BHT-206-SRM-1
APPENDIX A — CONSUMABLE MATERIALS
TABLE OF CONTENTS
Paragraph Page
Number Title Number
CONSUMABLE MATERIALS AND ORDERING INFORMATION
A-1 General ............................................................................................................... A-2
A-2 Identifying Sheet Aluminum Alloys...................................................................... A-2
A-3 General Procedure for Duplication of Parts ........................................................ A-3
A-4 Ordering Consumable Materials ......................................................................... A-3
A-5 Ordering Honeycomb Material ............................................................................ A-3
A-6 Ordering Composite Bond Materials................................................................... A-3
TABLES
Table Page
Number Title Number
A-1 Consumable Materials ........................................................................................ A-4
A-2 Composite Bond Material.................................................................................... A-5
A-3 Honeycomb Repair Material ............................................................................... A-6
ECCN EAR99 14 DEC 2010 Rev. 2 i/ii
BHT-206-SRM-1
APPENDIX A — ORDERING REPAIR MATERIALS
This section covers information pertinent to procuring the materials necessary to accomplish the repairs covered in
this manual.
ECCN EAR99 14 DEC 2010 Rev. 2 A-1
BHT-206-SRM-1
A-1 GENERAL.
Materials required for structural repairs can be divided into three classifications. They are:
a. Consumable materials,
b. Field (locally) fabricated parts, and
c. Purchased parts.
Consummable materials are those used for stripping, cleaning, surface preparation, bonding and finishing.
These are procured either locally or may be procured through your Bell Helicopter approved supply center.
Refer table A-1 for a list of the most commonly used consummable materials.
Field fabricated parts are those that can be locally fabricated using standard materials and sheet metal tools.
These may include items such as angles, channels, clips, skins and webs that can be duplicated by cutting,
shearing and/or brake forming of straight angle bends from standard sheet stock. Heat treatment and
forming of compound curves and joggles in flanged parts do not constitute a field fabricated part.
Generally, on the Model 206 series, the following materials are used in the construction of the airframe.
Formers, bulkheads, stringers, angle sections and thin web sections are made of 7075-T6 aluminum alloy
per QQ-A-250/13. Honeycomb panel facings, fuselage and tailboom skins are made of 2024-T3 aluminum
alloy per QQ-A-250/5. The engine pan and firewalls are made of titanium alloy per MIL-T-9046. Refer to
paragraph A.2 for additional information on materials identification.
Purchased parts are those available from Bell Helicopter approved supply centers. Purchased parts include
compound-formed sheet metal parts, joggled angles, compound contoured skins and parts requiring heat
treating after forming. Forgings, castings and machined parts, fasteners (nuts, bolts, rivets, etc) are also
classed as purchased parts.
A-2 IDENTIFYING SHEET ALUMINUM ALLOYS.
CAUTION
PREPARATION OF AND USE OF CHEMICALS SHOULD BE
ACCOMPLISHED BY QUALIFIED PERSONNEL ONLY.
1. IDENTIFYING ALUMINUM vs MAGNESIUM. Clean finish from one area of part to bare metal. Apply a
droplet of sodium hydroxide; a reaction indicates aluminum. As an alternate, apply a droplet of acetic acid;
a reaction indicates magnesium.
2. IDENTIFYING TYPES OFALUMINUM (7075 vs 2024 ALLOYS). Clean finish from one area of part to bare
metal. If part is clad, remove coating of pure aluminum to expose parent material. Apply a droplet of
cadmium chloride (CdCl 2 ) solution to cleaned surface. Within two minutes of contact the zinc present in
7075 alloy will turn black. Aluminum alloy 2024 contains insufficient zinc to react. Prepare cadmium
chloride as follows: in 100 ml of distilled water add 5mg of CdS0 4 (cadmium sulfate), 5mg of NACI (sodium
chloride) and 5 ml concentrated HCI (hydrochloric acid).
USE OR DISCLOSURE OF DATA CONTAINED ON THIS PAGE IS SUBJECT
A-2 TO THE RESTRICTIONS ON THE TITLE PAGE OF THIS DOCUMENT.
