Attachment_1_-_DMS2288.PDF

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Attached to: DMS 2288 Prepreg Adhesives Federal contract opportunity
Solicitation number: F3QCCM5328A001
Issued by: Department of the Air Force Materiel Command Lifecycle Management Center Robins Air Force Base

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MATERIAL SPECIFICATION DMS 2288

McDonnell Douglas Corporation REVISION: K A wholly owned subsidiary of Title Page

The Boeing Company

FIBER REINFORCED EPOXY PREPREG, 250°F CURE

RESTRICTIONS

Contract Numbers: F33657-81-C-2108 (C-17 FSED), F33657-95-C-2027 (C-17 Field Support), F33657-96-C-2059 (C-17

Multi-Year), F33657-97-C-0008 (C-17 Flexible Sustainment), F33657-01-2002 (C-17 Flex. Sustainment), F33657-02-C-2001 (C-17 Multi-year + 60) & F33657-01-C-0047 (C-130 AMP) and all contracts awarded to Boeing wherein the design and development work is performed at or for A&M So. Cal.

Contractor Name: McDonnell Douglas Corporation (A&M Wichita and A&M So. Cal.) a wholly owned subsidiary of The Boeing Company

Contractor Address: 2401 East Wardlow Road, Long Beach, CA 90807 Expiration Date: Not subject to expiration

This document may be released or disclosed outside the Government and the Government may authorize persons to whom release or disclosure has been made to use, modify, reproduce, release, perform, display or disclose this document if directly related to United States Government C-17 Purposes, C-130 Avionics Modernization Program (AMP) Purposes and Government Purposes directly related to those portions of items developed with Government funds by or at A&M So. Cal. Prior to release or disclosure of this document outside the Government, the intended recipient shall be subject to the non-disclosure agreement at DFARS 227.7103-7. As used in this legend, “Government Purpose” means any activity directly related to the above listed programs in which the United States Government is a party, including cooperative agreements with international or multinational defense organizations, or sales or transfers by the United States Government to foreign governments or international organizations. Government Purposes include competitive reprocurement for the programs listed above, but do not include the rights to use, modify, reproduce, release, perform, display, or disclose this technical data for commercial purposes, nor authorize others to do so. Any reproduction of this document or portions thereof must also reproduce the above restrictions.

(End of clause)

C-17 DISTRIBUTION STATEMENT: Distribution authorized to DoD and DoD contractors only.

Critical Technology 1989.

Other requests for this document must be referred to ASC/YCC.

C-130 DISTRIBUTION STATEMENT C: Distribution authorized to US Government agencies and their contractors;

Critical Technology; 30 July 2001.

Other requests shall be referred to the C-130 Systems Program Office (SPO), WR-ALC/LB, Warner Robins Air Logistics Center, Georgia.

DESTRUCTION NOTICE: Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

WARNING EXPORT CONTROLLED: Warning - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C. App.

2401, et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with the provisions of DoD Directive 5230.25.

Any reproduction of this document or portions thereof must also reproduce the above legends on the first sheet (i page) of the drawing

Revised February 29, 2008

THE BOEING COMPANY ‐ This information is subject to data rights legends on title page or first page.

DAC 25‐1710 REV (1 AUG 2007)

PROCESS ENGINEERING ORDER

THE BOEING COMPANY

LONG BEACH, CA

SHEET 1 OF 1 DMS 2288

DATE 05‐15‐08 1 COMPLETE REVISION

DATE 2 ADVANCE CHANGE

TITLE

FIBER REINFORCED EPOXY PREPREG, 250°F CURE

DATE 3 SERIALIZED CHANGE

DATE 4 NEW

DATE 5 REISSUE TO REVISE

HANDLING INSTRUCTIONS (HI):

2. COMPLY AT SPECIFIED EFFECTIVITY.

3. COMPLY WHEN INVOKED BY DRAWING OR OTHER AUTHORITY.

4. COMPLIANCE OPTIONAL; NO ENGRG. REQUIREMENT.

5. NOTED.

RELEASE APPROVALS

PARA. MODEL

HI.

NO. EFFECTIVITY

PEO MADE BY:

G. R. Bonnar

DAE/AR COML ‐ M&P

MAFW 05‐15‐08

All Coml & 2 Future Procurement

Mil CUSTODIAN COML ‐ M&P

G. Bonnar 04‐28‐08

BACK‐UP COML ‐ M&P

J. Harpt 04‐30‐08

GOVERNMENT ‐ M&P

S. Dao 05‐05‐08

GOVERNMENT ‐ IPT

A. Amin 05‐06‐08

DISTRIBUTION

STANDARD

LIMITED

SPECIALTY MANUAL NUMBERS

PRODUCT CONFIGURATION CONTROL

MAJOR MINORX

M&P QCB NO.

CCN

E6UFL004

EWO

This PEO is authority to release DMS 2288, Revision “K”. This Revision replaces and includes Revision “J”.

Summary of Changes & Reasons:

1.2.3, 2.1 & Table 2

‐ Changed MIL‐C‐9084 reference to AMS‐C‐9084.

Reason: AMS‐C‐9084 superseded MIL‐C‐9084.

‐ Changed ASTM titles.

Reason: To update to current.

5.6.1 ‐ Changed requirement for Purchase Order number placement on labels placed on material rolls and bags to be optional.

Reason: To allow material suppliers to fill orders from inventory.

GRB:ah

TABLE OF CONTENTS

Subject Page

DMS 2288

FIBER REINFORCED EPOXY PREPREG, 250°F CURE

1. SCOPE 1

1.1 Scope 1

1.2 Classification 1

1.2.1 Types 1

1.2.2 Classes 1

1.2.3 Grades 2

1.3 Fiber Orientation 2

2. APPLICABLE DOCUMENTS 3

3. REQUIREMENTS 4

3.1 Preproduction Approval 4

3.2 Production Approval 4

3.2.1 Supplier Specifications 4

3.2.2 Supplier Test Results 4

3.3 Component Requirements 4

3.3.1 Resin 4

3.3.2 Fiber 4

3.3.3 Woven Fabric 5

TABLE 1

CARBON FIBER PROPERTIES 5

3.4 Preimpregnated Material Requirements 6

3.4.1 Roll Characteristics 6

3.4.2 Defects in Fabric 6

3.4.3 Defect Record 6

3.4.4 Worked Fabric 6

3.4.5 Preimpregnated Material 6

TABLE 2

MATERIAL DEFECT LIMITS* FOR GRADES A, B, C, D, I & J 7

TABLE 3

UNCURED PREPREG REQUIREMENTS 8

TABLE 4

PREPREG CHEMICAL TESTS 9

4. QUALITY ASSURANCE PROVISIONS 9

4.1 Supplier Responsibilities 9

4.2 Quality Control 9

4.3 Inspection and Test Requirement 9

4.3.1 Inspection Records 9

4.3.2 Conformance 9

4.3.3 Test Reports 9

4.3.4 Defects 9

4.4 Definitions 10

4.4.1 Batch 10

4.4.2 Roll 10

4.4.3 Tow 10

TABLE OF CONTENTS (Continued)

DMS 2288

FIBER REINFORCED EPOXY PREPREG, 250°F CURE

4.5 Sampling 10

4.5.1 Sampling Plan 10

4.5.2 Sampling Procedure 10

4.6 Classification of Tests 10

4.6.1 Preproduction Tests 10

4.6.2 Production Tests 10

4.6.3 Quality Control by the Supplier 10

4.6.4 Receiving Testing by the Procuring Activity 11

4.7 Test Methods and Procedures 11

4.7.1 Physical Tests of Preimpregnated “B” Stage Material 11

TABLE 5

CURED PROPERTY REQUIREMENTS FOR INCOMING PRODUCTION

QUALITY CONTROL*** 12

4.7.2 Chemical Tests for Prepreg 15

LIQUID CHROMATOGRAPHY PEAKS

FIGURE 1 16

4.7.3 Specimen Fabrication 16

BAGGING PROCEDURE FOR NO‐BLEED CURE

FIGURE 2 17

STRAIGHT‐UP CURE CYCLE

FIGURE 3 18

4.7.4 Methods of Test ‐ Mechanical Properties of Laminates 19

TENSILE SPECIMEN

FIGURE 4 21

TENSILE LOAD ‐ DEFORMATION CURVE

FIGURE 5 22

COMPRESSION SPECIMEN

FIGURE 6 23

INTERLAMINAR SHEAR SPECIMEN AND TEST FIXTURE

FIGURE 7 25

FLEXURAL SPECIMEN

FIGURE 8 26

4.8 Retests 27

4.9 Reprocess by Supplier 27

4.10 Examination 27

4.10.1 Inspection by Supplier 27

4.10.2 Inspection by Procuring Activity 27

4.11 Acceptance/Rejection Criteria 27

4.11.1 Acceptance 27

4.11.2 Nonconforming Material 27

4.12 Recertification by Procuring Activity 27

5. PREPARATION FOR DELIVERY 28

5.1.1 Materials 28

5.1.2 Location of Separator Film 28

TABLE OF CONTENTS (Continued)

DMS 2288

FIBER REINFORCED EPOXY PREPREG, 250°F CURE

iii

5.1.3 Material Edge Straightness 28

5.2 Packing 28

5.3 Preservation 28

5.4 Shipping 29

5.5 Storage 29

5.6 Marking 29

5.6.1 Identification 29

5.6.2 Shipping Carton 29

6. NOTES 30

6.1 Intended Use 30

6.2 Ordering Data 30

6.3 Proprietary Materials 30

ISSUE OF 05‐15‐08

REPLACES REVISION “J”

DMS 2288K

THE BOEING COMPANY

THE BOEING COMPANY ‐ This information is subject to data rights legends on title page or first page.

UNPUBLISHED ‐ CREATED ON PREPARATION DATE OF THIS DOCUMENT. ALL RIGHTS

RESERVED UNDER THE COPYRIGHT LAWS BY THE BOEING COMPANY.

DOUGLAS MATERIAL SPECIFICATION

DAC 37‐102 (REV. 03 AUG 2004)

THE BOEING COMPANY CODE�IDENT.�NO.�88277

1. SCOPE

1.1 Scope ‐ This specification establishes the requirements for a 250°F (121°C) curing “B” stage epoxy resin impregnated fabric. The material is intended to be cured in the autoclave under positive pressure and at a temperature of 250°F (121°C) and has a useful service operating temperature from ‐65° to 160°F (‐54° to 71°C).

1.2 Classification ‐ Material shall be furnished in the following types, classes, and grades:

1.2.1 Types ‐ The type denotes material reinforcement.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁType 1 ‐ Unidirectional carbon tape reinforcedÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Type 2 ‐ Woven carbon cloth reinforced

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Type 3 ‐ Woven glass cloth reinforced

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Type 4 ‐ Woven aramid (Kevlar) cloth reinforced

1.2.2 Classes ‐ The class denotes nominal resin content.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Class 1 ‐ Resin content 35 percent by weight

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁClass 2 ‐ Resin content 39 percent by weightÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Class 3 ‐ Resin content 40 percent by weight

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Class 4 ‐ Resin content 45 percent by weight

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Class 5 ‐ Resin content 52 percent by weight

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Class 6 ‐ Resin content 60 percent by weight

DMS 2288K

1.2.3 Grades ‐ The grade shall specify the fiber areal weight of reinforcing fiber and the standard thickness per ply for calculation of mechanical properties.

ÁÁÁÁÁ

GRADE

ÁÁÁÁÁÁÁ

FIBER AREAL

WEIGHT

(g/m2)

ÁÁÁÁÁÁÁÁÁ

MATERIAL FORM

ÁÁÁÁÁÁÁÁ

STANDARD

THICKNESS PER

PLY (INCH)

ÁÁÁÁÁÁÁÁ

CONTROLLING

SPECIFICATION

ÁÁÁÁÁ

A ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

145 ÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ

Tape, Carbon ÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

0.0055 ÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

N.A.

ÁÁÁÁÁ

B ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

193 ÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ

Plain Weave, CarbonÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

0.0075 ÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

See para. 3.2.1

ÁÁÁÁÁ

C ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

280 ÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ

5 Harness Satin, Carbon

ÁÁÁÁÁÁÁÁ

0.0105 ÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

See para. 3.2.1

ÁÁÁÁÁ

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ

8 Harness Satin, Carbon

ÁÁÁÁÁÁÁÁ

0.0138

ÁÁÁÁÁÁÁÁ

See para. 3.2.1

ÁÁÁÁÁ

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ

120 Style, Glass

ÁÁÁÁÁÁÁÁ

0.0045

ÁÁÁÁÁÁÁÁ

AMS‐C‐9084,

Type 3, Class 2ÁÁÁÁÁ

ÁÁÁÁÁ

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ

181 Style, Glass

ÁÁÁÁÁÁÁÁ

0.0100

ÁÁÁÁÁÁÁÁ

AMS‐C‐9084,

Type 8B, Class 2

ÁÁÁÁÁ

G ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

61 ÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ

120 Style, Aramid ÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

0.0045 ÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

AMS 3902

ÁÁÁÁÁ

H ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

170 ÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ

285 Style, Aramid ÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

0.0100 ÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

AMS 3902

ÁÁÁÁÁ

I ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

280 ÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ

2x2 Twill ‐ 6k Carbon Fiber

ÁÁÁÁÁÁÁÁ

0.0105 ÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

See para. 3.2.1

ÁÁÁÁÁ

J ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

370 ÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁ

2x2 Twill ‐ 12k, Carbon Fiber

ÁÁÁÁÁÁÁÁ

0.0138 ÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

See para. 3.2.1

1.2.3.1 Grade I material may be substituted for Grade C; Grade J material may be substituted for Grade D.

1.3 Fiber Orientation ‐ The fiber orientation denotes fiber direction with 0° being in the lengthwise direction of the material.

ÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁFiber orientation 0° (tape)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁ

Fiber orientation 0/90°

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

(cloth: fiber woven in 0° and 90° direction to length.)

ÁÁÁÁÁÁÁÁÁÁÁ

Fiber orientation ± 45° ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

(cloth: fiber woven in ± 45° direction to length.)

THE BOEING COMPANY ‐ This information is subject to data rights legends on title page or first page.

2. APPLICABLE DOCUMENTS

2.1 The following specifications and standards (and subsidiaries thereof), drawings, and publications of issue in effect on date of invitation for bid, form a part of this specification to the extent specified herein.

ÁÁÁÁÁÁÁÁÁÁ

STANDARDS ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Douglas Process Standard

ÁÁÁÁÁÁÁÁÁÁ

DPS 3.301 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Supplier Packaging

ÁÁÁÁÁÁÁÁÁÁ

OTHER PUBLICATIONSÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

American Society for Testing and Materials

ÁÁÁÁÁÁÁÁÁÁ

ASTM D 695

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Standard Test Method for Compressive Properties of Rigid Plastics

ÁÁÁÁÁÁÁÁÁÁ

ASTM D 790

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials

ÁÁÁÁÁÁÁÁÁÁ

ASTM D 2344 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Standard Test Method for Short‐Beam Strength of Polymer Matrix Composite Materials and Their Laminates

ÁÁÁÁÁÁÁÁÁÁ

ASTM D 3039 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Standard Test Method for Tensile Properties of Polymer Matrix Composite Materials

ÁÁÁÁÁÁÁÁÁÁ

ASTM D 3529 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Standard Test Method for Matrix Solids Content and Matrix Content of Composite Prepreg

ÁÁÁÁÁÁÁÁÁÁ

ASTM D 3530 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Standard Test Method for Volatiles Content of Composite Material PrepregÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

ASTM D 3532

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Standard Test Method for Gel Time of Carbon Fiber‐Epoxy PrepregÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

ASTM D 3990

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Standard Terminology Relating to Fabric Defects

ÁÁÁÁÁÁÁÁÁÁ

ASTM E 4 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Standard Practices for Force Verification of Testing MachinesÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

ASTM E 168

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Standard Practices for General Techniques of Infrared Quantitative AnalysisÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

ASTM E 682

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Standard Practice for Liquid Chromatography Terms and Relationships

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁMcDonnell Douglas Corporation ReportÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

MDC‐92K1058

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Test Plan for Qualification of Fiber Reinforced Epoxy Prepreg to DMS 2387ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Aerospace Material Specification

ÁÁÁÁÁÁÁÁÁÁ

AMS‐C‐9084 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Cloth, Glass, Finished, for Resin Laminates

3. REQUIREMENTS

3.1 Preproduction Approval ‐ The material furnished under this specification shall be a product that has been tested and has passed the requirements specified in McDonnell Douglas Corporation (MDC) Report MDC‐J1980, “Test Plan for Qualification of 250°F Cure Fiber Reinforced Epoxy Prepreg to DMS 2288.” After preproduction approval, the properties and method of manufacture shall not be changed without written approval from The Boeing Company. The supplier shall use the same resin system for all products submitted.

3.2 Production Approval ‐ The material furnished under this specification shall be a product that has been tested and has passed the production tests specified herein.

The supplier shall certify that the product formulation and methods of manufacture are identical to that used in the initial qualification test material and shall not be changed without written approval from The Boeing Company.

3.2.1 Supplier Specifications ‐ Suppliers shall submit their quality control specifications and obtain The Boeing Company approval for control of the equipment, processes, test procedures, and raw materials for the manufacture of the product. If necessary, an agreement of secrecy with The Boeing Company shall be stipulated to safeguard the supplier's rights.

3.2.2 Supplier Test Results ‐ Unless otherwise specified by the procuring activity, the supplier shall provide two copies of all required production test results, including individual values for each specimen, to demonstrate that the material submitted for approval meets the requirements of this specification. One copy shall be submitted with the shipment and one copy sent to the procuring activity Quality Control department.

3.3 Component Requirements

3.3.1 Resin

3.3.1.1 The epoxy resin shall be capable of meeting the requirements of this specification. The cured resin shall not be affected by temperatures ranging from ‐65° to 160°F (‐54° to 71°C).

3.3.1.2 Resin Certification ‐ The supplier shall include a material certification with each prepreg batch and provide documentation that the resin system after impregnation meets the requirements of Table 4.

3.3.2 Fiber ‐ The fibers shall be capable of meeting the requirements of this specification.

3.3.2.1 Fiber Splices ‐ The fiber yarn, used to weave the fabric, shall not contain more than three splices per pound of yarn per bobbin and one splice per each additional one‐third pound increment.

3.3.2.2 Fiber Requirements ‐ The carbon fiber yarn or tow form shall meet the requirements shown in Table 1. The glass and aramid fibers shall meet the requirements of the applicable specification referenced in paragraph 1.2.

3.3.2.3 Fiber Certification ‐ The prepreg material supplier shall provide documentation that the carbon fiber reinforcement meets the requirements of Table 1 or applicable specification referenced in paragraph 1.2.

THE BOEING COMPANY ‐ This information is subject to data rights legends on title page or first page.

3.3.2.4 Fiber Test Methods ‐ Test methods for fiber properties shall be agreed upon by the prepreg supplier and documented in a material specification, approved by the The Boeing Company. Laminate tow test data or impregnated tow, normalized to 100 percent fiber volume, shall be used for Table 1 carbon fiber requirements for ultimate tensile strength and tensile modulus.

3.3.3 Woven Fabric ‐ The woven fabric shall be made from the fibers identified in paragraph 3.3.2. Unless otherwise specified, the fiber orientation for the warp and fill directions shall be 0°/90°.

TABLE 1

CARBON FIBER PROPERTIES

ÁÁÁÁÁÁÁ

PROPERTY

ÁÁÁÁÁÁ

UNIT

ÁÁÁÁÁÁÁÁÁÁÁ

REQUIREMENT DRY

TOW TEST

ÁÁÁÁÁÁÁÁÁÁÁ

REQUIREMENT RESIN

IMPREGNATED TOW

TEST

ÁÁÁÁÁÁÁ

Ultimate Tensile Strength*

ÁÁÁÁÁÁ

psi

ÁÁÁÁÁÁÁÁÁÁÁ

N.A.

