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TRI Austin developed a series of room temperature cure syntactic foam products for Aircraft Battle Damage Repair (ABDR). A single component elevated temperature cured epoxy syntactic foam was developed that will require a hot bonder or heat blanket cure of the foam.

A “fast repair” epoxy putty was also developed. Repaired parts were subjected to cyclic fatigue tests, sectioned, and inspected. Repairs were conducted using optimized formulations under field conditions. The repairs were evaluated with regard to overall quality, adhesion, and void fraction. Product modification will occur as needed based on user feedback. A product specification was developed that included detailed repair procedures.

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