Boeing Proprietary Manufacturing Control Specification BAC5578

These flashcards cover key elements from Boeing's proprietary manufacturing control specification, focusing on compliance, material handling, inspection, and fabrication processes.

What does the ECCN 9E991 indicate regarding Boeing proprietary information?

It defines the export control regulations applicable to Boeing's proprietary technology.

What is the primary purpose of the Boeing Manufacturing Control specification BAC5578?

To establish requirements for the fabrication of carbon fiber reinforced advanced composite parts.

What does 'Type I' inspection require as per the BAC5578 specification?

Type I inspection requires both visual and dimensional inspection of each production part.

What is the maximum acceptable gap for splices in prepreg materials?

0.06 inch max gap with a max of 1.00 inch overlap.

What are the materials used for bonding primary composite structures according to BAC5578?

BMS5-160, Type I and Type II.

What temperature is required for autoclave curing of BMS8-413, Type I?

Cure temperature range between 345 to 365°F.

What is an acceptable handling life limit for BMS8-413, Type I materials?

720 exposure units.

Describe the process for applying tackifier resin film according to BAC5578.

Apply tackifier resin film to the tool surface or tool-side of the first ply, without inter-layer application.

What operation is prohibited in Controlled Contamination Areas (CCAs)?

Processes that produce uncontrolled spray, dust, fumes, or particulate matter.

What must be done if a thermal profiling plan fails to meet established requirements?

An interim thermal profiling report must be submitted for approval before production can begin.

What is the required action for storing uncured parts when environmental conditions are insufficient?

They must be placed in a sealed bag and stored in the freezer or other defined storage methods.

Which type of inspection requires a sampling frequency equivalent to BSS7286?

Type II inspection.

What should processors do if contaminated bond surfaces are detected?

They should be solvent cleaned and prepared for bonding as per specification.

How must prepreg materials be handled to avoid contamination?

Keep in sealed moisture-proof bags and protect from exposure to contaminants.

What is the importance of the Facility Operating Regulations (FOR) in the BAC5578 specification?

It outlines requirements for operations, maintenance, and materials handling within the CCA.

What is the acceptable pressure limit during the vacuum bag leak check?

The vacuum gauge reading must not drop more than 5 inches Hg in 5 minutes.

What defines the 'bond faying surface' in composite assemblies?

The cured surface of a part intended for adhesive bonding.

What must be verified for equipment used in critical operations?

It must be qualified in accordance with BSS7120.

List one requirement for applicable standard inspection according to BAC5578.

NDI systems must be qualified in accordance with Section 13.7.

What must not be allowed to touch uncured materials during curing?

Silicones and other contaminants that could affect adhesion.

What is the acceptable limit for porosity in laminate areas?

Less than or equal to 2 percent porosity.

What defining factor determines the classification of parts in the BAC5578 specification?

The processing category based on similar design and material properties.

What does the term 'debunking' refer to in the BAC5578 specification?

Applying temporary vacuum or pressure and heat to remove trapped air and compact the layup.

What does a Class 1 requirement in section 2.2 specify?

First Part Qualification (FPQ) is required.

How should vacuum bagging of the part for cure be performed?

Prevent inadvertent wrinkles which can affect the part surface.

What is the purpose of using a thermal profiling report?

To ensure that part heating and cooling rates, and cure temperature are maintained within specification.

Identify a requirement for representing a part/tool during thermal profiling.

A sketch of the part/tool showing thermocouple locations and dimensions.

What must be included in the Production Manufacturing Plan Approval?

Verification processes to ensure compliance with Engineering Drawings.

What is a critical feature of the tools used in the BAC5578 processes?

They must prevent contamination of the work surfaces.

Name one of the rework procedures for the composite parts according to BAC5578.

Prepare surface and coat area with resin in accordance with Section 8.6.

What is the required action for every tool before the production of parts on that tool?

Conduct a tool leak check.

What constitutes a visual inspection according to the BAC5578 requirements?

Monitoring the process and end-items to ensure compliance with quality standards.

Describe what must be done with adhesive not bonded correctly after initial application.

It must be cleaned and re-preped to ensure proper bonding.

What distinguishes Class 3 parts from others in the specification?

Class 3 is reserved for verification film parts.

What action is required if discrepancies exceed acceptable limits?

Rework is required to bring the discrepancy within acceptable limits.

State the purpose of having an NDI system in the manufacturing control process.

To detect internal defects reliably without damaging the items being tested.