Aircraft Composite Structure: Inspection, Damage Assessment and Repair, Level 3 (SAE AIR4938 Part 3) Gain in-depth knowledge of aircraft composites structures and damage mapping on aircraft structures

This advanced composite level 3 course has been developed to meet the knowledge and skill requirements of a composite manufacturing and/or repair technician. 

The participant who successfully complete this composite training program has in-depth understanding of Source Documents Review, