ASK 21 Repair Manual 2016 09 26

User Manual: ASK-21 Repair Manual 2016-09-26

Open the PDF directly: View PDF .
Page Count: 34

nsH 2t

Flight Manua I

lnstructions For Continued

Airworth iness

Repair Manual

ALEXANDER SCHLEICHER GMBH & CO., SEGELFLUGZEUGBAU

D-361 63 POPPENHAUSEN (WASSERKUppE)

Tel. +49 (0) 06658 /89-0 Fax +49 (0) 06658 I 8940

www. alexander-schleicher.de

REPAIR MANUAL

Repair Manual

REPAIR MANUAL

Table of Contents

2. GeneralDirections

3. Repair Methods & Classification

4. Repair Materials + Useful Aids

5. Preparing the Parts for Repair

6. Repair Classes

7. Summary

8. New Materials Carbon & Aramid

9. Tables and Diagrams

Materials Used and Supply Reference

Repair lnstructions and Technical Notes

Page 1

Page 2

Page 3

Page 4

Page 5

Page 7

Page 8

Page 1 1

Page22

Annex

January 1994

July 1994

July 1998

April1999

ALEXANDER SCHLEICHER with the

lssue February 1983

Amended and corrected :

Amended :

Published by the author

assistance of Martin Heide.

Translation into English has been done by best knowledge and judge-

ment. ln any case of doubt the original text in German language is

controlling.

Alexander Schleicher GmbH & Co. D-36'163 PoppenhausenM/asser-

kuppe

consent of the publisher.

Rev.No./Date Sig.

13.04.'1999 Juw

Author Date

Heide Feb.1983

Page no.

Repair Manual

2. General Directions

Any material to be used for a repair must be suitable

for tha intended repair purpose, must fullfill the ac-

ceptance requirements of the compstent Civil or Milit-

ary Acceptance Authority, and must be stored aecording

to the makers' prescriptions.

To ensura that these ponditions ate met, it is advis-

able to obtain a stock of fiber cloth, resin and har-

dener, as well as the manufacturer's main layer scheme

drawings, already before the beginning of competitions

and to store the materials {even the clothl in air-

tight packs at about 20 oC. lt is also advisable to

make yourself familiar with the literature relevant to

the subiect on fiber composite repair methods.

We recommend -

in German: 'rYortiufige Richttinien f0r die ReparEtur von GFK-Tei

ten (i.e. Provisionat Guidetines for the Repair of GRp Compo

nents.r); nay be obtained from: DLR, Litienthal.pl.att.7,

38108 ERAUllSCHrrEIc.

or in English: I|IL-HDBK-23 Part 1; nay be obtained from: Govern

Dent Printing Office, lrashington 25 D.C., USA.

Abrupt change in thickness of laminate should be avoid-

ed in order to prevent stress concentration areas, and

wherever possible the areas cut out should . be oval and

circular instead of rectangular. The transition bet-

ween repair and undamagad area should be as gradual

and smooth as possible.

The scarf or taper angles for fiber composite materi-

als should be between 1 : 50 and to 1 I 100. Thin lami-

nate layers cannot be scarfed; here the joints must

overlap. ln case of bFdirectional cloth (equal number

of fibers in warp and weft), the overlap lengths should

be about 10 mm per 100 g/m- of cloth weight. With pre-

dominantly uni-directional cloth {reinforced warp) the

overlap Jengths of the warp should be - 20 mm per

100 g/m-. The weft fibers need not overlap. For exact

values see diagram "Overlap Lengths".

Rev.No.lDate. SiS. Author Date

July 1994 Page No.

Repair Manual

Fiber composite materials are susceptible to water.

Therefore, wet sanding of repaired areas must' be avoid'

ed. For the same reason it is also important that all '

repaired areas be preserved by paint finish after the

inspection - wherever neceqsary by a licensed inspec-

tor.

3. Reoair Methods & Classification

The methods described hereafter apply only to smaller

repairs. Maior repairs must only be carried out by the

manufacturer of the relevant part, or by an appropri-

ately licensed aviation repair station; major repairs

also require a new release inspection. Many referencss

given hereafter apply to the repair of sandwich areas

because they are particularly tricky for repair due to

their structure. These described methods are analogous-

ly applicable to any simple fiber composite skin re-

pair.

Repair Classilication

Sometimes it may be necessary to do a temporary repair

while ths permanent repair over a larger area will

then be carried out later by the manufacturer. Such

provisional repairs ar€ usually done mostly only super-

ficially and are not the subiect of these repair in-

structions.

Repairs are divided into the following classes, accord-

ing to the extent to which the damage affects the air-

worthiness of the entire aircraft.

CTASS 1: Large area destructions requiiing partial re-

placement of the componont or a repair over

a large erea, i.e. damage to highly stressed

components which impair the airworthiness,

must only be repaired by the manufacturer of

the relevant component, or by an appropriate-

ly licensed aviation repair station.

Rev.No./Date. SiS. Author Date

July 1994 Page llo.

Repair Manual

5. Preoarino the oarts for reoair

Wherever possible all damaged components should be rc'

moved from the aircraft prior to their repair. They '

should then be cleaned with soap-suds and thoroughly

dried. Now use a solyent (tri'chlor'ethylene, carbon

tetra-chloridel to remove any wax and grease residues

from the repair area. Finally the aree is sanded using

glass paper of grade 60 to 80. The surrounding areas

are covered with stout paper or plastic foil to pro-

tect them from being soiled by resin drops.

6. Reoair Classes

Class 4 Reoair

Surface abrasions, scratches and grooves (provided the

fiber glass laminate has not been damaged) usually ony

require a new protective coat. Polyester paint is

ideal for this {mixture of 100 parts UP gelcoat, white

03-69469, with 3 parts hardener 07-20500). To fill

dee+sr grooves, the paint can be allowed to gel slight-

ly {about 30 min.}. lf the reinforcement layers have

been damaged, the areas must be cleaned and, if neces-

sory, smoothed down lightly with glass paper. Then one

layer of fine glass cloth is applied over the erea and

covered with plastic foil. When the resin has harden-

ed, use filler and re-paint.

Class 3 Reoair

The damaged outer laminate skin is cut out over a suf-

ficiently large area in rounded shapes. Be careful to

remove any detached laminate layers from the core ma-

terial. Then the edges of the damaged outer skin must

be sanded down to a very flat taper. The laminate

layers which become visible like coniour lines, pro-

vide a good guide for the evenness of the taper. lf

the supporting core material has also been damaged, it

must be removed, where necessary, right down to the

inner laminate. Please note that the core material is

repaired usirp Balsa wood of the specific weight 0'15

- 0.19 kg/dm'. Scarf ratio is 1 : 5 in the direction

of the fiber.

Rev.No./Date, SiS. Author Date

July 1994

Page ilo.

Repair Manual

No scarf is made at right angles to the fiber direc-

tion. The foam cors matarial - Conticell or Rohacell -

is not scarfed (see Fig. 3a and 3b).

The cloth for the new outer laminate skin is now cut

to size; where the largest cut piece should just cover

ths entire sanded area and the smallest cut piece

should be the size of the removed core material area.

All remaining layers shpuld be graded in equal steps

between these two extreme sizes.

A suitable technique is: a suitably larger piece of

cloth is laid on a plastic foil and impregnated with

resin, using a paint brush or a rubber smoother, then

it is covered with a second plastic foil and all air

bubbles and excess resin is squeezed out. Together

with these foils tha laminates are then cut to size'

Now first the new core material piece is impregnated

and inserted in its place. Then the laminates are laid

in, starting with the largest cut piece. To do this

the bottom foil is torn off, the laminate inserted,

and then the upper foil is peeled off, etc. All

further repair steps are similar to those described

under Class 4. For unsupported skin laminates proceed

analogously. Perhaps it needs in this case first a

piece of foam to be glued to the bottom surface to pre'

vent the

(Fig.1.). wet cloth laminate from sagging down

Class 2 Reoairs

Damage which has penetrated both laminate skins, can

be repaired as follows: alt damaged areas in the skins

and in the core material are cut out; the skins here

again being cut in either oval or round shape. GRP lam-

inate skins are sanded to a very ftat . laper (1 :50 up

to 1 : 100) and the Balsa wood is scarfed in along the

fiber direction (1 : 5). When the new core material

has been inserted, the laminates are glued in as des'

cribed under Class 3 repairs. First on one side only,

and then after the first skin has cured completely,

the laminate on the other side is glued on {Fig.2}.

Rev.No./Date. Sis. Author Date

July 1994

Page No.

Repair Manual

lf there is no or only very difficult access to the

inner skin of the sandwich, the repair area should

be prepared as shown in Fig.3. Becausa the inner

skins of thE sandwiches (wing; tailplanel are very

thin throughout, they ca0not be scarfed, but. only

overlapped. However, this fact simplifies the re'

pair somewhat as the lower laminate skin need not

be scarfed.

The cloth layers of the upper laminate skin are pre-

pared as described for Class 3 repairs. The lower

skin layers are laminated onto the underside of the

core materiat and then allowed to gel for 2 to 3

hours at 20 to 23 oC. Now fresh resin-hardener mix-

ture is applied to the glue joints and the core

pieca with the lower laminate skin already glued

on, is inserted and glued into place under light

pressure. The upper laminate skin can then be re-

paired as described for Class 3 repairs.

lf there is the risk tespecially in the case of larg'

er holes) that this thin, unsupponed inner laminate

skin will ba displaced when the core material is

glued in place. then it should be supported from the

inside by some foam pieces beforehand. Styro-foam

used with Uhu'por glue has proved useful here. lf

the inside area is inaccessible, the foam pieces can

remain in these repaired areas permanently.

Class 1 Reoairs

Such repairs should be reserved to the manufacturer

or to an appropriately licensed aviation repair sta-

tion. ln any case the manufacturer and the compa-

tent Civil Aviation Authority must be contacted'

7. Summino uo,

the following Points

successfi.tl repairs: are particulary important for

1. A bright, warm (20 ocl, and dry room (50 % rela-

tive humidity).

2. Grease-free, cleanly sanded glue surfaces (watch

hand sweat!).

Rev.No.lDate. Sig. Author Date

July 1994 Page No.

Bepair Manual

3. Use of original materials; resin

must not be older than 2 years. and hardener

4. Glass cloth treated with Volan A finish or I 550

finish, stored in dry condition. Observing pot

life and curing time. A well mixed resin/harden'

er mixture {crystallized hardener can be regen-

erated by warming it up to 30 ocl.

8. New Materials CarboJL& Aramid

There are now in addition to the so tar used standard

glass fibers the late-technology carbon and aramid

fibers (aramid is also known as Kevlar or PRDI which

have alredy been used for main components in the

series construction of the ASW 22. ln composite with

3 resin system these materials are known as CFRP (gar-

bon Eber Beinforced fllastics) and SFRP E standing

for the aramid fiber including $ynthetic Eiberl.

Components in various SCHLEICHER sailplanes are built

from these new fibers, e.g. -

- Wng spar flanges Carbon fiber rovings {ASW 22).

- Wing shells CFRP-Conticell sandwich {ASW22}

- Fuselage tail boom CFRP fabric strips (ASW 22)

- Control surfaces & SFRP and SFRP-Rohacell-sandwich

flaps {ASW 20 B/C and ASW 22}

The general repair instructions given here before for

GRP fibers, are also applicable to the above new ma-

terials. dny differences for repairs with carbon and

kevlar fibers are described hereafter.

Soecial Notes

Resin

When repairing CFRP and SFRP components it must be ob-

served that these fibers require a different type of

resin-hardener system than GRP repairs. ln order to

get ths maximum use of the strength of carbon and

kevlar fibers at higher temperatures, an epoxy resin

must be used which provides still sufficient strength

at 54 oC temperature.

Rev.No./Date. Sis. Author Date

July 1994 Page llo.

Repair Manual

For this reason tho usual Epikote 162 cannot be used.

SCHLEICHER uses for these components the resin L 160

with hardener 163 (100 parts resin : 28 parts harden-

er). Tha components must be cured at least 15 hours

at above 55 oC.

Carbon fibers

Broken CFRP parts splinter badly so that there is in-

creased risk of injury; gloves should always be worn

when working on such fractures. A major disadvantage

for sueh repairs is that thg delaminations do not

show distinctly by visible white areas - as in the

case of glass repairs. To detect the extent of the

damage, therefore, the areas surrounding a damaged

region must be examined with the greatest care for

hardly visible cracks, e.g. by loading or pressing

them.

Even when only the paint appears to be damaged. you

will find sometimes damage in a CFRP laminate where a

GRP laminate would have been still undamaged under-

neath.

Basically cloth or rovings trom carbon fibers can be

worked up in the same way as glass fibers. lf you

have to repair laminates where the carbon fibers run

into one direction only while glass fibers run in the

other direction (e.9. lnterglas 02902), such layers

are treated as uni-directional or warp-reinforced

layers and the glass need not be scarfed.

Overlap lengths of th6 different cloth weaves or rov-

ings (mats) are given in the diagram. Note that the

scarf length must only be half as long as the over-

laps.

When wetting them with reiin you will notice that the

wetting through of the cloth is not visible. The solu-

tion here is to weigh the cut carbon piece which is

to be used for the repair, and to work on it with the

corresponding calculated resin-hardener amount. For a

Rev.No./Date. Sig. Author Date

July 1994 Page llo.

Repair Manual

CTASS 2: Holes and fractures which e.g. run through a

sandwich structure destroying both laminate

skins, but only over a smaller area.

CTASS 3: Small holes and fractures in the outer skin

which have not resulted in any internal da-

mage, neither to ths core material {foam,

Balsa, tubus! nor to the inner laminate

skin.

CLASS 4: Abrasions, scratches and grooves which do

not involve a fracture or break.

4. Reoair materials and useful aids

For all repairs it is important C know the number of

layers, the cloth weight per rh', and the fiber direc-

tion of the laminated cloth. This information is de-

tailed in the layer scheme drawing of the component in

question or can be inquired of the manufacturer. ln an

emergency, it is possible to establish the composition

of a laminate by burning out the resin {gas welding

torch) on a broken piece from the area needing repair.

The glass cloth used must be treated with Volan A

finish, or !-550, and be stored in dry conditions. lf

in doubL the glass cloth should be dried briefly with

a fan heater before being used.

For GRP repair work the resin mixture to be used

should be 100 parts (by weight) of Epikote 162 and

38 parts by weight of Laromin C 260 (Epikure 1131.

Clean containers and thorough mixing {approx. 2 min.}

are a basic pre-requisite to success. The pot life of

a 100 g resin mixture is about 25 min. 'at 23 oC. When

the mixture has gelled, i.e. has becorne noticeably

mors viscous, it must no longer be used, as it cannot

wet out ' the cloth sufficiently any more. We point out

distinctly that the original strength of a component

cannot be achieved without final heat treatment {cur-

ing for 12 hours at 60 oCl.

But temperatures above 80 oC must be avoided.

Rev.No./Date. Sis. Author Date

July 1994 Page No.

Repair Manual

CFRP laminate applied by hand the correct proportion

of fiber weight is about 35 %; this means that the

proportion of the resin used must be 65 % (exception:

this does not apply to roving sparsl.

Aramid fibers

You will come across the first difficulty in working

with Aramid right at th.e point when attempting to cut

the cloth. This material can only be cleanly cut when

using really sharp cutting tools {serrated cuftErs}.

When sanding it, you will quickly realize that it is

virtually impossible to obtain a sanded surface free

from fiber fluff. lt helps to rub it down wet with

wet-and-dry paper, Of course. the sanded area must aI

once be dried thoroughly. using a fan heater, before

further work is continued.

As the Kevlar fiber absorbs moisture, by which it

will be deteriorated, it must be stored always in dry

conditions or at least dried out before use.

Kevlar must be protected from UV light, both in its

unprocessed and processed condition. A Kevlar repair

area therefore must immediately be painted. using a

paint with a UV-filter. The UP paints (former desig-

nation was PE paint) used by SCHLEICHER do contain

this UV protection {titanium dioxide as white

pigment).

Thin Kevlar skins as e.g. in the control surfaces and

flaps of the ASW 22 cannot be scarfed and should be

repaired by simple overlap. The resulting disalign-

ment in height is corrected with filler and smoothed

down. ln view of aerodynamics this has' no longer any

influence for flaps or ailerons.

When repairing mass-balanced control surfaces their

tailheavy rnoment must be checked in any case after

the repair is done.

Rev.No./Date, Sis. Author Date

July 1994 Page t{o.

Repair Manual

It may be useful to determine the tailheavy moment

atready prior to the repair. Thus it is possible to

estimate whether it will at all be feasible to stay

within the limits after a rePair.

ln case of large damage. to these parts a replace-

ment by new parts makes more sense anyhow.

Overlap lengths are given in the relevant diagram

for Aramid. Scarf lengths are half as long as over'

lap lengths.

Dressinos

eaiUon and Aramid fibers are treated with a dres-

sing to make it possible to weave cloths from the

libers. For carbon fiber cloths this dressing also

provides for better working qualities. lt is an

Epoxy resin which is used as dressing for carbon

fiber.

The Aramid fibers are even dressed with a substance

tpoty vinyl alcohol) which is also used as a re'

lease agent. For this reason it is absolutely essen'

tial to wash out the Aramid cloth very thoroughly

{dressing residue < 0.05 %}.

WARNING: Only such Aramid cloth qualities must be

used where the manufacturer states expli-

citly that the dressing has been washed

out.