ÁÁÁÁÁÁÁÁÁÁÁ

500,000 minimum

ÁÁÁÁÁÁÁ

Tensile Modulus*

ÁÁÁÁÁÁ

l06 psi ÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁ

N.A. ÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁ

32 to 38

ÁÁÁÁÁÁÁ

Elongation at Failure

ÁÁÁÁÁÁ

percent ÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁ

N.A. ÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁ

1.4 Min

ÁÁÁÁÁÁÁ

Density ÁÁÁÁÁÁ

ÁÁÁÁÁÁ

g/cm3 ÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁ

1.70 to 1.85 ÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁ

N.A.

ÁÁÁÁÁÁÁ

Sizing

ÁÁÁÁÁÁ

percent weight

ÁÁÁÁÁÁÁÁÁÁÁ

1.6 maximum

ÁÁÁÁÁÁÁÁÁÁÁ

N.A.

ÁÁÁÁÁÁÁ

Twist ÁÁÁÁÁÁ

ÁÁÁÁÁÁ

turns per inchÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁ

0.0 to 0.8 ÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁ

N.A.

ÁÁÁÁÁÁÁ

Filament Count

ÁÁÁÁÁÁ

nominal number per tow

ÁÁÁÁÁÁÁÁÁÁÁ

Grade A ‐ 3K, 6K, or 12KÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁ

N.A.

ÁÁÁÁÁÁÁÁÁÁÁ

Grades B, C, and D ‐ 3K ÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁ

N.A.

ÁÁÁÁÁÁÁÁÁÁÁ

Grade I ‐ 6k

ÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁGrade J ‐ 12k

N.A. = Not Applicable

* Normalized to 100 percent fiber volume K = Thousands

3.3.3.1 Weaving Defects

3.3.3.1.1 Single Yarn Defects ‐ Defects, such as broken fibers, distortions, and wrinkles, shall not number more than three over a distance of six lineal feet of fabric. If two single yarn defects are closer than six inches, they shall be considered as a continuous defect.

3.3.3.1.2 Continuous Defects ‐ Defects, such as wrinkles, cut fibers, and crushed distorted tows, shall be considered a continuous defect if they involve more than one tow and shall be considered an unacceptable area of the material.

3.3.3.1.3 Defect Description ‐ Terms for defect description are per ASTM D 3990.

3.3.3.2 Carbon Cloth

3.3.3.2.1 Fiber Direction ‐ In addition to the carbon fibers, the woven fabric shall use Kevlar or colored fiberglass tracers to indicate warp and fill direction. The tracers shall be positioned approximately every 2.0 ± 1.0 inches in the warp direction and every

6.0 ± 1.0 inches in the fill direction.

3.3.3.2.2 Selvage Requirements ‐ The selvage shall be of such width (1.5 inches maximum) as to allow no distortion of the fibers when the material is unrolled.

3.3.3.2.3 Statement of Weaving Quality ‐ The prepreg supplier shall verify that the woven fabric meets the requirements of paragraph 3.3.3.1. The material, tooling, and methods used for the weaving operations shall not affect the characteristics of the carbon fibers.

3.4 Preimpregnated Material Requirements

3.4.1 Roll Characteristics

3.4.1.1 Size ‐ The width and total weight or length of material shall be specified by the procuring activity.

3.4.1.2 Weight ‐ Unless otherwise specified by the procuring activity, individual roll weight shall not exceed 100 pounds.

3.4.1.3 Width ‐ Width shall be as specified, excluding selvage, and width tolerances shall be ± 0.15 inch for every 12 inches of material width or fraction thereof.

3.4.1.4 Material Splicing ‐ Prepreg may be spliced to meet material length requirements. Splices shall be overlapped a maximum of three inches with a maximum of one splice per roll. Material splices shall not be within 36 feet of the end of the roll.

Five linear feet of additional material shall be provided for each splice. Splices shall be identified per paragraphs 3.4.2.1, 3.4.2.2, and 3.4.3. Material splicing deviations shall be allowed when agreed upon in writing between the procuring activity and supplier.

3.4.2 Defects in Fabric ‐ Identification of defects and allowable limits shall be in accordance with Table 2.

3.4.2.1 Each defect shall be identified and flagged with a colored mark positioned on the edge of the material. A continuous defect shall be identified with a colored mark at the start and with a different colored mark at the end of the defect.

3.4.2.2 The defective areas shall not be considered as part of the total length of the roll or its weight. The defect area shall be considered as the length of the defect multiplied by the width of the roll.

3.4.3 Defect Record ‐ Each roll shall have a defect record attached to it, recording the location and length of all defects (if any) for that roll.

3.4.4 Worked Fabric ‐ The Grade B prepreg fabric shall be worked to minimize any open spaces between the warp and fill direction of fiber.

3.4.5 Preimpregnated Material ‐ Preimpregnated material, sampled per paragraph

4.5 and tested per paragraphs 4.7.1 and 4.7.2, shall not exceed the defect limits in Table 2 and shall meet the physical and chemical requirements specified in Tables 3 and 4, as applicable.

THE BOEING COMPANY ‐ This information is subject to data rights legends on title page or first page.

3.4.5.1 Handling Characteristics ‐ A separator film shall be used to permit easy removal of the prepreg from the roll and the prepreg material shall be easily removed from the separator without loss of resin, tearing, shredding, or other damage. The material shall be capable of being cut without disarray of the filaments and without other visible damage. Cut material, when placed on a flat surface, shall not have wrinkles form.

TABLE 2

MATERIAL DEFECT LIMITS* FOR GRADES A, B, C, D, I & J

ÁÁÁÁÁÁÁ

SUBJECT

ÁÁÁÁÁÁ

MATERIAL

FORM

ÁÁÁÁÁÁÁÁÁÁ

DEFECT

ÁÁÁÁÁÁÁÁÁÁÁÁ

ALLOWABLE LIMITS

ÁÁÁÁÁÁÁ

Gaps & Alignment

ÁÁÁÁÁÁ

Fabric

ÁÁÁÁÁÁÁÁÁÁ

Warp yarn deviation from a straight line.

ÁÁÁÁÁÁÁÁÁÁÁÁ

0.18 inch/3 feet length

ÁÁÁÁÁÁÁÁÁÁ

Fill yarn deviation from a straight line.

ÁÁÁÁÁÁÁÁÁÁÁÁ

1.0 inch/21 inches width or proportion thereof

ÁÁÁÁÁÁ

Tape

ÁÁÁÁÁÁÁÁÁÁ

Fiber deviation from a straight line.

