浇铸非金属垫片的安装INSTALLATION OF CASTABLE NON-METAL SHIMS
1. INTRODUCTION 介绍
A. This data in this subject comes from Boeing Process Document D042T613. The airline has or can get a copy of this document.
本主题中的数据来自波音工艺文件 D042T613。航空公司已经或可以获得该文件的副本。
B. The data is general. It is not about all situations or specific installations. Use it as a guide to help you write minimum standards.
数据是通用的。它不适用于所有情况或特定安装。请将其作为帮助您编写最低标准的指南。
C. Refer to SOPM 20-00-00 for a list of all the vendor names and addresses.
供应商名称和地址列表请参考SOPM 20-00-00。
2. SCOPE 范围
A. This subject tells how to make and install castable non-metallic shims. The overhaul instructions will tell you when to use these procedures.
本主题介绍如何制作和安装浇铸非金属垫片。大修说明将告诉您何时使用这些程序。
B. If the overhaul instructions are different from those in this subject, use the overhaul instructions.
如果大修说明与本主题中的说明不同,请使用大修说明。
3. MATERIALS 材料
NOTE: Unless specified, equivalent substitutes must not be used without Boeing approval.
注意:除非另有说明,未经波音公司批准,不得使用等效替代品。
A. Adhesive — Hysol Adhesive EA934NA, Part A and Part B, V33564
粘合剂——Hysol Adhesive EA934NA,A 组分和 B 组分,V33564
B. Methyl Ethyl Ketone (MEK) — TT-M-261 (Ref SOPM 20-60-01)
甲基乙基酮(MEK)——TT-M-261(参考 SOPM 20-60-01)
C. Methyl Isobutyl Ketone (MIBK) — TT-M-268 (Ref SOPM 20-60-01)
甲基异丁基酮(MIBK)——TT-M-268(参考SOPM 20-60-01)
D. Masking Tape — Source optional (Ref SOPM 20-60-04)
遮蔽胶带——可选来源(参考SOPM 20-60-04)
E. Mold Release Agent — Garan 225 (Ref SOPM 20-60-04)
脱模剂——Garan 225(参考SOPM 20-60-04)
F. Mold Release Agent – Frekote 1711 (Ref SOPM 20-60-04)
脱模剂——Frekote 1711(参考SOPM 20-60-04)
G. Cheesecloth — Source optional
粗棉布——可选
H. Milled Glass Fibers — 1/32 or 1/16 inch length, cationic binder, V45255, or equivalent
研磨玻璃纤维——1/32或1/16英寸长,阳离子粘合剂,V45255或同等产品
I. Phenolic sheets — MIL-P-15035
酚醛板——MIL-P-15035
J. Series 88 solvents (Ref SOPM 20-30-88)
88系列溶剂(参考SOPM 20-30-88)
K. Series 91 solvents (Ref SOPM 20-30-91)
91系列溶剂(参考SOPM 20-30-91)
4. PREPARATION OF SURFACES TO BE SHIMMED 待安装垫片表面的准备
A. Composite Surfaces
复合表面
(1) Mark off the areas to be shimmed.
标记出待安装垫片区域。
(2) Apply masking tape around to be shimmed to let unwanted adhesive be squeezed out on the masking tape and not on the surfaces of the parts. Give the area protection from contamination until the shim is applied.
在需要垫片的区域周围贴上遮蔽胶带,将多余的粘合剂挤出到遮蔽胶带上,而不是零件表面。在垫片安装前,防止该区域受到污染。
(3) With sandpaper, 150 grit or finer, remove the finishes from the surface to be shimmed. Do not go into the fibers or Tedlar bondable film on the inner surface.
使用150目或更细的砂纸,去除需要安装垫片的表面的涂层。不要触及内表面的纤维或Tedlar可粘合膜。
NOTE: Most composite parts have a bondable film layer (Tedlar) on the inner surface. This layer must not be removed, grit or sandblasted. Adhesive must be applied directly over the bondable film.
注意:大多数复合零件的内表面都有一层可粘合的薄膜(Tedlar)。 切勿去除、打磨或喷砂这一层。 粘合剂必须直接涂在可粘合的薄膜上。
(4) Clean the film or the sanded surface with a Series 91 solvent (Ref SOPM 20-30-91) with clean, oil-free cheesecloth.
用91系列溶剂(参考SOPM 20-30-91)和干净的无油粗棉布清洁薄膜或打磨表面。
B. Metal Surfaces
金属表面
(1) Mark off the areas to be shimmed.
标记出需要垫片的区域。
(2) Apply masking tape around the area to be shimmed, as in Paragraph 4.A.(2) above.
在需要垫片的区域周围贴上遮蔽胶带,如上文第4.A.(2)段所述。
(3) Do not remove the finishes from the mating metal surface which will touch the shim.
不要去除与垫片接触的金属表面的涂层。
(4) Clean surface to be shimmed with a Series 88 solvent (Ref SOPM 20-30-88) with clean, oil-free cheesecloth.