BHT-206-SRM-1
A-3 GENERAL PROCEDURE FOR DUPLICATION OF PARTS.
Parts that are eligible to be field fabricated may be made in the following manner. Determine the type of
material and alloy used in the original part and obtain a piece of material of the same alloy, hardness and of
the specified thickness, large enough to make the part.
Layout the part and form. Alodine treat and prime all bare aluminum.
A-4 ORDERING CONSUMMABLE MATERIALS. Refer to table A-1 for ordering information.
A-5 table A-2 for ordering information.
ORDERING HONEYCOMB MATERIAL. Refer to table
A-6 ORDERING COMPOSITE BOND MATERIALS. Refer to table A-3 for ordering information.
table A-3
USE OR DISCLOSURE OF DATA CONTAINED ON THIS PAGE IS SUBJECT
TO THE RESTRICTIONS ON THE TITLE PAGE OF THIS DOCUMENT. A-3
BHT-206-SRM-1
TABLE A-1. CONSUMABLE MATERIALS.
Item no. Nomenclature Source
S100 Chemical Film Material (alodine 1200), per MIL-C-81706, class 1 A, form II Commercial
(dip tank) or form Ill (brush-on). Refer to paragraph 3-2-14 for mixing and
application instructions.
S103 Chromi.c Acid (brush-on solution). Chromic acid and calcium sulfate. Commercial
chapter 33 for mixin.g instructions.
Refer to Standard Practices Manual chapter
S204 Epoxy Polyamide Primer, per MIL-P-23377. Commercial
S305 Aliphatic Naphtha, per TT-N-95, Type II Commercial
S308 Sealant (fuel exposure application), per MIL-S-8802 cl. B2. Bell Commercial
Specification 299-94 7-107, type Ill, class 7. BHT Spares
S309 Methyl Ethyl Keytone (MEI<), per TT-M-261 B. Commercial
S316 Acetone, per Q-A-51 . Commercial
$317 Adhesive (general purpose, potting and bonding), per Bell Specification BHT Spares
299-947-100, type 11, class 2.
S318 Cleaning Solution Compound, alkaline based per MIL-C-25769H, maximum Commercial
pH value 12.
S344 Alcoholic Phosphoric Acid (Turco W.O. 1), pH 7. 61102
$353 Sealant (firewall applications), per MIL-S-38249, type I. 83527
S363 Adhesive (wet lay-up), per Bell Specification 299-947-100, type II, class BHT Spares
3.
S392 Sealant (high corrosion resistance), per MIL-S-81733, type II. Commercial
S404 Fiberglass Cloth, per MIL-C-9084C, type VlllA or VlllB, weave 181-150 or BHT Spares
181-75DE
S407 Abrasive Pad, Nylon Web (Scotchbrite) L-P-0050, Type 1, Class 1, Size 1. Commercial
S409 Crocus Cloth, per A-A-1206. Commercial
$422 Aluminum Wool, MIL-A-4864, Type II. Commercial
S423 Abrasive Cloth, per P-C-458 or abrasive paper, per P-P-101 all grits. Commercial
S477 Tedlar (release film), Vac Pac No. 3760P 85670
USE OR DISCLOSURE OF DATA CONTAINED ON THIS PAGE IS SUBJECT
A-4 TO THE RESTRICTIONS ON THE TITLE PAGE OF THIS DOCUMENT.