Latest service life fatigue tests with carbon lamin-

ates have dernonstrated that the type of Epoxy resin

used as dressing must match the resin with which

the laminate has been made.

Therefore, it is important to usg only the original

materials stated.

9. Tables and Diaora.ms

6 Tables, 3 Figures, 3 Diagrams.

Rev.No./Date. Sis. Author Date

July 1994

Page llo.

Repair Manual

a(d

org

(, o)

+(O

6o)

oz-

-C

()

NOD

(Dd _=

;g)

*l OE N

b8.

rU) a

1r)

lr)

C\I

C,)tr

gb, c9

CY)

(o cY)

E-

Rev.No./Date. SiS. Author Date

July 1994 Page No.

Repair Manual

a(d

A-

--E

(, o)

il(O

6o)

oz-

(D11{

.o)

OE N

r, 8-

rr)

cr)

C\I

.9', E

9ts,

c\I

rJ)

cf)

Rev.No./Date. Sig. Author Date

July 1994 Page No

Repair Manual

-o

()

'iD

-o

c\l

C\I

Rev.No./Date. Sig. Author Date

July 1994 Page No.

Repair Manual

-o

'-6 I

-oE

(5t

O(l)

-.E

!oo-

LUX

TLU

.h (J

-E LU

LUX LU

;AF

rd (J

-(E LU

Yco

:< (5

Lf-I L

-o_

cc<

(5 cc

<nA

:< (5

UlL-

-o-

cc<

(58

xR -6.

ir OF

o) r- -o \z

E{ sij

:6 ou'r

IIN EN

'6r r- -E :z

EI s(j

.9f

l:'

.9f

.CN

.g',' E

gb, c)

cr)

c\I

Rev.No./Date. Sig. Author Date

July 1994 Page No.

Repair Manual

-o

-A

-oE

(EE

()(D

-c

o-.]

(D;i

(DU

-.8

oo_

Yco

:< (5

frr-

-o-

(E<

(,tr

CJ)

)

CJ)

LLI

.9f

(f)

rr)

cr)

.CN

.9, E

gb @

C\I

Rev.No./Date. Sig. Author Date

July 1994 Page No.

Repair Manual

-,E

+$ rO

o(O

o7 o

.(-)

N(/)

(Dtr(

m-=

-OP

o i'i

c\l

rr)

1r)

.f,

cr)

rr)

cr)

c.l

rr)

c\I

cr)

-C or

.9E

gb, cr)

(o o

c\I

C\I

Rev.No./Date. Sig. Author Date

July 1994 Page No.

Repair Manual

Fig.l REPARATUR DER KLASSE REPAIR CLASS

Fig.2 REPARATUR DER

{lnnenseite zugiinglich}/ (inside KLASSE 2/ REPAIR CLASS

skin accessible)

, Sctpumod. lubuslcrn

Fig.3a REeARATUR DER KLASSE 2 t REPATR clAss

(lnnenseite unzuginglich)/ (inside skin inaccessible)

Vorbereitung der Reparaturstette /Preparing the repair area

:1-'" '^ 3 ? '.-; i:; j;: -"1:;

The taper

gerated. of all scarf joints rs shown greatly exag-

'i i-'oii'"';'-:."

3-. - ,i-o... c-.4 I

Rev.No./Date. Sis. Author Date

July 1994 Page No.

Repair Manual

Diagram: overlap length for glass fiber

E'I

Cf,

921t+6

2145

o roo aoo 3oo I+o

Scarf lengths are half as long as overlaps.

(r,rol

-T

) 500

rveight tg/m?l

Rev.No./Date. Sis.

0q.99

Author Date

July 1994 Page llo.

Repair Manual

Diagram: overlap length for Aramid fiber

Scarf lengths are half as long as overlaps,

,15

(ll

300

weight tg/#l

tl $

.-f#.

-f,r

.-s/

,.rs/ (

Rev.No./Date. SiS.

0q.9e

Author Date

July 1994 Page llo.

Repair Manual

Diagram: overlap length for Carbon fiber

Eso

-E 80

t70

n56t03492t

300

weight

Scarf lengths are half as long as overlaps.

ctc ?96 / I

Rigitor AXT 250/

orbotex [X 25

031',16

b*P

031?t+ I CCC I+69

fit 0 t a2924

Rev.No./Date. SiS.

&.99 Author Date

July 1994 Page l{o.

Repair Manual

l{ateriEls used and supptv reference! As per! 16.01.94

Any of the materiats hercafter may be obtained by ilessrs.ALEXAilDER

SCHLE I CIIER.

I formerty:

Reein Gtycid5ther 162 lEpikotc 162 lAratdit tY 1525 B0

Hardener Epikure tt3 llaromin c 260 I BY 2954

llenufacturer! lilanufacturer:

Deutsche SheLt Chemie 6mbH lCiba-Geigy AG

X6tner straBe 5 |

65760 Eschborn [Frankf urt/l-lain

Resin 1285 I Lt60

llardener x2851286t287 | H 165

llanufecturcr: Hartin G. Scheufter

Am Ostkai 2tl22

70327 stuttgart-Obertiirkheim

Gtass fiber ctoth from E-Glaes I carbon and Kevtar ctoth

rith Finish Votan-A or I 550 I

Nanuf.cturerl CS-IIITERGLAS AG I C. Cramer GmbH & Co. (G

BenzstraBe 14 | treberstr. 2t

89155 Erbach | 486f9 Heek-llienborg

CANBOX FIBER }IATS

cerbotex csT 125. csT 250 I nisitor AXT 125, AxT 250 Hith dress-

ing for Epoxy resins.

Io be supptied: from lrlessrs.ALEXA}|DER SCHLEICITEI.

novl ltGs -

E-Gtass: Ec 9-716 l( 4l (68) llanufacturer!

vetrotex Deutschiand GmbH

Bicherouxstra8e 51

52134 llerzogehrath

Carbon fiber: KC 20 SDY LtI 29 966 and CF-fabric strips (KDU)

l.lanufacturer: Sigri GmbH

' lrerner-von-sienens-strage l8

86405 xeitingen

Rev.No./Date. SiS. Author Date

July 1994 Page llo.

