For P&WC Reference Only. Engineering Source for... Qualified Source - Engineering Control. Qualified Source - Laboratory Control

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1 Specification For P&WC Reference Only Engineering Source for... Qualified Source - Engineering Control Qualified Source - Laboratory Control Specification Supplement Material Safety Data Sheet Required. None of the above CPW 478 Revised: Issued: Page: 1 of 26 WARNING - PROPRIETARY RIGHTS NOTICE - This document is the property of Pratt & Whitney Canada Corp. (P&WC). You may not possess, use, copy or disclose this document or any information in it, for any purpose, including without limitation to design, manufacture, or repair parts, or obtain FAA or other government approval to do so, without P&WC s express written permission. Neither receipt nor possession of this document alone, from any source, constitutes such permission, use, copying or disclosure by anyone without P&WC s express written permission is not authorized and may result in criminal or civil liability. VISUAL STANDARDS OF COMPOSITE COMPONENTS 1. SCOPE 1.1 Purpose This specification defines the acceptance limits for visual inspection and the limits for the rework of in-process deviations and dimensional deviations for composite components. 1.2 Application This specification is applicable when referenced on a P&WC drawing or on Supplementary Product Data (SPD) sheets. Rework must be carried out at the supplier prior to delivery. This specification does not apply to used parts. 2. APPLICABLE DOCUMENTS The following publications form a part of this specification to the extent specified herein; unless otherwise specified the latest issue must apply. 2.1 Pratt & Whitney Canada Corp. Specifications Available from Pratt & Whitney Canada Corp. (P&WC) 1000 Marie Victorin, Longueuil, Quebec, J4G 1A1. CPW 100 Control of Materials, Processes and Parts - Laboratory Requirements for Tests, Controls, Reports and Procedures for Source Qualification. CPW 135 Engineering Source Approval CPW 463 Adhesive, Two-Component, Low Viscosity CPW 503 Liquid Epoxy Resin CPW 504 Adhesive, Paste, Epoxy CPW 505 Potting Compound, Epoxy, Two Component CPW 543 General Requirements for Visual Inspection

2 CPW DEFINITIONS Basic definitions applicable to this specification are as follows: 3.1 Adhesive, squeeze out Excess of adhesive material at the edge joint between two mating surfaces. 3.2 Blister A debond from part surface visable as a rounded elevation on the surface with a more or less sharply defined boundaries resembling a blister on the human skin. 3.3 Bridging A condition where fibers do not move into or conform to radii and corners during moulding, resulting in voids, see Figure 1. Figure 1: Bridging 3.4 Burn Thermal decomposition or charring of the resin and/or fibers resulting in discoloration, distortion, destruction, or conversion of the surface laminate. 3.5 Burnish Marks A shiny area resulting from the rubbing against a hard, smooth surface; may contain scratches of no apparent depth. 3.6 Burr A fragment of excess laminate material which remains attached to the surface after machining. 3.7 Chip A defect in an edge or surface of the part resulting from the loss of material due to impact damage. 3.8 Crack, surface resin A crack existing only on the surface of the laminate within the surface resin layer with no broken fibers. 3.9 Crack, through An actual separation of the laminate extending through the thickness.

3 CPW Crack, through partial A crack that causes separation of the laminate and fiber breakage, but does not extend through the thickness of the part Crazing A network of fine surface resin cracks with no broken fibers Delamination, edge Physical separation of one or more plies making up the laminate, creating a gap on the edge surface, but with no broken fibers, see Figure 2. Figure 2: Edge Delamination 3.13 Dent A depression which does not rupture plies or debond the composite structure Depressed Imperfection One that is below the general surface of the part; must have smooth edges and bottom Disbond An adhesion failure or the separation of two bonded parts within a bonded interface Distorted Honeycomb Distorted honeycomb is defined as any cell that is not hexagonal in shape, may be rounded or oval in shape. See Figure 3. Figure 3: Distorted Honeycomb

4 CPW Elongated Honeycomb Any honeycomb cell that has been distorted by no less than 1/2 the original width Fiber fraying Face sheet strands protruding from the surface due to forming, sanding, machining or drilling, see Figure 4. Figure 4: Fiber Fraying 3.19 Hole An absence of resin and fiber extending through a laminate Honeycomb Cell Width The hexagonal cell width as shown in Figure 5. Figure 5: Honeycomb Cell Width 3.21 Inclusion A physical and mechanical discontinuity occuring within a material or part, usually consisting of solid encapsulated foreign material Laminate A product made by binding together two or more layers (plies) of material Linear Depression A smooth indentation with a length three or more times its width.

5 CPW Mould Under Fill A surface depression formed by inadequate material filling to the surface of the mold Nick A surface indication, with no fiber breakage, having sharp edges, corners or base caused by the impact of a sharp object Nodal Bonds That area of the honeycomb core where the cell walls are adhesive bonded Non-Linear Depression - Wire Mesh Dimple like surface indentations or imprints resulting from the wire mesh being drawn into the acoustic holes of the parts Porosity Small voids in a laminated part or an adhesive bond line caused by trapped air, water vapour, or volatiles coming out of solution at low cure pressure, see Figure 6. Figure 6: Porosity and Blister 3.29 Raised Imperfection An imperfection that is above the general surface of the part Resin Rich Area Localized area filled with resin and lacking reinforcing material Scratch, Groove A narrow linear depressions with a sharp or round base.

6 CPW Stain A slight surface discolouration due to various processing methods Surface impressions, mold side Minor imprint in localized areas transferred from the mold (e.g. tool indications, tape marks) Surface Inclusion A physical and mechanical discontinuity occuring in the surface of a material or part, usually consisting of solid encapsulated foreign material Surface resin ridges A build up of resin on the part which may be caused by a parting line between two details of a mold Surface resin starvation Fiber strands not coated with resin, see Figure 7. Figure 7: Surface Resin Starvation 3.37 Tracer A fiber, tow or yarn added to a prepreg for verifying fibre alignment Unbond An area within a bonded interface between two adherents in which the intended bonding action failed to take place, or where two layers of prepreg in the cured component do not adhere to each other Waviness Depressions and/or high spots due to the moulding process resulting in varying thickness of the panel. Changes in thickness must be gradual Wrinkle An indication in the surface of a laminate that has the appearance of a crease or fold molded into a ply of fabric, see Figure 8.

7 CPW Figure 8: Wrinkles 4. TECHNICAL REQUIREMENTS 4.1 Inspection Requirements Inspection must be carried out in accordance with P&WC Specification CPW 543 except that the requirements of this specification take precedence over those in Specification CPW 543. Requirements on Engineering drawings, Supplementary Product Data (SPD) sheets and associated sketches take precedence over those in this specification and any others. 5. GENERAL ACCEPTANCE LIMITS 5.1 Appearance Each part must have a uniform color over the laminated surface. Tint variation is allowed, but parts having abrupt changes in color must be referred to P&WC Engineering Review. For fan case abradable moulding see section Indications in excess of those permitted in Table 1 and visual non-conformities not specified in Table 1 are not acceptable and rework is not permitted, unless otherwise specified. Parts not conforming must be referred to P&WC Engineering Review. Indications must be classified according to area class and type. Area classes are defined in 5.2.

8 CPW Area Classes Class I areas Flanges, attachment holes, mating surfaces, plus a one inch (25 mm) zone adjacent to the flanges and holes Class II areas All laminate surfaces except areas covered by Class I. Table. 1: General Acceptance Criteria and Rework Instructions Unless Otherwise Specified TYPE OF INDICATION ACCEPTABLE LIMITS REWORKABLE LIMITS Adhesive, squeeze out Smooth and uniform. All class 1 and class 2 areas REWORK Blister Class I areas, not acceptable. Class II areas, inch (6.35 mm) diameter maximum. Indications 0.25 to 0.50 inch (12.7 mm) diameter maximum. Bridging Not Acceptable Not acceptable Not Permitted Burn Not Acceptable Not acceptable. Not Permitted Chip 0.04 inch (1 mm) by 0.04 inch (1 mm). Must not have caused fiber breakage. Maximum depth: down to top surface of fiber. Crack, surface resin 0.04 inch (1 mm) by 0.04 inch (1 mm). Must not have caused fiber breakage. Maximum depth: down to top surface of fiber. Crack, through or partial through Not Acceptable Not acceptable Not Permitted Crazing, surface resin Must not have caused fiber damage. Maximum length of each individual indication 0.25 inch (6 mm).

