A method for quickly repairing punctures and damage to fuel tanks using metal tape.

Abstract

This invention relates to the field of aircraft fuel tank damage repair technology, specifically a method for rapidly repairing fuel tank punctures using metal tape, comprising: 1) damage assessment and removal; 2) adhesive surface treatment; 3) tape cutting and application; 4) metal patch manufacturing and fastener selection; 5) mechanical connection of the metal patch; 6) additional tape cutting and application; and 7) repair quality inspection. This invention overcomes the problem of long sealant curing time in traditional repair methods by using metal tape in conjunction with metal patches to mechanically connect the entire fuel tank structure, achieving rapid repair of fuel tank punctures, effectively improving sealing and mechanical performance, ensuring the safety and reliability of aircraft operation, and possessing the advantages of simple operation, speed, efficiency, and safety.

Description

Technical Field

[0001] This invention relates to the field of aircraft fuel tank damage repair technology, specifically a method for quickly repairing fuel tank punctures using metal tape. Background Technology

[0002] Integral fuel tanks are an important component of aircraft structure, making full use of the volume of structural elements in the fuselage and wings to increase fuel storage capacity and reduce aircraft weight. However, during flight service, high-speed impacts such as shrapnel and bird strikes can cause damage to the integral fuel tank structure, leading to reduced structural sealing and malfunctions such as fuel leaks and seepage, which seriously threaten the safety and service life of the aircraft.

[0003] Currently, the repair of punctures in aircraft fuel tanks typically involves mechanically connecting metal patches and blind rivets to the tank structure using sealant. While this method offers high reliability, the need to apply 2-3 layers of sealant (each layer requiring approximately 24 hours of curing time) results in a lengthy repair cycle and significantly reduces efficiency. Therefore, there is an urgent need to design a rapid repair method for aircraft fuel tank punctures, addressing the issue of long curing times associated with sealant repairs, shortening the repair cycle, improving the overall tank structure's sealing and mechanical properties, and ensuring flight safety and reliability. Summary of the Invention

[0004] To address the aforementioned technical problems, this invention proposes a method for rapidly repairing punctures and damage to fuel tanks using metal tape. This method aims to improve the fuel tank's sealing and mechanical properties, effectively shorten the repair cycle, and ensure the safety and reliability of the aircraft.

[0005] The technical problem to be solved by this invention is achieved by the following technical solution:

[0006] A method for quickly repairing punctures in fuel tanks using metal tape includes the following steps:

[0007] 1) Damage assessment and removal:

[0008] Record the geometric parameters of the damaged area on the overall fuel tank, determine the size of the damaged area of ​​the overall fuel tank, and record the diameter as d. Trim the damaged area of ​​the skin, and wipe the repair surface with a fine cloth soaked in acetone until there are no obvious stains or debris on the surface of the fine cloth.

[0009] 2) Surface treatment for bonding:

[0010] Use 60# to 80# sandpaper to sand the surface of the skin repair area. The sanding area should be larger than the metal tape bonding area. Use acetone-soaked fine cloth to wipe the repair surface until there are no obvious stains or debris on the surface of the fine cloth. Use a brush to apply AC-130 surface active treatment reagent to the sanded skin surface.

[0011] 3) Cutting and applying metal tape:

[0012] Cut the metal tape with scissors and a ruler, use tweezers to pick up and lay the metal tape layer by layer, use a scraper to press the metal tape from the center to the periphery to remove air between the metal tapes, and use a soft rubber roller to press the metal tape firmly multiple times, requiring a smooth and flat surface without air holes, wrinkles, or warping.

[0013] 4) Manufacturing of metal patches and selection of fasteners:

[0014] Metal patches are manufactured using shears or cutting tools. The thickness and material grade of the metal patches are consistent with the thickness and material of the overall fuel tank. The diameter of the metal patch is denoted as D. The diameter of the fastener is determined with reference to the "Steel Structure Design Standard" and denoted as A.

[0015] 5) Mechanical connection of metal patches:

[0016] Use a marker to mark the location of the fasteners on the metal patch, and use pneumatic tools to connect the metal patch to the damaged area on the overall fuel tank.

[0017] 6) Cutting and applying additional metal tape:

[0018] Apply two layers of additional metal tape to the outer surface of the metal patch. When the width exceeds the bonding area of ​​the metal tape, the metal tape is allowed to overlap. The application parameters are the same as in step 3).

[0019] 7) Repair quality inspection:

[0020] The cut edges of the metal tape should be free of burrs, and the metal tape should be flat, smooth, free of air holes, wrinkles, and warping.

[0021] As a further improvement of the present invention, in steps 1) and 2), the acetone wiping of the repaired surface requires wiping in a unidirectional direction from top to bottom.

[0022] As a further improvement of the present invention, the size requirements for the metal tape in step 3) are as follows: the distance between the metal tape and the damaged edge on the overall fuel tank is 25mm; the overlap distance of the metal tape is 12.5mm; and the tolerance range is 1mm to 2mm.

[0023] As a further improvement of the present invention, the diameter of the metal patch in step 4) is: D = d + 4e, where e = 2.5A.