Repair Manual

FOAI{ }IATERIILS As Per! 14.01 .94

PVC hard foan 5.1560.2 according to DIll e9 898

I formertyr

Divinycett ll 60 .l Conticelt 60

llanufacturer: I Hanufaeturer;

Divinycett Internationat GmbH I Continent.t AG

llax-von-Laue-Str. 7 |

30965 tlemingen I Hannover

Pl.lI hard foam 5.1460.2 according to DIll 29 898 (Rohacelt A7l)

llanufacturer! Rohm GDbH

Chemische Fabrik

Kirschenattee 45

64293 Dgrnstadt

NESII FILLENS.:

Aerosit llanufacturer: A+E Fischer

Postfach 15 02 45

65090 Hiesbaden

Cotton flocks, Type FB 1/035 (formerly Type FL lf)

llanufacturer: Schrarzr$tder Texti trerke

Postfach 4

77771 Schenkenzet l

llicro baltoon, Bhite llanufacturer: OilYA GmbH

Postfach 51 08 40

509t4 r6tn 51

PI I }IT

lforrnerty:

uP-getcoat T 35 rhite I uP-getcoat rhite 03-69 469

UP-hardener sF 2 ./ sF 10 | UP-hardener llo. 07-20 500

Thinner SF I thinner llo. 06-10 170

l,lanuf acturer: I llanuf acturer:

tlartin G. Scheufter I lxZo Coatings cmbH

Am O8tk6i 21122 I

70327 stuttgart-obertiirkheim I stuttgart

Hev.No./Date. Sig. Author Date

July 1994 Page llo.

DEEE I:

'1 o, ?Er rH lltstt{ut;llt lI

for ,fl Fib.r Comporat Alrcrafi

Annlx to llrr Bcprh Mlnud

Alerrndor Schlelchor

ffita

xiQffi

Subiact:

S€risl number

aoplicabilitv:

Rsason:

Acltotri

new Post Cods: D-36183

Repairs on fibar composite construcdon aircraft for which ths

original rgsin syatenrs ana no longer availabli in ths msrtot.

All Eerlsl no.s of SCHLEICHER aircraft made from tiber composite

mat€rials.

Th€ ffrst fiber composito akc.aft typss havs baen buih almost

30 yeara ago and it b€com8s more and more ditficuh to obtain

the oriOinal roain syEtams,

Thk repair instrucdon stst6 which resin types can b€ used fot

whbh sircraft npas on fgpairs.

The following sircraft qrpes mads from glass fibers -

ASVI, 12 (dl modsl variants and serial numb€rs)

ASW 15 (a[ model varianB and serial numbors]

ASW 17 {all modsl variants and serial numbars; oxcspt fot

such fuselago buih as per TN no.4, i.a, with carbon ffber)

ASW tg (aS mod variants and Eerial numbsrsl

ASyl, 20 {a[ model variant3 and orial numbes; sxoapt for fi€

coatrol Esrfac63 & flaps of ASW 20 B, 8L and ASW 20 C, CL var-

i.nts!

ASK 21 (a[ modsl variants and serisl nrxnbersl

ASK 23 l.ll model va.ianb aad serial numbersl

have baan d sre still b{J[t wi$ tig resln ayE&rns:

Epoxin 182 with hadanEr Leromin C260, subs€qucrrtly renam€d

es: Epikote 182 witlr hardener Eplkure 113, 8ubsequenily renamed

a9; Glycidertar 182 witt hard€nor Epikur€ 113.

ln cas€ $at liess original ma&riaE are no bnger available,

ttre following resin sy8lem can bs u!6d ,ot' ths repalr :

Scieufler L 285 wi$ hardenarc H 285 trapld). or H 286 lmadiuml

or H 287 (dowl.

P.ftr.ry rtructra compmants wftkh have bsan bult whh the

Sclr{lrfl.r Irrh ry.tcm L 285, CANilOT bc rcpaind wiitr Epiko.

to 162 ' Epi*rra l13l

Th€ carbon fibe, rsinforced ASW 17 lusalages ss p€r TN no.4a

wsrs bullt .with the rsain Eyatem: Bak6lito L 2O & hardener SL.

ThB ASW 22 (all modal vadants and scriat numbe.s) was built

with tln resin systern: CIBA XB 3052A & hardener XB 30528; sub-

E€quenuy ronamod as: LY 5053 & hardEner HY 5052:

and with Scheuflor resin L 160 and hard€ner H 161. H 162, H 1628

or H 16i1. which was roplacad after tg85 by the Scheuflor resin

L 285 whh hardonors H 285. H 288 or H 287.

l'dEt I :

2al 2REFAIE INSTRUCTIOIII

for dl Fhcr Conposlt! Aircratt

Ann.r to tr. B.prk Marud

ALxrEdcr Schloich.r

wl6

x{xm*

Post Code: D-36143

ThB sam6 lailn systsrls as on tig ASW 22 wEre ,lso us6d fo, th6

cont ol curf.ces & flaps of AS:W 20 B, BL .nd ASW 20 C, CL varF

ents.

The aircrsft rypes ASW 24, ASH 25 snd ASH 26 E (8tt modd ver+

aBta 6nd 3srial numbsrs rBspsctlvelyl w€re built onty wlth th3

raEin 6y8t6mt Schoufler L 288 wirh hardenars H 2gS, H 296 or

H 287 - oxcept for suct haat{esiltdnt sngine parts which rs-

quir8 sxplichly othor milerial.

For ell b€fu.6-menfon6d aircreft ryp63 .spal'3 can b6 done

uslno eitha, tie original rasin 8y$iams or Scheufl6r L 2gS with

hard6neru H 285, H 288 or H 287 (dop6nding on fie desirsd pot

lifu and curlng condidoruil.