9 CPW Table. 1: General Acceptance Criteria and Rework Instructions Unless Otherwise Specified TYPE OF INDICATION ACCEPTABLE LIMITS REWORKABLE LIMITS Delamination, edge Not Acceptable indications up to 0.50 inch (12 mm) by 0.25 inch (6 mm) or acceptable equivalent area. REWORK Disbond Not Acceptable Disbonded joint. Fiber fraying Not Acceptable Not associated with delamination. Hole, laminate Not Acceptable Not acceptable. Not Permitted Inclusion 0.25 inch (6.4 mm) diameter maximum. Not acceptable. Not Permitted Porosity, surface Areas of porosity must not be greater than 6 inches (152 mm) diameter and must not extend through the thickness of the part. Total area of porosity must not exceed 10% of the surface area of the part. See Figure 6. Surface porosities. Scratch, groove, dents and nicks 0.04 inch (1 mm) by 0.04 inch (1 mm). Must not have caused fiber breakage. Maximum depth: down to top surface of fiber. Surface impressions, mold side Maximum mismatch inch (0.8 mm). No sharp edges with a radius less than inch (0.1 mm) permitted. From inch (1-1.5 mm) mismatch or under 0.03 inch (1 mm) sharp edges. Surface Inclusions Area of each inclusion or each inclusion cluster must be not longer than 3 inches (76 mm) by 0.25 inch (6.4 mm) wide, Total area of inclusion must not be more than 0.50 percent of the surface area. Greater than 0.5% and less than 1.5% surface area.

10 CPW Table. 1: General Acceptance Criteria and Rework Instructions Unless Otherwise Specified TYPE OF INDICATION ACCEPTABLE LIMITS REWORKABLE LIMITS REWORK Surface resin ridges Class I area: not acceptable. Class II area: up to 0.02 inch (0.5 mm). Class I area: all ridges. Class II area: from 0.02 inch (5 mm) and above. Surface resin starvation Acceptable if surface finish is not affected. (i.e. no depression). Less than 6 inches (15 mm) diameter and not extended through thickness. Total rework area not to exceed 10 % surface area. Tracer Acceptable Not required Wrinkles - External and Internal Acceptable on surfaces that are not a product of the mold. Not acceptable on mold side of part. See Figure 8. Not required Not permitted on mold side. Wrinkles - Depressed Acceptable if surface finish is not affected, i.e. no depression. Maximum depth 0.03 inch (0.8 mm), see Figure 8. Depressions up to 0.03 inch (1 mm). 5.3 Structural skins Delamination Delamination on interface flanges: i.e. Front Duct; Fan Casing; Aft Body; Thrust Reverser; Access Panels and Doors is not acceptable. Flange edge delamination is not acceptable. Flange edge delamination must be reworked by acceptable method provided: Length does not exceed 2 inches (25 mm). Radial depth does not exceed 0.02 inch (5.0 mm). Spacing between delamination is not less than 2 inches (50 mm). There are not more than 3 such discontinuities per flange Delamination of Flange Holes Delamination around flange holes is not acceptable. Delamination around flange holes must be reworked by acceptable method provided: Maximum radial width does not exceed 0.10 inch (2.5 mm). Only the outer and penultimate layers are affected.

11 CPW Fibre Fraying Fiber fraying is not acceptable. Frayed fibres associated with machined apertures must be reworked by acceptable method provided: The frayed fibers are contained within a 0.12 inch (3.0 mm) band width from the machined edge Blister Blisters are not acceptable Burn Burn is not acceptable Burrs Burrs are not acceptable unless otherwise permitted Burrs on all length of the edges are acceptable provided maximum size does not exceed 0.10 inch (0.25 mm) Crazing Crazing must be reworked by acceptable method Cracks in Surface Resin Cracks in surface resin must be reworked by acceptable method Crack, Through or Partial Through Cracks are not acceptable Resin Rich Ribs or Ridges Resin rich ribs on face of flanges caused by extruded resin in the tooling joints are not acceptable unless otherwise permitted. Resin rich ribs in external surfaces of body adjacent to flange is acceptable provided maximum height of rib does not exceed 0.04 inch (1 mm) Resin Rich Areas a) Resin rich flanges are not acceptable unless otherwise permitted. b) Resin rich areas on flanges is acceptable provided Part is layed-up net with no machining of flange edges afterwards. The resin rich area is contained within a 0.08 inch (2.5 mm) band width from the edge of the flange. c) Resin rich areas on corner radii (bridging) are acceptable provided that the sectional thickness is not affected. d) Cavities on resin rich corners are acceptable provided that only the resin is affected and any resultant jagged edges are dressed smooth. e) Resin rich areas in the body are not acceptable.

12 CPW f) Areas that have excess resin removed are acceptable provided no fibre damage is incurred Resin Starved Areas Resin starved areas are not acceptable Surface Roughness and Wrinkles a) Winkles on the tool side are not acceptable. b) Surface roughness on bag side where finish is not defined is acceptable. c) Surface roughness due to shallow indentations on the bag side caused by creases or overlaps in the bleed fabric is acceptable to the following limits: Length does not exceed 8 inches (200 mm). Depth does not exceed 0.02 inch (0.5 mm). There are not more than 5 per component Surface Cavities, Scratches, Grooves, Dents, Nicks, Chips a) Surface cavities, scratches, grooves, dents, nicks, or chips on flanges are not acceptable. b) Surface cavities, scratches, grooves, dents, nicks, or chips on the outer edge of flange must be reworked by acceptable method provided: It is contained within a 0.10 inch (2.5 mm) width band from the edge of the flange. There are not more than 50% of the circumference of any flange is affected. c) Surface cavities, scratches, grooves, dents, nicks, or chips in resin rich areas must be reworked by acceptable method provided it is contained within the surface resin. d) Scratches, grooves, dents, nicks, or chips must be reworked by acceptable method provided it does not cause fibre breakage. e) All other cavities, scratches, grooves, dents or nicks are not acceptable Surface Inclusions a) Surface inclusions are not acceptable unless otherwise permitted. b) Surface inclusions are acceptable to the following limits: Maximum size does not exceed 0.04 square inch (25 square mm). Maximum depth does not exceed 0.02 inch (0.5 mm). Minimum spacing between inclusions is not less than 2 inches (50 mm). There are not more than 2 inclusions in any 400 square inch (2500 square cm). No visual evidence of excessive fibre packing or distortion Surface Resin Starvation Areas a) Resin starved surface is not acceptable. b) Surface resin starved areas must be reworked by acceptable method provided: Only outermost plies are affected Size does not exceed 0.25 square inch (144 square mm). Spacing between dry areas is larger than 0.80 inch (20.0 mm).

13 CPW There are not more than 2 such areas per component Resin Starved Areas Creases Resin starved areas affecting more than the surface ply is not acceptable. Creases caused by vacuum bagging materials are acceptable Trace Fibres Colour trace fibre in the material is acceptable. 5.4 Perforation on the Structural Skins Mis-Spacing of Holes a) Mis-spacing of a row of holes is acceptable to the following limits: It is in a straight line. Minimum Pitch is maintained There are not more than 4 mis-spaced rows per component. Minimum spacing between occurrences is not less than 6 inches (150 mm). b) Pitch mis-spacing is acceptable to the following limits: Minimum Pitch is kept Maximum mis-spacing does not exceed one and a half that of normal pitch. Maximum mis-spacing does not exceed twice the diameter of the hole. 5.5 Access Panel Cutout Reinforcement Frame (Bonded) Delamination a) Delaminations around Access Panel Reinforcement Frame Holes are not acceptable. b) Delaminations on edge of Access Panel Reinforcement Frame are not acceptable. c) Delaminations on circumferential sides of Access Panel Reinforcing Frames and holes, excluding (a) must be reworked by acceptable method provided: Delamination is contained within a 0.10 inch (2.5 mm) band width. Maximum length does not exceed 1 inch (25 mm). Minimum spacing is not less than 2 inches (50 mm). There are not more than 3 such discontinuities per component. d) Body delamination is not acceptable. e) Delaminations around machined apertures must be reworked by acceptable method provided: It is contained within 0.10 inch (2.5 mm) band width from the machined edge. Only the outer and penultimate layers are affected Blister Blisters are not acceptable.

14 CPW Crazing Crazing must be reworked by acceptable method provided length of each indication is not more than 0.30 inch (7 mm) Cracks in Surface Resin Cracks in surface resin must be reworked by acceptable method Crack, Through or Partial Through Cracks are not acceptable Resin Rich Areas a) Resin rich areas are acceptable provided sectional thickness is unaffected. b) Cavities in resin rich corners are acceptable provided only the resin is affected and any resultant jagged edges are dressed smooth Surface Roughness & Wrinkles a) Surface roughness on bag side where finish is not defined is acceptable. b) Surface roughness due to shallow indentations on the bag side caused by creases or overlaps in the bleed fabric is acceptable to the following limits: Length does not exceed 8 inches (200 mm). Depth does not exceed 0.02 inch (0.5 mm). There are not more than 5 per component Surface Cavities, Scratches, Grooves, Dents, Nicks, Chips a) Cavities, scratches, grooves, dents, nicks or chips on reinforcement frame are not acceptable. b) Cavities on the outer edge of reinforcement frame must be reworked by acceptable method provided: It is contained within a 0.10 inch (2.5 mm) width band from the edge of the flange. There are not more than 50% of the circumference of any flange is affected. c) Cavities in resin rich areas are acceptable provided it is contained within the surface resin. d) Scratches, grooves, dents, nicks, or chips must be reworked by acceptable method provided it does not cause fibre breakage. e) All other cavities, scratches, grooves, dents and nicks are not acceptable Surface Inclusions a) Surface inclusions are not acceptable unless otherwise permitted. b) Surface inclusions are acceptable to the following limits: Maximum area does not exceed 0.04 square inch (25 square mm). Maximum depth does not exceed 0.01 inch (0.25 mm). Minimum spacing between inclusions is 2 inches (50 mm). There are not more than 2 inclusions per component.