ÁÁÁÁÁÁÁÁÁÁÁÁ

0.03 inch/foot

ÁÁÁÁÁÁÁÁÁÁ

Edge deviation from a straight line.

ÁÁÁÁÁÁÁÁÁÁÁÁ

0.02 inch/foot

ÁÁÁÁÁÁÁÁÁÁ

Gap between adjacent tows.

ÁÁÁÁÁÁÁÁÁÁÁÁ

a) 0.03 inch wide x 6.0 inches long max.

b) 0.02 inch wide x 24 inches long max.

c) 0.01 inch wide x continuous length.

ÁÁÁÁÁÁÁ

Continuous Defects

ÁÁÁÁÁÁ

Tape & Fabric

ÁÁÁÁÁÁÁÁÁÁ

Multiplicity of defects;

e.g., excess resin accumulation, starved areas, unwetted fibers, blisters, foreign materials, single defects.

ÁÁÁÁÁÁÁÁÁÁÁÁ

Defects more than three feet apart (exclude selvage area).

ÁÁÁÁÁÁÁ

Tow Splices ÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

Splices on adjacent tows.

ÁÁÁÁÁÁÁÁÁÁÁÁ

No splices on adjacent tows within 1/2 inch of each other.

ÁÁÁÁÁÁÁ

Material Splices

ÁÁÁÁÁÁÁÁÁÁ

Spliced across material width.

ÁÁÁÁÁÁÁÁÁÁÁÁ

One splice per roll.

ÁÁÁÁÁÁÁ

Single and Continuous Defects

ÁÁÁÁÁÁÁÁÁÁ

‐ ÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁ

10 percent of the roll.

* Defect limits for Grades E through H shall be per AMS‐C‐9084.

3.4.5.2 Storage of Material

3.4.5.2.1 Cold ‐ When packaged and packed in compliance with paragraphs 5.1 and 5.2, and shipped and preserved as specified in paragraphs 5.3, 5.4 and 5.5, the material shall be capable of meeting the requirements specified in Tables 3 through 5 for a minimum of 180 days after shipment from the supplier to the procuring activity.

3.4.5.2.2 Room Temperature ‐ Rolled material shall be capable of meeting the requirements specified in Tables 3 through 5, as applicable, after an exposure to 70° to 80°F (21° to 27°C) and 50 ± 5 percent relative humidity for a minimum of 14 days (336 hours).

TABLE 3

UNCURED PREPREG REQUIREMENTS

ÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁPROPERTY

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁREQUIREMENTS

ÁÁÁÁÁÁÁÁ

METHOD OF

TEST

(PARAGRAPH)ÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁ

Volatile Content* (Percent by Weight)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

All Classes 2.5% Maximum

ÁÁÁÁÁÁÁÁ

4.7.1.1

ÁÁÁÁÁÁÁÁÁÁÁ

Wet Resin Content* (Percent by Weight)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Class 1 35 ± 3% Class 2 39 ± 3% Class 3 40 ± 3% Class 4 45 ± 3% Class 5 52 ± 3% Class 6 60 ± 3%

ÁÁÁÁÁÁÁÁ

4.7.1.2

ÁÁÁÁÁÁÁÁÁÁÁ

Fiber Areal Weight* (g/m2)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Grade A 145 ± 5 Grade B 193 ± 8 Grade C 280 ± 12 Grade D 370 ± 20 Grade E 104 ± 6 Grade F 293 ± 17 Grade G 61 ± 6 Grade H 170 ± 10 Grade I 280 ± 12 Grade J 370 ± 20

ÁÁÁÁÁÁÁÁ

4.7.1.3

ÁÁÁÁÁÁÁÁÁÁÁ

Flow* (Percent)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Type 1 & 2 ‐ 5 to 25% Type 3 & 4 ‐ 5 to 35%

ÁÁÁÁÁÁÁÁ

4.7.1.4

ÁÁÁÁÁÁÁÁÁÁÁ

Tack at Ambient Temperature

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

The material shall release from the separator film without distortion and adhere to the mandrel and self for one hour minimum. Report as pass or fail.

ÁÁÁÁÁÁÁÁ

4.7.1.5

ÁÁÁÁÁÁÁÁÁÁÁ

Drapability ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

No broken fibers. Report as pass or fail.

ÁÁÁÁÁÁÁÁ

4.7.1.6

ÁÁÁÁÁÁÁÁÁÁÁ

Gel Time at 275°F (135°C)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

3 to 12 minutes ÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

4.7.1.7

* Average of tests performed per sample.

THE BOEING COMPANY ‐ This information is subject to data rights legends on title page or first page.

TABLE 4

PREPREG CHEMICAL TESTS

ÁÁÁÁÁÁÁÁÁÁÁ

PROPERTY

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

REQUIREMENTS

ÁÁÁÁÁÁÁÁ

METHOD OF

TEST

(PARAGRAPH)

Infrared Spectrum Comparative result 4.7.2.1

Liquid Chromatography Spectrum

Comparative result 4.7.2.2

4. QUALITY ASSURANCE PROVISIONS

4.1 Supplier Responsibilities ‐ The supplier is responsible for the performance of all test and inspection requirements as specified herein. The supplier may use his own or any other test facility acceptable to the procuring activity. Test records shall be retained for a minimum of one year and shall be made available to the procuring activity. The procuring activity reserves the right to perform any of the tests or inspections to confirm that the product complies with the specification requirements. Procuring activity is defined as The Boeing Company or any subcontractor purchasing the product for use as a Boeing end item.

4.2 Quality Control ‐ The supplier shall maintain, through the entire processing of the material, all necessary quality controls and inspections of basic materials to demonstrate conformance to the requirements of this specification. As a minimum, the Quality Control system shall comply with MIL‐I‐45208 inspection system requirements.

4.3 Inspection and Test Requirement

4.3.1 Inspection Records ‐ Inspection records shall be kept by the supplier, complete and available to the procuring activity.

4.3.2 Conformance ‐ Each batch of material covered by this specification and delivered to the procuring activity shall include a supplier conformance statement that the components (fiber and resin), and processing used in the manufacture of the material meet the requirements as stated in Section 3.

4.3.3 Test Reports

4.3.3.1 In addition to the conformance statement required by paragraph 4.3.2, the supplier shall furnish with each batch a report stating the quantitative results of all quality control tests and inspections. Both individual and average test results shall be included. The reports shall include all necessary identification to correlate the inspections and test results with the roll and batch of material and with the purchase order or contract.

