI Travel PLC - 29 Questions? TUI Travel PLC - 30
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