15 CPW Surface Resin Starvation Areas a) Surface resin starved areas are not acceptable. b) Surface resin starved areas must be reworked by acceptable method provided: Only the surface plies are affected Size does not exceed 0.25 square inch (144 square mm). Spacing between dry areas is not less than 0.80 inch (20 mm). There are not more than 2 dry areas per component Resin starved areas Resin starved areas affecting more than the surface ply are not acceptable Frayed Fibres a) Frayed fibres are not acceptable. b) Frayed fibres associated with machined apertures and edges must be reworked by acceptable method provided: The frayed fibers are contained within a 0.12 inch (3.0 mm) band width from the machined edge Creases Creases on the bag side caused by vacuum bagging materials are acceptable Trace Fibres Colour trace fibre in the material is acceptable Burn Burn is not acceptable Burrs a) Burrs are not acceptable unless otherwise permitted. b) Burrs on whole length of edges are acceptable provided maximum size does not exceed 0.01 inch (0.25 mm). 5.6 Skins, Perforated Skins and Skin Sections That are Precured Surface Texture Moulded sheet must be of a uniform texture. Surface dry areas (Resin starved areas) on the surface a) Surface resin starved areas are not acceptable. b) Surface resin starved areas must be reworked by acceptable method provided: Only the surface plies are affected Size does not exceed 0.25 square inch (144 square mm). Spacing between affected areas is more than 0.80 inch (20.0 mm). There are not more than 2 such areas per component.

16 CPW Surface Resin Starvation Areas Resin starved areas affecting more than the surface ply is not acceptable Surface Roughness & Wrinkles a) Surface roughness and wrinkles is not acceptable unless otherwise permitted. b) Surface roughness on bag side where finish is not defined is acceptable. c) Surface roughness due to shallow indentations in the outer surface caused by creases or overlaps in the bleed fabric is acceptable to the following limits: Length does not exceed 8 inches (200 mm). Depth does not exceed 0.02 inch (0.5 mm). There are not more than 5 per component Surface cavities, Scratches, Grooves, Dents, Nicks, Chips a) Surface cavities, scratches, grooves, dents, nicks, or chips on flanges are not acceptable. b) Surface cavities, scratches, grooves, dents, nicks, or chips on the outer edge of flange must be reworked by acceptable method provided: It is contained within a 0.10 inch (2.5 mm) width band from the edge of the flange. There are not more than 50% of the circumference of any flange is affected. c) Surface cavities, scratches, grooves, dents, nicks, or chips in resin rich areas must be reworked by acceptable method provided it is contained within the surface resin. d) Scratches, grooves, dents, nicks, or chips must be reworked by acceptable method provided it does not cause fibre breakage e) All other cavities scratches, grooves, dents, nicks, or chips are not acceptable Surface Inclusion a) Surface inclusions are not acceptable unless otherwise permitted. b) Surface inclusions are acceptable to the following limits: Maximum size does not exceed 0.04 square inch (25 square mm). Maximum depth does not exceed 0.02 inch (0.5 mm). Minimum spacing between inclusions is not less than 0.80 inch (20 mm). There are not more than 4 inclusions in 400 square inch (2500 square cm). No visual evidence of excessive fibre packing distortion Mis-Spacing of Holes a) Mis-spacing of a row of holes is acceptable to the following limits: It is in a straight line. There are not more than 4 mis-spaced rows per component. Minimum spacing between occurrences is not less than 6 inches (150 mm). b) Pitch mis-spacing is acceptable to the following limits: Maximum mis-spacing does not exceed one and a half that of normal pitch. Maximum mis-spacing does not exceed twice the diameter of the hole.

