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The rudder has left and right shells. Each shell has GFRP skins with a rigid foam core. The shells bond
together at a flange.
The canopy is a CFRP molding with inner and outer frames which bond together. The canopy has a
large one-piece acrylic glass window. The passenger door is a CFRP molding with inner and outer
frames. The frames bond together. The door has an acrylic glass window.
A polyurethane paint finish protects the outside skin of the airplane from ultraviolet rays and humidity.
AIRCRAFT
Standard Practices and
Structures
DA 40 Series
AMM
Page 2
20 Sep 2007 51-00-00 Doc # 6.02.01
Rev. 5
2. Types of Structure
The DA 40 is constructed from 2 main types of composite structure.
A. Glass Fiber Reinforced Plastic (GFRP)
GFRP is very thin glass fibers bonded together by resin. The glass fibers give most of the strength
and the resin maintains the shape. The resin also bonds to other structural components such as
metal attachment brackets or metal bushings.
The glass fibers are woven to make glass cloth. The orientation and weave of the glass in the cloth
affects the structural strength of the cloth. A component can have many layers of cloth bonded
together with resin. This is called lamination.
GFRP has very good properties. It is strong and flexible. It is very resistant to chemical attack and
very little maintenance is necessary.
B. Carbon Fiber Reinforced Plastic (CFRP)
CFRP is very thin carbon fibers bonded together by resin. The carbon gives most of the strength
and the resin maintains the shape. The resin also bonds to other structural components such as
metal attachment brackets or metal bushings.
CFRP is very similar to GFRP. The main advantage of CFRP is that it is stronger and more rigid
than GFRP.
3. Laminated Components
A laminated component has 2 or more layers of glass/carbon cloth. The direction of the fibers in the
cloth give the properties for each layer. Extra layers are bonded to areas to give more strength.
4. Sandwich Structure
Many of the components in the DA 40 have a sandwich of 2 skins and a core. GFRP or CFRP make
the skins and rigid plastic foam makes the core.
The skins must bond to the core of a sandwich structure completely. If the skins do not bond to the
core the component can fail.
AIRCRAFT
DA 40 Series
AMM
Standard Practices and
Structures
Doc # 6.02.01
Rev. 5 51-00-00 Page 3
20 Sep 2007
5. Bonded Components
A number of components can bond together to make a larger component. Special thick resin bonds
these components together and fills the gap in a joint.
6. Repair Limitations
Repairs which are categorized as 'Class 1' in accordance with Section 51-10, Paragraph 2, may only
be carried out in accordance with a repair scheme which has been approved by the manufacturer.
Such repairs are not described in this Airplane Maintenance Manual.
AIRCRAFT
Standard Practices and
Structures
DA 40 Series
AMM
Page 4
20 Sep 2007 51-00-00 Doc # 6.02.01
Rev. 5
Intentionally left blank
AIRCRAFT
DA 40 Series
AMM
Standard Practices and
Structures
Doc # 6.02.01
Rev. 5 51-10-00 Page 1
20 Sep 2007
Section 51-10
Investigation
1. General
This Section tells you how to assess the class of the damage. It also tells you how to inspect glass
fiber reinforced plastic (GFRP) and carbon fiber reinforced plastic (CFRP) composite structures.
Damage assessment and repairs must be carried out by approved persons.
Refer to Section 51-00 for the types of structure used in the DA 40 and for repair limitations. Refer to
Section 51-20 for general repair procedures.
2. Damage Classification
Damage is divided into the classes described below. In doubtful cases (i.e., if you are not sure about
the classification of a damage), you must contact the airplane manufacturer.
A. Class 1
) Major structural damage that requires the partial replacing of a structural component, or
) damage to a large area, or
) damage to a highly stressed component or part.
This type of damage restricts or voids airworthiness.
B. Class 2
Holes and cracks passing through both skins of a sandwich construction component. The core
damage must be able to be covered by a 75 mm (3 inches) diameter circle.
C. Class 3
Small holes or cracks in the outer skin where there is no internal damage to the component, the
sandwich material, or the inner skin.
D. Class 4
Minor scratches, abrasions or similar damage which is not a crack or a puncture in the skin.
AIRCRAFT
Standard Practices and
Structures
DA 40 Series
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