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AMM
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20 Sep 2007 51-10-00 Doc # 6.02.01
Rev. 5
3. Types of Damage
There are 2 basic types of hidden failure in composite structures:
) Disbonding.
) Delamination.
Disbonding is the failure of a bond between 2 components. For example between the fuselage skin
and a fuselage frame. Or between a composite component and a metal component. Or between a
composite skin and a sandwich core material.
Delamination is the failure of the bond between layers of glass/carbon cloth in a component.
There are also 2 main types of cracks:
) Micro cracks which occur in the surface of the resin.
) Major cracks with broken fibers. Major cracks do not occur with normal flight loads or normal
landing loads. You must repair major cracks.
4. Inspection Techniques
A. Examine Visually
Use this method to find all types of damage to composites. Use a bright light to examine visually
the inside of a component. GFRP must be green or brown. If the GFRP has white areas, then it
may be damaged. Look specially at areas where components bond to the GFRP.
CFRP must be black or black/brown. If the CFRP has white areas, then it may be damaged. Look
specially at areas where components bond to the CFRP.
Look carefully at the outer surface of a component. If the paint has cracks or bubbles, then the
composite may be damaged. Refer to Paragraph 5 in this Section.
Also look for dents. Look specially in areas where stones can hit the airplane below the fuselage
and the wings. Look specially in the areas of the walkways.
AIRCRAFT
DA 40 Series
AMM
Standard Practices and
Structures
Doc # 6.02.01
Rev. 5 51-10-00 Page 3
20 Sep 2007
B. Light Test
Use the light test to find delamination. Use this test on components which do not have rigid foam
inside.
CAUTION: DO NOT LET THE COMPOSITE GET HOT. HEAT CAN CAUSE
DAMAGE TO THE COMPOSITE.
Point a very bright light at the surface and look at the other side of the surface. Damage shows as
a dark area. You can point the light from the inside of a component or from the outside of a
component.
Note: You can use the light test on thick GFRP but it is difficult to use on CFRP.
C. Coin Tap Test
Use the coin tap test to find delamination and disbonding. Tap a coin on the laminate surface in the
area you will test. The sound of the coin tapping on the surface of the laminate will change as you
move the coin over damaged laminate.
Look specially at the area around the damage for secondary damage, which can remain
undetected.
5. Further Inspection
If you find paint damage when you examine a composite structure then do this further inspection.
Find a way to see the inside of a structure or a component. If necessary, remove panels (or other
components), or you can use remote viewing equipment. For example, remove the wing tip assembly
to see inside the wing. If you can see damage inside the component or structure you must do a repair.
Remove the paint coat in the area that you think is damaged. Remove the paint coat carefully, you
must not damage the cloth under the paint coat.
Look carefully at the surface. If you find cracks in the composite you must repair the structure.
If you do not find cracks in the composite then do this test. Push the middle of the area to be tested
with your thumb. If you can feel the skin hitting the core of a sandwich (or other layer/component), then
the skin is disbonded and you must repair the structure.
In some cases you must cut inspection holes in the structure to do the test correctly. If you must cut
inspection holes you must seek advice from Diamond Aircraft Industries.
AIRCRAFT
Standard Practices and
Structures
DA 40 Series
AMM
Page 4
20 Sep 2007 51-10-00 Doc # 6.02.01
Rev. 5
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AIRCRAFT
DA 40 Series
AMM
Standard Practices and
Structures
Doc # 6.02.01
Rev. 5 51-20-00 Page 1
20 Sep 2007
Section 51-20
Repair Processes
1. General
This Section tells you how to repair composite structures. Repairs must be carried out by approved
persons. Refer to Section 51-00 for data about the types of structures. Refer to Section 51-10 for data
about the classification of damage and inspection techniques. Refer to Section 51-30 for data about
approved repair materials.
2. Center of Gravity Limits
When you repair an airplane, you can change the weight of the airplane. If you change the weight of
an airplane, you can change the center of gravity. The further the distance of a repair from the center
of gravity, the greater the effect will be on the center of gravity. You must always weigh the airplane
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