17 CPW Delamination a) Delaminations on edges of skins are not acceptable. b) Delaminations on circumferential sides of skins are acceptable to the following limits: It is contained within a 0.20 inch (5 mm) band width. Maximum length does not exceed 1 inch (25 mm). Minimum spacing is not less than 2 inches (50 mm). There are not more than 3 such discontinuities per component. c) Delaminations around machined apertures must be reworked by acceptable method provided: It is contained within a 0.10 inch (2.5 mm) band width from the machined edge. Only the outer and penultimate layers are affected Delamination on Perforated Skins a) Patches of delaminations formed by a linking of delaminations between holes is acceptable to the following limits provided that: Delamination does not extend beyond the boundary of a 9-hole area. Minimum spacing is not less than 4 inches (100 mm). There are not more than 2 occurrences in an area of 16 square inches (400 square cm), and Delamination will be sealed at some time during assembly, e.g. paint or resin. b) Delaminations not sealed by any other means (e.g. sealing at bond assembly with adhesive film) must be reworked by acceptable method. c) Areas of edge delaminations caused by profile machining or hand dressing must be reworked by acceptable method provided: Maximum length does not extend beyond 8 holes. Delamination does not extend beyond 3 holes from the edge. Minimum spacing between occurrences is not less than 4 inches (100 mm). There are not more than 4 occurrences per 40 inches (1 meter) length of perimeter. d) Crack through a section of the component is not acceptable. e) Delamination of the glass ply over the carbon ply is acceptable provided the delamination, measured from the edge of the hole to the end of the delamination (in its longest direction), is not more than twice the maximum hole diameter Frayed Fibres a) Frayed fibres are not acceptable. b) Frayed fibres associated with machined apertures and edges must be reworked by acceptable method provided: The frayed fibers are contained within a 0.12 inch (3.0 mm) band width from the machined edge Blister Blisters are not acceptable.

18 CPW Cracks in Surface Resin Cracks in surface resin must be reworked by acceptable method Crack, Through or Partial Through Burn Burrs Cracks are not acceptable. Burn is not acceptable. a) Burrs are not acceptable unless otherwise permitted. b) Burrs on all length of edges are acceptable provided maximum size does not exceed 0.01 inch (0.25 mm) Trace Fibres Colour trace fibre in the material is acceptable. 5.7 Honeycomb Gaps between Honeycomb Sections a) Gaps between honeycomb Sections are not acceptable. b) Gaps between honeycomb sections of less than 6 inches (15 mm) must be reworked by acceptable method provided gaps are not more than 0.60 inch (15 mm) Burrs All light burring of machined and cut edges are acceptable Open cells Open cells are acceptable only in the perimeter of honeycomb segments Nodal Bonds a) Nodal unbonds are acceptable to the following limits: There are not more than 2 per component. Minimum spacing between occurrences is not less than 2 inches (50 mm). b) Unbonds in excess of allowable limits in must be reworked by acceptable method Torn cell walls Torn cell walls are acceptable to the following limits: The discontinuity is confined to one cell wall per cell. Maximum length does not exceed 0.08 inch (2 mm). Maximum number of affected cells does not exceed 10% of the total number of cells per component Distorted cells Distorted cell pattern is acceptable provided distorted area does not exceed 20% of the total component.

19 CPW Sole Plates and Bosses Surface Inclusions Inclusions are acceptable to the following limits: Maximum size does not exceed square inch (4 square mm). Maximum depth 0.02 inch (0.5 mm). Minimum spacing between discontinuities 2.40 inches (60 mm). There are not more than 3 discontinuities per 16 square inches (100 square cm) Surface Roughness a) Surface roughness on tool side is not acceptable. b) Surface roughness on bag side where finish is not defined is acceptable. c) Surface roughness due to shallow indentations on the bag side caused by creases or overlaps in the bleed fabric is acceptable to the following limits: Length does not exceed 8 inches (200 mm). Depth does not exceed 0.02 inch (0.5 mm). There are not more than 5 per component Surface cavities, Scratches, Grooves, Dents, Nicks, Chips a) Surface cavities, scratches, grooves, dents, nicks, or chips on flanges are not acceptable. b) Surface cavities, scratches, grooves, dents, nicks, or chips on the outer edge of flange must be reworked by acceptable method provided: They are contained within a 0.10 inch (2.5 mm) width band from the edge of the flange. There are not more than 50% of the circumference of any flange is affected. c) Surface cavities, scratches, grooves, dents, nicks, or chips in resin rich areas must be reworked by acceptable method provided: It is contained within the surface resin. d) Scratches, grooves, dents, nicks, or chips must be reworked by acceptable method provided: It does not cause fibre breakage e) All other cavities, scratches, grooves, dents, or nicks are not acceptable Frayed Fibres a) Frayed fibres are not acceptable. b) Frayed fibres associated with machined apertures and edges must be reworked by acceptable method provided: Fiber fraying is contained within a 0.12 inch (3.0 mm) band width from the machined edge Crazing Surface resin crazing must be reworked by acceptable method.