Any rspah ustng Scheuflar resin L 2BS rEquircs r Fost curing

for about 12 houre at 58 - 62ocl

Notes: Fu€l Tanb:

ASK t4 .nd ASK le fu6l tanks were buih uslng the restn 3y$em:

EpikorB 162[aromin C260.

Sirtco ths us€ of low{rade.bdnzols fuets (MOGAS.Eurosuper snd

Supar Plu3l drcse tsnkr hava beeome blind and sott

The tuel tank3 tor ASW 22 M, ASW 22 BE. ASW 24 E, ASH 2E E, and

ASH 26 E, as w€ll 8s new buih tanks for ASK 14 and ASK 16 were

buih wlth, Bskelite L 20 & hardenu H gl..

Thsy must bs repairad only with said Bakelite L 20 & H 91.

Popp€nheusBn. July 4, 1994

AI..EXATDER SCHT.HCHEB

GmbH & Co.

The renslati,on lnto Engli8h has b6en done by baEt knowl€dge and judgoment ln

any caso of doubt tie Germsn originel is eorltrolliog.

m7.E

Sh€6t

1of 1

REPAIR INSTRUCTION

CARBO{ FIBER CLOTH FOR ALL FIBER COT/I.

POSITEAIRCRAFT

Anncx to the Rep€ir Manu€l

Alexandc.r gchleich€r

qrbH & co.

S€g3frlrgalghu

D - 301fi! Poppe[hauson

gubleca:

Aopllc.bilitv:

R€raon:

Ac'tion:

Repalr ard produclion of tibe. composlis sircrsfl forwhic,h the typos of taMcs or rovlng lay-

€rs as dated in th€ layer saheme drawings are ns longer us€d.

AU AS aircrafr, seilplanqs and pourBr€d seildanes, made from fibsr comporiite rBinfor"sd

plestlcs (FRP).

tho der$gnahns ot tailios or mving layBE hav€ charEed in llre cours€ of the years or aIe

no longer in use erxl lor have beefl rephced by otner typ€s. This repair instrudion slates

wthtr types of fsbdcs or roving layers may b6 l,s€d as subciltutB.

Th€ metedals Ca6otex CX12 or CST125 (fabrlc ureight 125glst, Gfibor p6rcentag6

120dIIn and Cartotox CX25 orCST250 (faffic w€Eht 250drf. Gfiber perccntage

240 g/r0 aro no. longer us6d.

For repair and Foduction of FRP eitcrefl or FRP strudural compononls the follo\,ring sub.

slitute fabrhs or layer srybs may bo used ard the layer scheme dmwings amsndod oonE-

spordinsly.

Daslgnatioo

rTG e8320 (03 340)

MDL9M1

CCC - Style 763

1t2g!fif

140Cfif

140 glm.

Supplier

lnterglss

SlSd

l(ramer

Supplier

SiSri

SiSd

SlSrl

hterglas

Kramgr

Kramer

Gfibor pononlsgo

121 glfif

l2Oglnf

120 g/me

S fiberpercentage

218.1stnf

Sigratox KDU - lqrg f,5 mm wid€) 291dfiP

sbrstexKDU - 1012 (150 mm wide) 319 glnl.

zlayor! ITG 98320 '1329ffi

2 leyeG CCC - S-tyl6 763 140 gdm.

CCC.- Styh 79€ 2E0 g/tn'

X) CuneIltly availaH€ €)( $o€k frcm SCHLEICHERI

2E2.4glnt

400.4 g/mr

121 glfif

120 glnf

247 glfif

lJoEE3

Poppenheusen, July 7, 19S

IHEREAWAGEWEITdoG\ /bmdrhd RBGY

Alexander Schleicher

f\ GmbH&Co.

Byqd.r (#=-il,-E-J*

(Lutz-w. Jlryrw)

This Rgpslr lnSrudion mu* be inserted as AnrEx into thB Repair Maoual I

All fabrlc s mvirE lsyer matedals csn ba o{der€d trom

Alerander Schleicher cmbll & Co.

PO Box 50

D.36151 Popponllauscn

Tel +49 665E tgo 0f Fax +ilg 6858 4940

Shs6t

l oll Technlcel Note No. 01-98

fdall airsafttypes of

Glass Fib€r & Fib€r Composib ConstlJdion

Alemil!.r SchLlchar

GmDll A Co.

S.gdr{[({ba

D - 3816:l Poppenhauseo

N€ry ,sln systom for lemindim glass, cartoo. and Aramld fib€r cloth

All AS rtrc.8fr - saildsno elld pory9f€d saildana typs - forshirrt rssin leminatlng sys.

tcms srs used.

Nono.

The r€sin rnsnufsdusr Ma{tin G. Sohsuflsr has d€velopod e lemlnelirE r€sin L 335 wilh

the hsrd6nerE H3:15, H335-340 8rd H3{0 whlch can b€ usr{l insiesrt ot ihe r8sin

sy$em Edkotc 162 yrith llard€ns,s Egikur8 113 or Leromln C 260 rEpectlvsly. Produo-

lion of lhe rEh system Eplkote / Efrkure will bo dlscontlnuad.

Thls lsmlndiry lgsin system is qualified by lte t6sts 8s F€scrib€d by the kfifahlt-

Bundesemt (LBA) in m GuEBlinas tor Resin Fiber Compclto grudulls (G6rman:

RFM ard has b€€n certified by tha LBA rorlho svietion industry.

For a[ fib6f compodts comgonorns ufilch wsre built usine th€ lBgn system Eplkote 162

with haden€ts Epil$rs113 or LsrominC2So rcspedivaly, notv th€ hminaling lgliio

L 3:15 xrffi lha hsrdgnefs H 335, H il35 - 310 and H 3{0 can be u3€d whon lhe compo-

n€r{s s€ new built or rBp.lr€rl.

Spars mu* not bc rrfek€d ,ror new buih wiln th6 leminaliqg f3sin L 33!i ard the

had€flors H 335, ll ll35 - 3aO rnd H 340. ln oeEo of doubt il b mquired to oofitad lhs

comsry Ah€nder Schblcrl8r.

