DI-SESS-82451

Composite Repair Report

Describes the format, content, and use of the report documenting, monitoring, and approving individual item composite repairs at each stage of the repair process.

Approval DateJuly 9, 2024

AMSC NumberN10493

Preparing ActivityAS

Project NumberSESS-2024-048

OPR—

DTIC ApplicableNo

GIDEP ApplicableNo

Limitation—

Applicable Forms—

Approval Limitation—

Form Version—

DID Formatfree_text

963C CompliantYes

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

Supersedes

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Description & Purpose

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Application & Interrelationship

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Use & Relationship

The report will be used to document, monitor and approve individual item composite repairs at each stage of the repair process.

This DID contains the format, content, and intended use information for the data product resulting from the work task described in the contract SOW.

Preparation Instructions

1Reference documentsThe applicable issue of documents cited herein, including their approval dates and dates of any applicable amendments, notices, and revisions, shall be as specified in the contract.

2FormatThe report shall be in contractor's format.

3ContentThe report shall contain the following:

3.1Government Furnished Equipment Inventory

3.1.1Government Furnished Equipment Inventory (General)This section shall identify the following for each repairable item received:

3.1.1.1Contract Number

3.1.1.2Contractor's Cage Code

3.1.1.3Contractor Point of Contact

3.1.1.4Location of GFE

3.1.1.5Date Inventory Completed

3.1.2Government Furnished Equipment Inventory (Items)This section shall identify the following for each item that comprise the repairable item:

3.1.2.1Asset Identification Number (Asset ID#)

3.1.2.2Unique Item Identifier (UII) or DoD recognized Item Unique Identifier (IUID)

3.1.2.3National Stock Number (NSN)

3.1.2.4Unit or Item Cage Code

3.1.2.5Part Number (P/N)

3.1.2.6Nomenclature (NOMEN)

3.1.2.7Serial Number (S/N)

3.1.2.8Model Number (M/N), if applicable

3.1.2.9Manufacturer

3.1.2.10Quantity

3.1.2.11Delineation whether the item is the subject of this composite repair report

3.1.2.12Visual condition if the item is not the subject of this composite repair report

3.2Beyond Economical Repair (BER) DeterminationThis section documents the assessment of whether the item is BER. This shall include:

3.2.1Government Furnished Information (GFI) regarding how the item was damaged

3.2.2GFI provided description of the damage

3.2.3GFI photos of the damage

3.2.4Contractor's summary of how the BER determination was made, and the Contractor's final recommendation

3.3Repair Concept

3.3.1Preliminary Damage DeterminationThis section documents the extent of the damage to include:

3.3.1.1Description of the type and nature of damage that has occurredExamples include bond failure, crushed laminate, or oversized holes.

3.3.1.2Photographic documentation of the damaged area to include

3.3.1.2.1Location in inches from recognizable or geometric features(i.e. super-seam, bonded joints, or build-up regions) features and dimensions (length and width) of the damage shall be included.

3.3.1.2.2Photos should show close up, as well aslarge-scale views of the air vehicle so the damage location is apparent.

3.3.1.3Procedures and results of Nondestructive Inspection (NDI)

3.3.1.4A description of what NDI technique(s)/method(s) were usedto determine extent of damage, the input parameters used (as applicable), what reference standard was used (if applicable), and a test set-up summary (including orientation of item, test equipment/instrumentation and drawings, and illustrations or photographs for clarification). NDI procedures should be provided if available.

3.3.1.4.1Identification of each item of test equipment/instrumentation usedin the inspection as applicable. Include the nomenclature, model number, serial number, manufacturer, calibration status, and vendor provided accuracy if available.

3.3.1.4.2Identification of all documents usedExamples include prior test/inspection reports on the same item, test/inspection plans or procedure documents.

3.3.1.4.3Description of resultsShow results through tables, charts, and graphs as appropriate.

3.3.2Damage AssessmentThis section shall include the analysis and discussion of how the damaged area was assessed to include:

3.3.2.1A summary of the results for analysis of the damaged item

3.3.2.2Description of the assessment and why the methods used are sufficient for the given type of damageInclude the assumptions used to complete the analysis.

3.3.2.3Descriptions of the load cases and the determinationof how those load case(s) are worst case (i.e. critical) with respect to the damaged area.

3.3.2.4The new margins determined when taking the damage into accountIf the damage does not affect the margins this should be stated.

3.3.3Repair Concept, Analysis, and Validation PlanThis section shall describe the process used to determine the repair, details how the repair will be completed, and how the repair will be validated. This shall include:

3.3.3.1Details of the proposed repair to include

3.3.3.1.1Material that will be used for repair

3.3.3.1.2Material properties assumed for the repair, and how they were determined

3.3.3.1.3Material removal and patch preparation process

3.3.3.1.4Bonding, lamination, debulk and curing processes as appropriate

3.3.3.2Repair analysis that addresses the repair sufficiency forthe critical load case(s), and why the stiffness of the repair will not have a detrimental impact.

3.3.3.3Post-repair validation planIf proof load testing is proposed, address how the proof load test will stress the damaged area of concern, and provide any supporting analysis for the critical load cases(s).

3.3.3.4Other repair related data as needed

3.4Repair and Post Repair Validation

3.4.1RepairThis section shall document the steps of the actual repair. This shall include:

3.4.1.1Description and photographs of all repair steps

3.4.1.2Explanation of deviations from the previously generated RepairConcept, Analysis, and Validation Plan in paragraph 0.

3.4.1.3Damage mapping to illustrate the extent of the damage and the repair both before and after surface preparationLocation and dimensional references shall be included in all illustrations. Information on the number of remaining good plies and unaffected thickness shall be provided.

3.4.1.4Repair processes utilized and the standards, equipment, tools, calibrations used to complete the repair process

3.4.1.4.1Material removal and patch preparation process

3.4.1.4.2Bonding, lamination, debulk, and curing processes as appropriate

3.4.1.4.3Repair material lot and shelf life

3.4.1.5Repair Technician Certification or documentation of training

3.4.2Post Repair ValidationThis shall address the post repair validation per the planning discussed in paragraph 0. The purpose of this section is to show the item has been repaired properly. The information in this section shall include:

3.4.2.1NDI results of the area of repair demonstrating it was repaired properly

3.4.2.1.1A description of what NDI technique(s)/method(s) were usedto evaluate the repair, of input parameters used (as applicable), what reference standard was used (if applicable), test set-up summary (orientation of item, test equipment/instrumentation and drawings, illustrations or photographs for clarification). NDI procedures should be provided if available.

3.4.2.1.2Identification of each item of test equipment/instrumentation used inthe inspection as applicable: nomenclature, model number, serial number, manufacturer, calibration status, and vendor provided accuracy if available.

3.4.2.1.3Identification of all documents usedExamples include prior test/inspection reports on the same item, test/inspection plans or procedure documents.

3.4.2.1.4Description of resultsShow results through tables, charts, and graphs as appropriate.

3.4.2.1.5Acceptability of any identified voids or porosity

3.4.2.2If proof load testing is needed, provide test procedures and results

3.4.2.3Discussion of any repairs that failed validation via NDI and/or proof load testAddress the need for improved repair process/procedures and/or inspections, or test procedures.

3.4.3Airworthiness RecommendationThis section shall provide the Contractors airworthiness recommendation for the repaired item, and document any residual risks from an airworthiness perspective.

References

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