用88系列溶剂(参考SOPM 20-30-88)和无油干净的粗棉布清洁要垫片的表面。
CAUTION ：DO NOT LET MOLD RELEASE AGENT TOUCH MATERIALS OR PARTS WHICH COULD BE LATER PAINTED OR BONDED.
注意:不要让脱模剂接触以后可能被喷漆或粘合的材料或零件。
(5) Apply mold release agent to metal fitting surface to be shimmed. Spray it on, or wipe it on with clean cheesecloth. This agent will let you remove the shim later, if necessary.
在需要垫片的金属配件表面涂抹脱模剂。喷上或用干净的粗棉布擦拭。如有必要,脱模剂可让您以后移除垫片。
5. MIXING AND PREPARING OF ADHESIVE 粘合剂的混合和准备
A. Mixing
混合
(1) Thoroughly mix 98-102 parts by weight of part A (resin) and 32.5 – 33.5 parts by weight of part B (hardener).
按重量比充分混合 98-102 份 A 组分(树脂)和 32.5-33.5 份 B 组分(硬化剂)。
(2) Weigh 12-24 parts by weight of milled glass fibers.
称重 12-24 份研磨玻璃纤维。
(3) Gradually add glass fibers to mixture of Paragraph 5.A.(1) and mix fully. Continue to mix until the glass fibers are fully mixed with the adhesive.
将玻璃纤维逐渐加入第5.A.(1)段的混合物中,充分混合。继续混合直至玻璃纤维与粘合剂充分混合。
(4) If foam or air occurs in the mixture, vacuum de-aerating is recommended to minimize voids. Use a vacuum of 25 inches Hg until the foam diminishes. Release vacuum periodically to collapse the foam.
如果混合物中出现泡沫或空气,建议进行真空脱气以减少空隙。使用25英寸汞柱的真空度,直至泡沫减少。定期释放真空以使泡沫塌陷。
B. Pot Life and Storage
适用期和储存
(1) Pot life of mixture (part A and B blended) is a minimum of 30 minutes when mixed per Paragraph 5.A.(1).
按照第5.A.(1)段混合后,混合物的可使用时间(A、B两部分混合)至少为30分钟。
(2) After mixture is blended with glass fibers, it can be stored at temperature below -20°F for not more than 15 days. Material premixed and stored in this condition must be thawed at room temperature before you use it.
混合物与玻璃纤维混合后,可在低于-20°F的温度下保存不超过15天。预混合并在此条件下保存的材料在使用前必须在室温下解冻。
(3) Individual unmixed components of adhesive (part A and part B) must be stored in clean, airtight containers at room temperature (40-80°F). When stored in this condition, the shelf life of the individual unmixed components is a minimum of 90 days from the date of shipment from the supplier.
未混合的粘合剂各成分(A 组分和 B 组分)必须储存在干净、密闭的容器中,置于室温(40-80°F)下。在此条件下储存时,未混合的各成分自供应商发货之日起至少可保存 90 天。
6. SHIMMING PROCESS 安装垫片工艺
NOTE: If overhaul instructions do not specify any shimming process in particular, either Class 1 or Class 2 processes may be used.
注意:如果大修说明没有特别说明任何安装垫片工艺,则可以使用1级或2级工艺。
A. Class 1 Process — Curing pressure applied by clamp-up or tooling fixtures.
1级工艺——通过夹具或工具夹具施加固化压力。
(1) Before you apply the adhesive to the faying surfaces, temporarily put the mating surfaces together with clamps. Measure the gaps between the parts, by any method of measurement which will give a true gap reading.
在将粘合剂涂到接合表面之前,用夹具将配合表面暂时固定在一起。通过任何能够给出真实间隙读数的测量方法测量零件之间的间隙。
(2) Make sure that all gaps agree with the overhaul instructions before the adhesive is applied.
在涂胶前,确保所有间隙符合大修说明。
(3) Prepare surfaces to be shimmed per Paragraph 4.
根据第4段准备要安装垫片的表面。
(4) Prepare adhesive per Paragraph 5.
根据第5段准备粘合剂。
(5) Apply a thin layer (approximately 0.15 inch thick, with more at the center for resin squeeze-out) of mixed adhesive to faying surface of one of the mating parts.
在其中一个配合零件的接合面上涂上一层薄薄的混合粘合剂(约0.15英寸厚,中间部分要厚一些,以便挤出树脂)。
(6) Join the faying surface of the other metal fitting with the faying surface of the part with adhesive.
将另一金属配件的接合面与涂有粘合剂的零件的接合面接合。
(7) Apply clamping pressure at the bondline within the 30-minute pot life of adhesive. Pressure must be sufficient to keep the specified gap limits, as measured in Paragraph 6.A.(1) and Paragraph 6.A.(2) preceding, after the adhesive is cured.
在粘合剂30分钟的使用期限内,在接合面上施加夹紧压力。施加的压力必须足以保持第6.A.(1)段和第6.A.(2)段中规定的间隙限制,在粘合剂固化后测量。
(8) Make a check of the clamping pressure within 30 minutes after you first applied the pressure. By this time, the unwanted adhesive will be squeezed out at the bondline. Tighten the clamps as necessary to keep the gap of the overhaul instructions and be sure that contact exists of high spots stay in contact.