20 CPW Cracks in Surface Resin Cracks in surface resin must be reworked by acceptable method Crack, Through or Partial Through Blister Cracks are not acceptable. Blisters are not acceptable Lack of Consolidation Inserts Lack of consolidation is not acceptable. The face of all insert threads must be clear and free from resin. Incorrectly seated inserts must be reworked by acceptable method. 5.9 Assembly (Acoustic Honeycomb sandwich) For the assembly, all requirements of 5.3 Structural skins applies plus the following Blockage Unbond a) Blocked perforate is acceptable to the following limits: Percent open-hole areas meets drawing requirement. Blocked areas are around soleplate bonds Up to 3 rows either side of any butt joint line b) Blockage in excess of drawing requirement is not acceptable. a) Perforate skin unbond is not acceptable. b) Perforate skin unbond must be reworked by acceptable method and reopen perforate holes to meet drawing requirements provided: Length does not exceed 4 inches (100 mm). Width does not exceed 0.80 inch (20 mm). Minimum spacing between discontinuities is not less than 2 inches (50 mm). There are not more than 5 such discontinuities per perforate inner skin Joints a) Oversize joints are not acceptable. b) Oversize joints must be reworked by acceptable method provided width of joint does not exceed 0.24 inch (6 mm) and reopen perforation holes to meet drawing requirements.

21 CPW Distortion a) Distortion at the edges of the perforate skin must be reworked by acceptable method to the following limits provided that: Maximum length of distortion does not exceed 5.90 inches (150 mm). Maximum spacing between areas of distortion is not less than 2 inches (50 mm). There are not more than 5 discontinuities per component. b) Distortion in the perforated skin in excess of drawing tolerance is acceptable to the following limits: Area of distortion is not more than 4 square inches (2500 square mm). There are not more than 2 occurrences per component. Distorted skin must be reworked by acceptable method Damaged Skin (non perforated) Damaged skin (non perforated) detected by visual inspection must be determined by ultrasonic inspection using (A-scan or C-scan) to determine the actual size of the damage. a) Damaged skin is not acceptable. b) Damaged skin must be reworked by acceptable method provided: Damage area is not more than 1 square inch (625 square mm). Minimum spacing between discontinuities is 8 inches (200 mm) There are not more than 2 discontinuities per component.

22 CPW Edge Sealing Unbond Outer skin Unbond Edge Splice Honey Comb Inner Skin Figure 9: Unbond of Edge Splice a) Unbond in splice edge seal is not acceptable. b) Loose or lack of bond in splice edge seal must be reworked by acceptable method provided: Length of discontinuity does not exceed 8 inches (200 mm). There are not more than 3 discontinuities on any edge.

23 CPW Cavities in Filled Edges Outer skin Cavity Edge Splice Honey Comb Inner Skin 5.11 Inserts Figure 10: Cavity on Splice Film a) Cavities in filled edges are acceptable provided they do not exceed drawing limits. b) Cavities in excess of (a) must be reworked by acceptable method provided total loss of filler does not exceed 25% of the total area. a) Incorrect seated inserts are not acceptable. b) Incorrect seated inserts must be reworked by acceptable method Paint Application Paint application must be uniform in colour, free from paint runs, nodules, evidence of spew, excess filler, and of a good general appearance Rubber Seals Bonding A uniform fillet of adhesive is to be visible at all edges. a) All unbonds are not acceptable. b) Surface undulations of rubber seals up to 0.01 inch (0.25 mm) maximum is acceptable. c) All smears or finger prints of adhesive anywhere on the component/rubber seal assembly other than at the adhesive fillet are not acceptable.