[0024] As a further improvement of the present invention, the spacing between the fasteners in step 5) is denoted as p, where p = 4A.

[0025] The beneficial effects of this invention are:

[0026] This invention provides a method for quickly repairing punctures and damage to fuel tanks using metal tape. By using metal tape in conjunction with metal patches to mechanically connect the entire fuel tank structure, it overcomes the problem of long curing time for sealants in traditional repair methods, achieving rapid repair of punctures and damage to fuel tanks, effectively improving sealing and mechanical properties, and ensuring the safety and reliability of aircraft use. It has the advantages of being simple to operate, fast and efficient, and safe and reliable. Attached Figure Description

[0027] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0028] Figure 1 This is a schematic diagram of the overall perforation structure of the fuel tank;

[0029] Figure 2 This is a schematic diagram of metal tape bonding;

[0030] Figure 3 This is a schematic diagram showing the distribution of fasteners;

[0031] Figure 4 This is a schematic diagram for repairing metal tape.

[0032] In the diagram: 1. Metal tape; 2. Additional metal tape; 3. Fasteners; 4. Metal patch; 5. Overall fuel tank. Detailed Implementation

[0033] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0034] A method for quickly repairing punctures in a fuel tank using metal tape includes: 1) damage assessment and removal; 2) adhesive surface treatment; 3) tape cutting and application; 4) metal patch manufacturing and fastener selection; 5) mechanical connection of the metal patch; 6) additional tape cutting and application; and 7) repair quality inspection.

[0035] The specific steps described above are as follows:

[0036] 1) Damage assessment and removal.

[0037] Using measuring tools such as a ruler, record the geometric parameters of the damaged area on the overall fuel tank 5 to determine the size of the damaged area of ​​the overall fuel tank 5, with the diameter denoted as d. Trim the damaged area of ​​the skin on the overall fuel tank 5, and use an acetone-soaked fine cloth to wipe the repair surface from top to bottom in one direction until there are no obvious stains or debris on the surface of the fine cloth.

[0038] 2) Surface treatment for bonding.

[0039] Use 60# to 80# sandpaper to sand the surface of the skin repair area. The sanding area should be larger than the metal tape bonding area. Use acetone-soaked fine cloth to wipe the repair surface from top to bottom in one direction until there are no obvious stains or debris on the surface of the fine cloth. Use a brush to apply AC-130 surface active treatment reagent to the sanded skin surface.

[0040] 3) Cutting and applying metal tape 1.

[0041] Cut the metal tape 1 using scissors and a ruler. Use tweezers to pick up and lay the metal tape 1 layer by layer. Use a scraper to press the metal tape 1 from the center to the periphery to remove air between the metal tapes 1. Use a soft rubber roller to press the metal tape 1 firmly multiple times. The surface should be smooth and flat, without air holes, wrinkles, or warping.

[0042] The dimensions of metal tape 1 are determined as follows: the distance between metal tape 1 and the damaged edge on the overall oil tank 5 is 25mm; the overlap distance of metal tape 1 is 12.5mm; and the tolerance range is 1mm to 2mm.

[0043] 4) Manufacturing of metal patch 4 and selection of fastener 3.

[0044] Metal patch 4 is manufactured using scissors or cutting tools. The thickness and material grade of metal patch 4 are consistent with the thickness and material of the overall fuel tank 5. The diameter of fastener 3 is determined with reference to the "Steel Structure Design Standard" and is denoted as A.

[0045] In the above, the diameter of the metal patch 4 is denoted as D, specifically, D = d + 4e, where e = 2.5A.

[0046] 5) Mechanical connection of metal patch 4.

[0047] like Figure 3 As shown, the positions of fasteners 3 are marked on the metal patch 4 using a marker, and the spacing between fasteners 3 is denoted as p, where p = 4A. A pneumatic tool is then used to connect the metal patch 4 to the damaged area on the overall fuel tank 5.

[0048] 6) Cutting and applying additional metal tape 2.

[0049] according to Figure 3 and Figure 4 Two layers of additional metal tape 2 are applied to the outer surface of the metal patch 4. When the width exceeds the area where the metal tape is applied, the metal tape is allowed to overlap. The application parameters are the same as in step 3).

[0050] 7) Repair quality inspection.

[0051] Check that the cut edges of the metal tape 1 are free of burrs, and that the metal tape 1 is flat, smooth, free of air holes, wrinkles, and warping.

[0052] In this embodiment, taking an aluminum alloy metal oil tank with a hole damage of 30mm in diameter, 2mm in thickness, and made of 7B04 as an example, we carry out the repair of the mechanical connection of the metal tape.

[0053] Step 1: Damage assessment and removal.

[0054] Using measuring tools such as a ruler, determine the size of the damaged area of ​​the overall fuel tank 5, and record the diameter as d, where d is 30mm. Use an acetone-soaked fine cloth to wipe the repair surface from top to bottom in one direction until there are no obvious stains or debris on the surface of the fine cloth.

[0055] Step 2: Surface preparation for bonding.