Cornponords h'frlclr h8v€ bo3n r8ps[Bd or new hrili iyfih the r€sio L 3i]5 must bo tr{€d

for 15 h,rt e trmpefsluro ot 55.60 C'.

Thls TN muS be lnssfed G snnex into lh€ AS Repair Msnual.

The raEin sysilom L 335 cao be oHein€d from I

Alexar*lrr Sa$Hciar Gmbll & Co.

P.O. Box60

}'3E161 Poppenhfltsen llllasserkuppe

T€l 0605E - ECo ff Fex 0€656 - a940 or email A$$lldans@Fuld8.ne{

3ubir6:

App$c.bifty:

Colr|plLnce:

R6ason:

Poppenllgusen, Uedr 12, 1999

Alexander $chleicher

GmbH &Co.

avoa",Q,&-CI 5-/?D

(Lulz-W. Jullrtev)

Ths G8rman otlgtlrel of lfib Tedrniod NotB has bogn approvod by thg LBA under tfto date of Marcfi 10, 1999,

(slgnsture: JUNG ). The lrandslion into Erylish halr bean dons by best knoryledge and iudlsmenti in efly

cass ofdouH th€ Gerinsn orlginal is confo$ng.

She€t

l dl Technlcal Note No. 02-99

for all aircraft types of

Glass Fiber & Fiber ComposiE Constudion

Alerand€r Schhlchor

Gr$H & Co.

$agdn$m4nau

D - 36163 Popponhausen

SubJoct:

Appllcrhlllty:

Complianc.:

Rilsn:

Acton:

Poppenhzusen, Mardr 15, lggg Alexandor $chlelcher

GmbH & Co,

New fini8h fut giaEe fibBr do0l

All AS ahEatt - saldan€ and pori,6r€d sailphne tp€s - whtsi use ghss fiber clofi hr their

Gonstucton,

None,

CSINTERGI-AS AG, lhe rnanufaoftrl€r d glars fibe6, h6 dEvdopsd a n6w finlsh ,or Pd}b

ostff r€sin (UP), Vinyl 6ster resln (VE), Eporry resin (EP), and Polyamid Eystsms (PA); UrS

ne$ frnBh replecos t!6 pr€vbus finbh tlpee.

Tha n6w fnish FK 800 r*ad6 on th6 b66b ofAmirp-Silan, ofiera t ts follorlru advantagss:

- kxlEr Chlorkle values

- fasl€r wBttng d thg doth

- lrrlproved adhesbn b6ntve6n dolh and r€sh syst€m

- Chrome conlents 0%

- excellent meofialiod prserties.

This fink*l b qualin€d by thB r6ds as F€soribed by lh6 Luflf,ahrt€und63ril (LBA) ln ffte

GuEellnos fior Resin Fib6r Composlte Sbudurss {Gerrun: R}fV) and has begl certlfied by

the LgAfor he avktion industy.

Gless fibsI dolh wih th€ n6n, finish FK 800 can b€ used for dl fibel cdrposite compon€nts,

€lth6r ror nerry bullt pafu or ror r€palrs, lnstesd of lhe FBvi([l8ly us€d glass dolh typ€8.

Thb TN must b€ inserled as ann€x inlolhe AS Ropair Mmual.

by ord€r fu-fr,

(Lute-W. Jumbur)

Th6 G6man ofiglnel of thle Techbal l,lot6 hB b6en apprwed by tr€ LBA urd6r th6 dat€ d Apnl6, lS!€,

(sEnafuro: JUNG ). Tha fenEhlion inb Englilfi has be€n done by. b6st kno.riedg€ end Judgemont in any cas6

of doubt th6 Garman orighal i{r contolllng.

Sheot

l of 1

Tachnical Noh No.03-09

for a[ airareft d ttle

produclion S3rios AShl, ASK & ASW

Alsxmdar Schlelch.r

Gmtll & C4

S.gdf{ntela

D - 3616:l Poppenhausen

Sublect N€w m8terlal sp€dflca0onsfor coppor-dnc alloys (foflnerly bress).

Applic.bility: All A8 aircr.fl - selplan. .nd porrvBlrd saihlanr lypes - corcn$y in ptodudion as wsll as

manufaciura of sperD pad8 for thoso foflnsly ln prcdudlon.

Compliance: Non€.

Ree3on: DIN 17 66{, €m 17 00'l sil.ndald3 contrin psdy chengpd sp6dlicatiorls. mstBrlsl

aEidgEd slgns or nunb3rs rsspoctlvoly, for copp€r-dno slloy3 (formsrty bress).

The brass as orllhally slstod ln the dnwingE ls no hnger evaileue in oconomical querF

tities.

Action: This Tt{ Eup€rE€des lh€ mst6dal spocifleailons br copp€r-dnc alloys (fo[n€rly br€Es) on

lhe rB€ctlvs sisting dnnlqgs aod mrd bo hsad€d as snnex lntothaAS RepelrMe.F

uel,

ln$s8d of lh6 has6 mst€rial spedficalions rldlidr wore so fer statsd in thg drawings nw

ih€ folh|im mstcrt l abrlqpd s&m arxt rumbers c8n be llsad 83 substftute:

Mei.rirl:

Drrwinor:

') To be ssod as ftst crroica, wfiorg possiblel

FornBr ab.idged slil ln braddsl (Ms = br8ss)

Th€ brass met8rlal spedficrtlofis yvhhft vBre so far stat€d h the dradngs elts hel8vrlth

rDdaoad by the matsdal ab{flSod sigrrs and numb€f3 rsspedivety in this TN. The t€-

spor*lve drewirps nc€d nol be dlalE€d,

Popp€nheusen, MarEn 26, '1999 Alexander Schleicher

Gmbll & co.

,"*, @i -l)

(LgE-w' Ju

The G6men o,lginal ot lhls TGcfinicel Nots h83 been spproved by Ule LBA under the 6s16 61 Alril 8, 1999.