在首次施加压力后的30分钟内检查夹紧压力。此时,多余的粘合剂将被挤出粘接线。根据需要拧紧夹具,以保持检修说明中的间隙,并确保高点的接触保持接触。
(9) Clean up unwanted adhesive that squeezes out at the bondline, with cheesecloth wet with MIBK or MEK. Wipe the off solvent with a clean dry cheesecloth. Do not wait too long to clean, because the adhesive becomes more difficult to remove as it sets.
用蘸有MIBK或MEK的粗棉布清理溢出粘结线的多余粘合剂。用干净的干粗棉布擦去溶剂。不要等待太久才清理,因为粘合剂凝固后更难去除。
(10) Cure the adhesive as shown in Table 1. Keep the clamping pressure on the shim until cure is complete.
按表1所示固化粘合剂。在固化完成前保持对垫片的夹紧压力。
(11) Do not drill holes through the adhesive shim, as to install bolts, until the shim is set at room temperature for a minimum of 12 hours.
在粘合垫片在室温下放置至少12小时之前,请勿在粘合垫片上钻孔安装螺栓。
B. Class 2 Process — Curing pressure applied by pulling torque on bolts. (Lets you use the hole location callout to make installation easier)
2级工艺——通过螺栓的拉力施加固化压力。(使用孔位置标记,使安装更加容易)
(1) Drill a bolt hole (1/32 inch smaller than the bolt specified by the repair manual parts list) at each fastener location in each metal fitting and composite part to be shimmed. Hole size and condition must meet requirements of overhaul instructions by the time shim installation is completed. Make sure that holes in each part are properly aligned.
在每个需要垫片的金属配件和复合零件的每个紧固件位置钻一个螺栓孔(比修理手册零件清单中规定的螺栓小1/32英寸)。在完成垫片安装时,孔的大小和状态必须符合大修说明的要求。确保每个零件上的孔都正确对齐。
(2) Assemble the parts and install bolts in each hole.
组装零件,并在每个孔中安装螺栓。
(3) Measure the gaps between the parts at each bolt location, by any method of measurement which will give a true gap reading.
用任何能给出真实间隙读数的测量方法测量每个螺栓位置处零件之间的间隙。
(4) Make sure that all gaps agree with the overhaul instructions before the adhesive is applied.
在涂胶前,确保所有间隙符合大修说明的要求。
(5) Prepare surfaces to be shimmed per Paragraph 4.
根据第4段准备要安装垫片的表面。
(6) Apply mold release agent to the bolts to make them easier to remove after the adhesive is cured.
在螺栓上涂脱模剂,以便在胶固化后更容易拆卸。
(7) Prepare adhesive per Paragraph 5.
根据第5段准备粘合剂。
(8) Apply a thin layer (approximately 0.15 inch thick, with more at the center for resin squeeze-out) of mixed adhesive to faying surface of one of the mating parts.
在两个配合零件的接合面上涂上一层薄薄的混合粘合剂(约0.15英寸厚,中间部分要厚一些,以便挤出树脂)。
(9) Assemble the parts and install undersize bolts. Tighten the nuts on the bolts within the 30-minute pot life of the adhesive. Torque on bolts must be sufficient to keep the specified gap limits as measured in Paragraph 6.B.(3) and Paragraph 6.B.(4) preceding, after adhesive is cured.
组装零件并安装尺寸过小的螺栓。在粘合剂30分钟的适用期内拧紧螺栓上的螺母。粘合剂固化后,螺栓的扭矩必须足以保持第6.B.(3)和第6.B.(4)段中规定的间隙限制。
(10) Make a check of the torque on the bolts within 30 minutes after you first applied the torque. At this time, nuts can be tightened as necessary to keep the gap conditions specified per overhaul instructions and to be sure that high spots stay in contact between mating surfaces.
在首次施加扭矩后的30分钟内检查螺栓的扭矩。此时,可根据需要拧紧螺母,以保持大修说明中规定的间隙条件,并确保高点在配合表面之间保持接触。
(11) Clean up unwanted adhesive that squeezes out at the bondline, with cheesecloth wet with MIBK or MEK. Wipe off the solvent with a dry clean cheesecloth. Do not wait too long to clean because the adhesive becomes more difficult to remove as it sets.
用蘸有MIBK或MEK的粗棉布清理溢出粘结线的多余粘合剂。用干净的干粗棉布擦去溶剂。不要等待太久才清理,因为粘合剂凝固后更难去除。
(12) Cure the adhesive as shown in Table 1. Keep the pressure on the joint with the bolts in each hole until the adhesive is cured.
按表1所示固化粘合剂。用螺栓将每个孔中的接头保持加压,直到粘合剂固化。
(13) Remove the undersize bolts. Drill the holes to the size as given in the overhaul instructions. Then install fasteners as necessary. As each undersize bolt is removed, install the specified fasteners at that location before you remove the next bolt.
拆下尺寸过小的螺栓。按照大修说明中的尺寸钻孔。然后根据需要安装紧固件。在拆下每个尺寸过小的螺栓时,先在该位置安装指定的紧固件,然后再拆下下一个螺栓。