[0056] Use 0# to 80# sandpaper to sand the surface of the skin repair area. The sanding area has a diameter of 100mm. Use acetone-soaked fine cloth to wipe the repair surface from top to bottom in one direction until there are no obvious stains or debris on the surface of the fine cloth. Use a brush to apply AC-130 surface active treatment reagent to the sanded skin surface.

[0057] Step 3: Cutting and applying metal tape 1.

[0058] Cut a number of 100mm wide and 100mm long pieces of metal tape 1 using scissors and a ruler. Use tweezers to pick up and apply the metal tape 1 layer by layer. Use a scraper to press the metal tape 1 from the center outwards to remove air bubbles. Use a soft rubber roller to compact the metal tape 1 multiple times, ensuring a smooth, even surface free of air bubbles, wrinkles, and warping. The distance between the metal tape 1 and the damaged edge on the overall fuel tank 5 should be 25mm; the overlap distance of the metal tape 1 should be 12.5mm.

[0059] Step 4: Manufacturing of metal patch 4 and selection of fastener 3.

[0060] Referring to the "Steel Structure Design Standard", the diameter of fastener 3 is determined to be 5mm. A metal patch 4 with a thickness of 2mm and material grade 7B04 is manufactured using shears or cutting tools. The diameter of the metal patch is calculated to be 80mm according to D = d + 4e, where e = 2.5A.

[0061] Step 5: Mechanical connection of metal patch 4.

[0062] like Figure 3 As shown, the positions of fasteners 3 are marked on the metal patch 4 using a marker, with the fastener spacing denoted as p. Since p = 4A, p is 20mm. A pneumatic tool is then used to connect the metal patch 4 to the damaged area on the overall fuel tank 5.

[0063] Step 6: Cut and apply additional metal tape 2.

[0064] Two layers of additional metal tape 2 are applied to the outer surface of the metal patch 4. When the width exceeds the bonding area of ​​the metal tape 1, the metal tape is allowed to overlap. The application parameters are the same as in step 3).

[0065] Step 7: Repair quality inspection.

[0066] The cut edges of the metal tape 1 should be free of burrs, and the metal tape 1 should be flat, smooth, free of air holes, wrinkles, and warping.

[0067] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely prisms of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A method for quickly repairing punctures and damage to fuel tanks using metal tape, characterized in that: Includes the following steps: 1) Damage assessment and removal: Record the damage geometry parameters of the damaged area on the overall oil tank (5), determine the size of the damaged area of ​​the overall oil tank (5), and record the diameter as d. Trim the damaged area of ​​the skin, and use acetone-soaked fine cloth to wipe the repair surface until there are no obvious stains or debris on the surface of the fine cloth. 2) Surface treatment for bonding: Use 60# to 80# sandpaper to sand the surface of the skin repair area. The sanding area should be larger than the metal tape bonding area. Use acetone-soaked fine cloth to wipe the repair surface until there are no obvious stains or debris on the surface of the fine cloth. Use a brush to apply AC-130 surface active treatment reagent to the sanded skin surface. 3) Cutting and applying metal tape (1): Cut the metal tape (1) with scissors and ruler, pick up the metal tape (1) layer by layer with tweezers, press the metal tape (1) from the center to the periphery with a scraper to remove the air between the metal tape (1), and use a soft rubber roller to press the metal tape (1) multiple times. The surface should be smooth and flat, without air holes, wrinkles, or warping. 4) Manufacturing of metal patch (4) and selection of fastener (3): Metal patch (4) is manufactured using a cutting tool. The thickness and material grade of the metal patch (4) are consistent with the thickness and material of the overall oil tank (5). The diameter of the metal patch (4) is denoted as D. The diameter of the fastener (3) is determined and denoted as A. In step 4), the diameter of the metal patch (4) is: D = d + 4e, where e = 2.5A; 5) Mechanical connection of metal patch (4): Mark the position of the fastener (3) on the metal patch (4) with a marker, and use a pneumatic tool to connect the metal patch (4) to the damaged area on the overall oil tank (5); In step 5), the distance between the fasteners (3) is denoted as p, where p = 4A; 6) Cutting and applying the additional metal tape (2): Two layers of additional metal tape (2) are applied to the outer surface of the metal patch (4). When the width exceeds the bonding area of ​​the metal tape (1), the metal tape is allowed to overlap. The application parameters are the same as in step 3). 7) Repair quality inspection: The cut edges of the metal tape (1) should be free of burrs, and the metal tape (1) should be flat, smooth, free of air holes, wrinkles, and warping.

2. The method for quickly repairing punctures in a fuel tank using metal tape according to claim 1, characterized in that: In steps 1) and 2), the acetone wiping of the repaired surface should be done in a unidirectional direction from top to bottom.

3. The method for quickly repairing punctures in a fuel tank using metal tape according to claim 1, characterized in that: The size requirements for the metal tape (1) in step 3) are as follows: the distance between the metal tape (1) and the damaged edge on the overall oil tank (5) is 25mm; the overlap distance of the metal tape (1) is 12.5mm; and the tolerance range is 1mm to 2mm.

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