BHT-206-SRM-1
MATERIAL:
ALUMINUM 2024-T3 PER QQ-A-250/4 METAL
ALUMINUM 7075-T6 PER QQ-A-250/12 -:c----tt-7~ SHEET
TITANIUM TYPE I, COMPOSITION B PER MIL-T-9046
301 CRES PER 299-947-133, TYPE II OR MIL-S-50591/2 HARD
ALUMINUM 6013-T6 PER AMS 4216
PEEL
(3)
PLY~--''-------'----~
"B" CODE "A" CODE
~,-
.. __ ,
~~
TT ~~ WIDTH INCHES
LENGTH INCHES
(2FEETMAXI
EXAMPLEOFPA=s~:::~R: 15oj°21J-1] " 14FEE~~AXI (6)
DASH NO. FROM TABLE LENGTH IN 1-FT INCREMENTS, 4 FT MAX (6)
"A"= ADH/PLY BOTH SIDES WIDTH IN 1-FT INCREMENTS, 2 FT MAX (6)
131 "B" = ADH/PLY ONE
EXAMPLE: 150-021-16B2-4= 2024 5WL PATTERN REPAIR SHEET, .020 THICK, 2FT WIDE, 4FT LONG. ADHESIVE AND PEEL PLY ONE
SIDE
150-021-58A2-4 = 7075 SMOOTH REPAIR SHEET, .016 THICK, ADHESIVE AND PEEL PLY BOTH SIDES, 2 FT WIDE, 4 FT
LONG
TABLE A-2. COMPOSITE BOND MATERIAL
MATERIAL TYPE
MATERIAL TITANIUM
THKNS (1) 2024 2024 5WL 2024 6WL TITANIUM 7075 301 CRES 6013 (4)
5WL
SMOOTH RIGID. (2) RIGID. (3) SMOOTH SMOOTH 1/2 HD SMOOTH
RIGID.
0.012 -2 -12 -31 -41 -56 -71 -81
0.016 -4 -24 -33 -43 -58 -82
0.020 -6 -16 -60 -73 -83
0.025 -8 -20 -28 -62 -77 -84
0.032 -10 -39 -64 -79 -85
0.040 -14 -66 -75 -86
0.050 -18 -68 -76 -87
0.008 -69
0.063 -70
NOTES:
1. THKNS represents thickness of sheet material.
2. 5wl and 6wl designations are rigidizing pattern numbers of Rigidized Metal Corporation, Buffalo NY.
3. "A" code designates adhesive and peel ply on both faces of sheet, valid for smooth surfaces only. "B" code designates adhesive
and peel ply on one face only, valid smooth and rigidized surfaces.
4. Use with BHT engineering approval only.
5. All thicknesses may be ordered although they may not be actively stocked.
6. Materials may be available in one of either of the two following sizes: 1 ft X 2 ft and 2 ft X 4 ft.
USE OR DISCLOSURE OF DATA CONTAINED ON THIS PAGE IS SUBJECT
TO THE RESTRICTIONS ON THE TITLE PAGE OF THIS DOCUMENT. A-5
BHT-206-SRM-1
MATERIAL:
PER BHT SPECIFICATION 299-947-059 TYPE 4
THICKNESS -1 1-
T
INCHES
EXAMPLEOF ~;;;~_E_R_:_ _ _T_4-'3f x x 118 x 12 x 24
CELL SIZE (inch)
PANELTHICKNESS (fraction)
PANEL SIZE. W XL ( i n c h ) - - - - - - - - - '
EXAMPLE: T 43. 1 X . 125 X 1/4 X 12 X 24 = ALUMINUM HONEYCOMB, 3. 1 LB/SQ. IN.
DENSITY, 0.125 INCH CELL, 0.25 INCH THICK, 12 X 24 INCH SIZE PANEL.
T48.1 X .125 X 1 X 24 X 48 =ALUMINUM HONEYCOMB. 8.1 LB/SQ. IN.
DENSITY, 0. 125 INCH CELL, 1.0 INCH THICK, 24 X 48 INCH SIZE PANEL.
TABLE A-3. HONEYCOMB REPAIR MATERIAL
PANEL MATERIAL DENSITY (lbs./cu ft) PANEL SIZE (INCH)
THICKNESS
(INCH) 3.1 4.5 8.1 12 x 24 24 x 48
0.12(1/8) x N/A N/A x N/A
0.25 (1/4) x N/A N/A x x
0.38 (3/8) x N/A N/A x N/A
0.50 (1 /2) x x x x x
0.75 (3/4) x N/A N/A x N/A
1.00 (1) x N/A x x x
USE OR DISCLOSURE OF DATA CONTAINED ON THIS PAGE IS SUBJECT
A-6 TO THE RESTRICTIONS ON THE TITLE PAGE OF THIS DOCUMENT.