(signaturs: JUNG ). The Asnsletion into English has b€on dooe by Des* knorvledge sId Jtldgement h 8ny

c8se of douH ti8 celman origlnal is conlrclliftg.

MaterialAuldo€d sign Malsflgl NumDor Tensib S$orEth

N/mtrl. DIN

guzn3gPbz, heId

FaA Ht20 tlrss8l 2.036026 mln. 'a:lo 17 6€0 '

r7 670

Cuzn3gPt8, herd

Fr" r{ff &s 2.(x01.26 min.430 17 660 '

,t? 661

qrznx,PDz, naro

F4{ H125 nls58) 2.0402.26 mln.44O 17 6t6At

,7 *a

gu Znirrr nafu

F4.l Hl4ll lus88) 2.0p,21.fi mln,4ao 7 600,

7 eal

Cu 4137, hafll

Fla Hi7! ilrAl\ 2.0u21.32 mln.5.m 17 e6{t I

t7 e61

CuAr37, hard

Bl !,m lkml 2.03i!1.34 min.610 17Wt

t7 861

UU ',ITIU AZ ''

{SoMS 5EAlz} wLz.u{t€a.q+! mh.55{, 17 681

Page

1of 1

Technical Note

No. G!-2fi)8

Spar cap fibres EC9 756 P109

Alexander Schlelcher

GmbH & Co.

Segeltlugzeugbau

D - 361 63 Poppenhausen

Subiect Fibres ofthe type ECg 756 P109 replace the fibres previously used for glass fibre spar

caps.

Applicability: All As-aircraft with glass fibre reinforced spar caps

Classification: MinorChange

Urgency: None

Reason: The manufacturer of glass fibres Sainlcobain Velrotex replaces the finish of their ggm

glass fibres.

Denomination of the previous glass fibres type: ECg 756 Ktl3

Denominataon of the new glass fibres type: ECg 756 P109

The new material was tested statically and dynamically in comparison to the previous ma-

terial.

Actionr For all spar caps made from glass fibre reinforced plastic, the new type of fibres

ECg 756 P109 may be used for production or repair instead of the fibres that were used

before.

This TN is to be attached to the As-repair manual as an appendix.

Note: ln the meantime, the supplier Saint-Gobain Vetrotex has been acquired and has become

part of the company OCV Reinforcements.

Poppenhausen, 12.02.2004 Alexander Schleicher

GmbH & Co.

i.A. k c*;

(M. Greiner)

The German original has been approved by the EASA on the 1 8 March 2008 with change number

EASA.A.C.09208

Page

1of1 Technical Note

No. 01-2013

Replacement U-PICA-MAT

Alexander Schleicher

GmbH & Co.

Segelflugzeugbau

D - 36163 Poppenhausen

Subject: Replacement of sandwich-core U-PICAMAT through Lantor LRC Soric

Applicability: Sailplanesandpoweredsailplanes:

ASH 26 Type Certificate LBA 383

ASH 26 E Type Certificate LBA 883

ASW27 TCDS EASAA.22O

ASW28 TCDS EASAA.O17

ASW2&18 TCDS EASAA.O17

ASW2&18 E TCDS EASA A.034

ASW27-18 (ASG29) TCDS EASAA.220

ASW27-18E (ASG2sE) TCDS EASAA.220

ASH 31 Mi TCDS EASAA.538

all variants

Urgency: None

Reason: The produc't U-PICA MAT was used to create wall thickness between load carrying lay-

ers. The produc{ is no longer available.

U-PICA MAT was used in nominal thickness of 1mm. ln impregnated condition this corre-

sponds in respect of weight and thickness to the product Lantor LRC Soric 2mm.

Action: Vvhen U-PICA MAT is specified in drawings, alternatively Lantor LRC Soric may be used,

according to the following table:

Specified in drawing Replaced by

U-PICA MAT 1mm LANTOR SORIC LRC 2mm

Poppenhausen, 1. May 2O13 Alexander Schleicher

GmbH & Co.

i.A. H- f .-'*

(M. Greineo

This modification has been approved by the EASA at the date of the 07.06.201 3 with the Major Change Ap

proval 10045216.

Page

1ol 1

Technical Note

No. 02-2013

Usage of Pyrofil TR30S- 3K

Alexander Schleicher

GmbH & Co.

Segelflugzeugbau

D - 361 63 Poppenhausen

Subiect:

Applicability:

Carbon fibre cloth with fibre type Pyrofil TR30S 3K

Sailplanes and powered sailplanes:

ASW 17

ASW20

ASK21

ASW22

ASW22 BE

ASW24

ASW24 E

ASH 25

ASH 25 E

ASH 26

ASH 26 E

ASW27

ASW28

ASW2&18 E

ASH 31 Mi

all variants

Type Certif icate LB A 282

Type Certificate LBA 314

TCDS EASA A.221

Type Certificate LBA 351

Type Certificate LBA 834

Type Certificate LBA 366

Type Certificate LBA 859

Type Certificate LBA 364

Type Certificate LBA 858

Type Certificate LBA 383

Type Certificate LBA 883

TCDS EASA A,220

TCDS EASA A.017

TCDS EASA A.034

TCDS EASA A.538

Urgency:

Reason:

Action:

None

The company SGL proved the suitability of their carbon fabric with the carbon fibre Pyrofil

TR30S 3K. This fibre may be used in fabrlc and UD-reinforcements besides the other

carbon fibres used hitherto (Toho Tenax HTA, Toray FT300B-3000).

All carbon fabrics supplied by SGL may completely or partially be made from the carbon

fibre Pyrofil TR30S 3K.

Poppenhausen, 1. May 201 3Alexander Schleicher

GmbH & Co.

i.A H C;-

(M. Greiner)

This modification has been approved by the EASA at the date of the 07.06.201 3 with the Major Change Atr

proval 10045216.

ASK 21 Repair Manual 2016 09 26

Navigation menu

Versions of this User Manual:

Views

Navigation