4.3.3.2 Fiber Density and Cured Resin Density ‐ When required by the procuring activity, the average density of the fibers and the cured epoxy resin in grams per cubic centimeter shall be stated on the test report. These densities shall be used in the determination of fiber volume and void content measurements for cured laminates.

4.3.4 Defects ‐ Credit shall be given to the procuring activity by the supplier for any defective portion of material discovered during use that was not previously detected.

4.4 Definitions

4.4.1 Batch ‐ A prepreg batch is defined as the prepreg made in one continuous manufacturing operation, under substantially identical conditions (except normal rest periods and daily shift changes), using a combination of fiber type with traceability to fiber lot and a single batch of epoxy resin. Batch numbers shall be designated by the supplier.

4.4.2 Roll ‐ For the purpose of this specification, a roll shall be defined as all the material contained on one spool or in one roll. A master roll shall be defined as material that is manufactured in one continuous operation from which several rolls are split.

4.4.3 Tow ‐ A tow is defined as a group of fibers contained in one bundle for the purpose of weaving and meet the requirements of Table 1.

4.5 Sampling

4.5.1 Sampling Plan ‐ Sampling shall be representative of the material under consideration.

4.5.1.1 Supplier Sampling ‐ The supplier shall select rolls for testing from each batch of material based on a sampling plan approved by The Boeing Company.

Prepreg resin content is an exception and requires testing of each roll. A supplier may deviate from 100 percent resin content testing only when authorized in writing by the procuring activity and The Boeing Company.

4.5.1.2 Procuring Activity Sampling ‐ The procuring activity shall select rolls for testing from each shipment according to the quality control sampling plan approved by The Boeing Company. As a minimum, one roll from each batch in a shipment shall be tested as specified in paragraph 4.6.4.

4.5.2 Sampling Procedure ‐ Remove roll from cold storage, keep in moisture‐proof bag, and allow to stand at room temperature for a minimum of four hours or until no condensed moisture is present. Remove material for test, reseal unused material in a moisture‐proof bag and place bag in cold storage.

4.6 Classification of Tests

4.6.1 Preproduction Tests ‐ Preproduction tests for qualification of the material are listed in MDC report MDC‐J1980, “Test Plan for Qualification of 250°F Cure Fiber Reinforced Epoxy Prepreg to DMS 2288.”

4.6.2 Production Tests ‐ Production tests for acceptance of incoming material shall consist of all tests listed in Tables 3, 4, and 5 of this specification.

4.6.3 Quality Control by the Supplier

4.6.3.1 Test each roll of material for resin content per Table 3. Rolls subsequently split from a master roll do not require individual resin content tests if resin content is performed on representative samples taken from the master roll.

4.6.3.2 Test all other prepreg physical characteristics in Table 3 per the supplier sampling plan in paragraph 4.5.1.1.

THE BOEING COMPANY ‐ This information is subject to data rights legends on title page or first page.

4.6.3.3 Test for the chemical properties shown in Table 4 on a representative sample of resin extracted from the prepreg material. Send results to the procuring activity Quality Control within 30 days after shipping the material.

4.6.3.4 The physical and mechanical properties of the cured material shall be tested per Table 5 according to the sampling procedure in paragraph 4.5.

4.6.3.5 The supplier shall send a copy of all the test results to the procuring activity Quality Control department and shall keep the records (see paragraphs 4.3.1, 4.3.2, and 4.3.3) on file for five years.

4.6.4 Receiving Testing by the Procuring Activity

4.6.4.1 Supplier test reports shall be reviewed to confirm that all the required tests have been performed and that the test results comply with the specification.

4.6.4.2 The procuring activity shall sample per paragraph 4.5.1.2, and perform

(1) gel time and flow for all grades per Table 3; (2) short beam shear for Grades A, B, C, D, I and J, per Table 5; and (3) flexural strength for Grades E, F, G and H per Table 5.

4.6.4.2.1 Subsequent shipments of material from the same batch that has previously been tested per paragraph 4.6.4.2, shall be sampled per paragraph 4.5.1.2 and tested for gel time per Table 3. This is applicable for material shipments received within 180 days from date of manufacture.

4.6.4.3 Quality Control may perform any additional tests considered necessary to confirm the quality of the material.

4.6.4.4 All test results shall be recorded and filed in accordance with established Quality Control procedures.

4.6.4.5 Material meeting these requirements shall be acceptable for production use for a minimum of 180 days from date of receipt.

4.7 Test Methods and Procedures

4.7.1 Physical Tests of Preimpregnated “B” Stage Material ‐ The methods of test of preimpregnated “B” stage material are listed in Table 3.

4.7.1.1 Volatile Content ‐ The volatile content percent by weight of the preimpregnated “B” stage material shall be determined per ASTM D 3530 with the following exceptions:

4.7.1.1.1 Cut material specimens to a minimum size of 3 x 3 inches.

4.7.1.1.2 Weigh to the nearest 0.001 gram. Record the weight as W1.

TABLE 5

CURED PROPERTY REQUIREMENTS FOR INCOMING PRODUCTION QUALITY CONTROL***

ÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁPROPERTY****

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

MINIMUM AVERAGE* OR RANGE**

ÁÁÁÁÁÁ

TEST

METHOD

(PARAGRAPH)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁGRADEÁÁÁÁ

ÁÁÁÁA

ÁÁÁ

ÁÁÁB

ÁÁÁ

ÁÁÁC & I

ÁÁÁÁ

ÁÁÁÁD & J

ÁÁÁ

ÁÁÁE

ÁÁÁ

ÁÁÁF

ÁÁÁÁ

ÁÁÁÁG

ÁÁÁ

ÁÁÁHÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ

Ultimate Tensile Strength (psi x 103)

ÁÁÁÁ

ÁÁÁ

ÁÁÁÁ

ÁÁÁ

44.0 (1)

ÁÁÁ

44.0 (1)

ÁÁÁÁ

70.0 (1)

ÁÁÁ

70.0 (1)

ÁÁÁÁÁÁ

4.7.4.2

ÁÁÁÁÁÁÁÁ

Modulus Range (psi x 106)

ÁÁÁÁ

16.0 ‐ 23.0

ÁÁÁ

8.0 ‐ 11.0

ÁÁÁ

7.8‐ 11.4

ÁÁÁÁ

8.0 ‐ 11.5

ÁÁÁ

ÁÁÁÁ

ÁÁÁ

ÁÁÁÁÁÁ

4.7.4.2

ÁÁÁÁÁÁÁÁ

Ultimate Compressive Strength (psi x 103)

