Generally, the properties of a wet layup repair are not as good as a repair with prepreg material; but by using a DVD method, the properties of the wet layup process can be improved. The DVD process is a technique to remove entrapped air that causes porosity in wet layup laminates. The DVD process is often used to make patches for solid laminate structures for complex contoured surfaces. The wet layup patch is prepared in a DVD tool and then secondary bonded to the aircraft structure. [Figure 7-70] The laminating process is similar to a standard wet layup process. The difference is how the patch is cured.

The double vacuum bag process is used to fabricate wet layup or prepreg repair laminates. Place the impregnated fabric within the debulking assembly, shown in Figure 7-70. To begin the debulking process, evacuate the air within the inner flexible vacuum bag. Then, seal the rigid outer box onto the inner vacuum bag, and evacuate the volume of air between the rigid outer box and inner vacuum bag. Since the outer box is rigid, the second evacuation prevents atmospheric pressure from pressing down on the inner vacuum bag over the patch. This subsequently prevents air bubbles from being pinched off within the laminate and facilitates air removal by the inner vacuum. Next, heat the laminate to a predetermined debulking temperature in order to reduce the resin viscosity and further improve the removal of air and volatiles from the laminate. Apply the heat through a heat blanket that is controlled with thermocouples placed directly on the heat blanket. Once the debulking cycle is complete, compact the laminate to consolidate the plies by venting the vacuum source attached to the outer rigid box, allowing atmospheric pressure to reenter the box and provide positive pressure against the inner vacuum bag. Upon completion of the compaction cycle, remove the laminate from the assembly and prepare for cure.

DVD tools can be purchased commercially but can also be fabricated locally from wood two-by-fours and sheets of plywood, as illustrated in Figure 7-70.

After the patch comes out of the DVD tool, it is still possible to form it to the contour of the aircraft, but the time is typically limited to 10 minutes. Place a film adhesive, or paste adhesive, on the aircraft skin and place the patch on the aircraft. Use a vacuum bag and heater blanket to cure the adhesive. [Figures 7-71 and 7-72]

Precured patches are not very flexible and cannot be used on highly curved or compound curved surfaces. The repair steps are similar as in External Bonded Repair With Prepreg Plies, except step 3 and 4 that follow.

Consult the SRM for correct size, ply thickness, and orientation. You can laminate and cure the precured patch in the repair shop and secondary bond to the parent structure, or obtain standard precured patches. [Figure 7-73]

Apply film adhesive or paste adhesive to the damaged area and place the precured patch on top. Vacuum bag the repair and cure at the correct temperature for the film adhesive or paste adhesive. Most film adhesives cure at either 250 °F or 350 °F. Some paste adhesives cure at room temperature although an elevated temperature could be used to speed the curing process.

Bonded repair concepts have found applicability in both types of manufacturing assembly methods. They have the advantage of not introducing stress concentrations by drilling fastener holes for patch installation and can be stronger than original part material. The disadvantage of bonded repairs is that most repair materials require special storage, handling, and curing procedures.

Bolted repairs are quicker and easier to fabricate than bonded repairs. They are normally used on composite skins thicker than 0.125-inch to ensure sufficient fastener bearing area is available for load transfer. They are prohibited in honeycomb sandwich assemblies due to the potential for moisture intrusion from the fastener holes and the resulting core degradation. Bolted repairs are heavier than comparable bonded repairs, limiting their use on weight-sensitive flight control surfaces.