24 CPW Wire Mesh over Acoustic Face Sheet Burnish Marks Burnish marks are acceptable Non-Linear Depressions Non-linear depressions surrounding the acoustic holes in the face sheet are acceptable provided it do not exceed inch (0.4 mm) in depth Linear Depressions Linear depressions in the woven mesh are acceptable provided it exhibit a smooth and continuous surface with no evidence of disbond and do not exceed 0.010inch (0.25 mm) in depth or the diameter of the acoustic hole in the face sheet. No more than three linear depressions per panel are permitted. Linear depressions can extend the full length or the full width of the part Scratches Scratches in the woven mesh are acceptable provided it contain no broken wires and do not exhibit raised material. No more than three scratches per part are permitted. Scratches must not exceed 10 inches (254 mm) in length Stains Stains that exhibit a slight surface discolouration are acceptable Adhesive Filled Acoustic Holes Acoustic filled acoustic holes are acceptable up to a total of two holes in the second row may be filled with adhesive, provided no more than a total of four filled holes per part Broken Wires One broken wire per part is acceptable provided it is completely bonded with no exposed sharp edge. Test by cotton swab over area, any cotton fiber snagging is unacceptable Depressed and Raised Imperfections Depressed or raised imperfections are acceptable up to five total per part provided its diameter do not exceed 0.20 inch (5 mm) and depth or height do not exceed inch (0.4 mm) Fan Case Abradable Moulding Appearance Variations in colour and gloss, and colour stripes in molding are acceptable unless otherwise specified. Colour patches from surface rework is acceptable. Gray colour demarcation is acceptable unless otherwise specified in the part drawing.

25 CPW Mould Under Fill Mould under fill is acceptable to limits shown in Table Fan Case Abradable Potting, Honeycomb Impregnated Conditions not addressed in this standard are unacceptable General Limits (applies to all part surfaces) The following imperfections revealed by visual inspection are acceptable: Burnish marks Water Discoloration Superficial Imperfections Colour shade variations An elongated honeycomb cell is acceptable Impressions are acceptable provided the drawing profile tolerance is not violated Nomex Honeycomb acceptance limits When the edge of Nomex honeycomb is visible, missing Nomex is acceptable to the following limits: Up to one (1) cell width from edge on long sides (circumferential directions) Up to one-half (1/2) cell width from edge on short sides (axial width) Machined Surface Table. 2: Mould under fill Acceptance Limits for Fan Case Abradable Moulding Depth Length Width Acceptance Limits Under inch (0.5 mm) Not Applicable Not Applicable Up to 1 sq inch (6.50 sq cm) per mold segment Over inch (0.5 mm) Under 0.15 inch (3.8 mm) Under 0.10 inch (2.5 mm) Over inch (0.5 mm) Under 0.20 inch (5 mm) Under 0.15 inch (3.8 mm) Over inch (0.5 mm) Up to 0.50 inch (13 mm) maximum individual Under 0.03 inch (0.8 mm) Unlimited Voids or pits up to inch (1.5 mm) diameter are acceptable provided they are clearly separated and cover less than 8 percent of the surface Distorted honeycomb up to 25 percent of area is acceptable. Distorted honeycomb cells must retain at least half the original cell width Waviness is acceptable when in compliance with drawing profile tolerance. Up to 3 areas per mold segment Up to 1.50 inch (38 mm) length total per mold segment

26 CPW Honeycomb separation up to one (1) cell width and one-half (1/2) panel axial length is acceptable provided there are no more than 4 per panel and there is a minimum separation of 3.0 inches (76.2 mm) in circumferential direction. Multiple separations that are in line axially may be considered as one occurrence. 6. REWORK 6.1 Recording of Rework The following information must be recorded by the supplier and kept available for review by P&WC for each part reworked for delamination, perforate skin unbond or distortion, and skin damage. Purchase order number, P&WC part number, Part serial number, if applicable, Type of defect Rework location, Size of defect before rework, Identification of the process used, Signature or stamp of the inspector. 7. CONTROL Must be in accordance with P&WC Specification CPW APPROVAL All rework procedures for composite components must be subject to Engineering Source Approval per P&WC Specification CPW ACKNOWLEDGMENT The supplier must mention this specification number and its revision letter in all quotations and when acknowledging purchase orders. 10. REJECTION Parts not conforming to this specification or to authorized modifications will be subject to rejection. 11. NOTES The ( ) symbol used to indicate technical changes is not used in this revision to identify changes with respect to the previous issue due to the extent of the changes. Dimensions and properties in inch/pound units and the Fahrenheit temperatures are primary; dimensions and properties in SI units and Celsius temperatures are shown as the approximate equivalents of the primary units and are presented only for information.