ÁÁÁÁ

155 ÁÁÁ

ÁÁÁ

90.0ÁÁÁ

ÁÁÁ

90.0ÁÁÁÁ

ÁÁÁÁ

85.0 ÁÁÁ

ÁÁÁ

NRÁÁÁ

ÁÁÁ

NRÁÁÁÁ

ÁÁÁÁ

NR ÁÁÁ

ÁÁÁ

NRÁÁÁÁÁÁ

ÁÁÁÁÁÁ

4.7.4.3

ÁÁÁÁÁÁÁÁ

Short Beam Shear Strength (psi x 103) (1)

ÁÁÁÁ

11.1 ÁÁÁ

ÁÁÁ

8.5 ÁÁÁ

ÁÁÁ

8.5ÁÁÁÁ

ÁÁÁÁ

8.5 ÁÁÁ

ÁÁÁ

NRÁÁÁ

ÁÁÁ

NRÁÁÁÁ

ÁÁÁÁ

NR ÁÁÁ

ÁÁÁ

NRÁÁÁÁÁÁ

ÁÁÁÁÁÁ

4.7.4.4

ÁÁÁÁÁÁÁÁ

Ultimate Laminate Flexural Strength (psi x 103) (1)

ÁÁÁÁ

ÁÁÁ

ÁÁÁÁ

ÁÁÁ

55.0

ÁÁÁ

65.0

ÁÁÁÁ

45.0

ÁÁÁ

54.0

ÁÁÁÁÁÁ

4.7.4.5

ÁÁÁÁÁÁÁÁ

Cured Laminate Thickness, Minimum (Inch/ply x 10‐3)

ÁÁÁÁ

5.0 ÁÁÁ

ÁÁÁ

7.5 ÁÁÁ

ÁÁÁ

10.5ÁÁÁÁ

ÁÁÁÁ

13.8 ÁÁÁ

ÁÁÁ

NRÁÁÁ

ÁÁÁ

NRÁÁÁÁ

ÁÁÁÁ

NR ÁÁÁ

ÁÁÁ

NRÁÁÁÁÁÁ

ÁÁÁÁÁÁ

4.7.4.6

NR = Not Required

* No single test specimen result shall be more than 10 percent below the minimum average requirement.

** All test specimen results shall be within the modulus range.

*** A minimum of three test specimens shall be used to determine the average value for each condition.

**** Tests performed at ambient temperature.

FOOTNOTE: (1) Data requirements based on actual specimen thickness. All other mechanical test properties are calculated using standard thickness per ply per paragraph 1.2.3.

4.7.1.1.3 Place the specimens on a removable tray (areas of tray in contact with specimens shall be covered with a parting film, such as Mylar or Teflon) in an air‐circulating oven preheated to 250° ± 10°F (121° ± 5°C). Hanging specimens in the oven is acceptable provided that there is no resin loss.

4.7.1.1.4 Expose the specimens to 250° ± 10°F (121° ± 5°C) for a minimum of 15 minutes.

4.7.1.1.5 Remove specimens from oven and place in a desiccator.

4.7.1.1.6 Cool specimens to room temperature inside desiccator for a minimum of 10 minutes. Reweigh to the nearest 0.001 gram and record the weight as W2.

THE BOEING COMPANY ‐ This information is subject to data rights legends on title page or first page.

4.7.1.1.7 Calculate volatile content percent as follows:

W1 ‐ W2 x 100 W1

Volatile Content Percent =

Where: W1 = Original weight of specimen, grams.

W2 = Final weight of specimen, grams.

4.7.1.1.8 Report all individual results and the arithmetic mean of three specimens.

4.7.1.2 Wet Resin Content ‐ The wet resin content percent by weight of the preimpregnated “B” stage material shall be determined per ASTM D 3529 with the following exceptions:

4.7.1.2.1 Cut sufficient material to obtain a specimen with a minimum area of 16 square inches or 100 square cm. Weigh to the nearest 0.001 gram. Record the weight as W1. Measure length and width in mm and calculate area in square meters to within 10 mm2 for use later in fiber areal weight calculation.

4.7.1.2.2 Wash specimens in a suitable agitated solvent. Decant the solvent. The solvent used shall be selected on the basis of being able to completely dissolve the resin under the conditions of this test.

WARNING

Solvent vapors are extremely flammable, and the solvent agitation should be conducted under a suitable vapor hood.

4.7.1.2.3 Repeat the steps in paragraph 4.7.1.2.2 for three complete wash cycles or until resin has been completely dissolved from the fibers.

4.7.1.2.4 Dry the fibers by placing them in an air‐circulating electric oven maintained at 200°F (93°C) minimum until fibers are dry. Remove and place in a moisture‐free container at room temperature.

WARNING

Solvent vapors are extremely flammable, and the solvent drying should be conducted in an explosion resistant oven.

4.7.1.2.5 After specimens have cooled to room temperature, remove specimens from desiccator and weigh to the nearest 0.001 gram. Record the weight as W2.

4.7.1.2.6 Calculate resin content percent by weight as follows:

W1 ‐ W2 x 100 W1

Wet Resin Content Percent by Weight =

Where: W1 = Original weight of specimen, grams.

W2 = Final weight of specimen, grams.

4.7.1.2.7 Calculate the arithmetic mean of at least three determinations as resin content of the specimen. Report all individual results and the arithmetic mean.

4.7.1.2.8 Optional Method for grades E and F.

4.7.1.2.8.1 Cut three specimens 4” x 4” and weigh to the nearest 0.001 gram.

Record as W1.

4.7.1.2.8.2 Place samples in a muffle furnace at a temperature greater than 1000°F (538°C) for a period long enough to allow resin to be completely burned away.

4.7.1.2.8.3 Remove the samples and allow to cool to room temperature. Weigh samples to the nearest 0.001 gram. Record as W2.

4.7.1.2.8.4 Calculate wet resin content per paragraph 4.7.1.2.6.

4.7.1.3 Fiber Areal Weight ‐ Calculate the fiber areal weight, AW, in grams per square meter for each of three specimens as follows:

Final Weight of Specimen (W2 in paragraph 4.7.1.2.5) in GramsAW = Area of Specimen from Paragraph 4.7.1.2.1 in Sq. Meters

4.7.1.3.1 Report all individual results and the arithmetic mean.

4.7.1.4 Flow ‐ The flow of the preimpregnated “B” stage material shall be determined as follows:

4.7.1.4.1 Cut four pieces of prepreg 4 x 4 inches and stack in a 0/90/0/90 orientation. Weigh the sample to the nearest 0.001 gram (W1).

4.7.1.4.2 Place on each side of the sample in order, one ply porous separator, three plies of 7781 or equivalent bleeder and one ply of nonporous separator.

4.7.1.4.3 Place the completed layup in a press preheated to 275° ± 5°F (135° ± 3°C) and apply 50 ± 5 psi pressure. Cure for five minutes past the gel time.

4.7.1.4.4 Remove sample and allow to cool to room temperature.

4.7.1.4.5 Remove separator, bleeder plies and resin flash from the cured sample.

Weigh to the nearest 0.001 gram (W2).

4.7.1.4.6 The percent resin flow shall be calculated as follows:

W1 ‐ W2 W1 x 100 = % Resin Flow

4.7.1.4.7 Report the arithmetic mean of at least three determinations.

4.7.1.5 Tack ‐ The tack at ambient temperature of the preimpregnated 'B” stage material shall be determined as follows:

4.7.1.5.1 Cut sufficient material to obtain three specimens, 10 ± 1 inches long in the lengthwise direction (0° direction for tape, warp direction for cloth) by 3.0 ± 0.5 inches wide.

4.7.1.5.2 Wrap the specimen around a 2.0 ± 0.1 inches diameter mandrel so each layer will be in contact with the next. Examine for adhesion and separator release properties.

4.7.1.5.3 Report the results of the three tests as “pass” or “fail” per Table 3. All three tests must pass or material has failed to meet the tack test.

4.7.1.6 Drapability ‐ The drapability of the preimpregnated ”B” stage material shall be determined as follows:

4.7.1.6.1 Cut sufficient material to obtain three specimens two inches long by three inches wide minimum.

THE BOEING COMPANY ‐ This information is subject to data rights legends on title page or first page.

4.7.1.6.2 Bend specimens over a 1/16 ± 1/64 inch radius mandrel with the 0° direction perpendicular to the mandrel, at ambient temperature. Visually inspect for filament damage.

4.7.1.6.3 Repeat the test for at least three separate specimens.

4.7.1.6.4 Report the results as ”pass” or ”fail” per Table 3. All three tests must pass or material has failed to meet the drapability requirement.

4.7.1.7 Gel Time ‐ The gel time of the resin in the preimpregnated “B” stage material shall be determined per ASTM D 3532 with the following exceptions:

4.7.1.7.1 Cut a randomly selected specimen of prepreg approximately 1/4 x 1/4 inch.

4.7.1.7.2 Precondition a hot plate to 275° ± 2°F (135° ± 1°C).

NOTE: An equipment capable of this tolerance is a Fisher‐Johns Melting Point apparatus.

4.7.1.7.3 Place a microcover glass, sample, and cover, on the hot plate, and begin timing within five seconds. After the resin softens and during the first 30 seconds, probe the top microcover glass and isolate a drop of resin on the periphery of the specimen. Observe the fluidity and color of the isolated resin drop periodically (continuously as the end point approaches). The lateral (spreading) movement of the resin upon probing will decrease, and the color shade will be altered as the gel point approaches. Stop the timer at the first indication of resin immobility, and record elapsed time to nearest second.

4.7.1.7.4 Record the individual results and the average of three determinations.

4.7.2 Chemical Tests for Prepreg ‐ The methods of tests are listed in Table 4 and shall consist of the following:

4.7.2.1 Infrared (IR) Analysis ‐ IR analysis shall be performed per ASTM E 168 with a detail enhancement test procedure documented in a specification approved by The Boeing Company. The IR scan shall include the frequency range of 4000 cm‐1 to 600 cm‐1.

4.7.2.1.1 Report ‐ The infrared analysis scan with appropriate absorption peak records which can be used to obtain determinations of major components shall be supplied to the procuring activity when requested. The report shall record and compare the batch sample analysis with the resin standard infrared analysis spectra established during preproduction qualification. The major absorption bands which are typical of the resin system must be present and the frequency vary no more than ±5 cm‐1 in wave number. Unless otherwise requested by the procuring activity, the infrared analysis scan and reference standard shall be compared and reported as pass/fail.

4.7.2.2 Liquid Chromatography ‐ The high pressure liquid chromatography (HPLC) sample extraction, analysis, and report shall be patterned after the general approach given in ASTM E 682, with a detail enhancement test procedure documented in a specification approved by The Boeing Company.

4.7.2.2.1 The supplier shall develop an HPLC analysis to provide a chromatographic “fingerprint” of key ingredients and advancement of the matrix resin system.

4.7.2.2.2 Two specimens per sample shall be tested and the tabulation of the integrated areas of significant peaks shall be reported as shown in Figure 1.

4.7.2.2.3 Report ‐ A standard chromatogram with appropriate value peak integration for standards which can be used to obtain quantitative determinations of major components and advancement shall be established by the supplier. The report shall record and compare the batch sample significant ratios with the resin standard's significant peak ratio ranges established during production qualification.

TIME ‐ MINUTES

LIQUID CHROMATOGRAPHY PEAKS

FIGURE 1

4.7.3 Specimen Fabrication ‐ The material shall be fabricated into panels of a size large enough for incoming preproduction and production laminate qualification tests.

4.7.3.1 Lay Up ‐ The warp direction of the woven materials shall be the zero degree direction as shown on the specimen drawings (Figures 4, 6, 7, and 8). Ensure alignment and fiber direction is maintained in every layer. Lay up laminates in a balanced configuration: warp/fill ‐ fill/warp. (0/90°) is defined as one ply of woven fabric prepreg with the warp direction being in the zero degree.

4.7.3.2 Bagging ‐ The layed‐up test panels shall be vacuum bagged on a scratch‐free caul plate (minimum 0.20 inch or 5.1 mm thick) using the no‐bleed process, and Method I or Method II bagging procedure as shown in Figure 2. Check to ensure that there is no vacuum loss through the vacuum bag.

4.7.3.3 Panel Cure ‐ The bagged test panels shall be cured using the processing cycle shown in Figure 3.

THE BOEING COMPANY ‐ This information is subject to data rights legends on title page or first page.

BAG SEALANT

BREATHER PAD (1)

SEPARATOR FILM OR FABRIC

PART

RELEASE AGENT OR FILM ON TOOLTOOL

TO VACUUM

NYLON VACUUM BAG

BREATHERPRESSURE PLATE (OPTIONAL)

1″ MIN

3/4″ MIN

NOTES: (1)� Breather pad shall be connected directly to the vacuum source.

(2)� To provide a passage for the release of air and volatiles and maintain a net resin in the laminate apply separator material and breather per one of the following methods;

Method I (a) Apply one layer of a gas permeable separator film or fabric over the laminate and extend to the middle of the breather pad. (Gas permeable separator material allows air and volatiles to escape and retain a net resin).

(b) Apply one layer glass fabric style 181 over laminate.

Connect to the breather pad with a strip of glass fabric 2 to 4 inches wide.

Method II (a) Place fiberglass threads along edges of laminate and…

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File details come from the government source that posted it. Updated Nov 14, 2017.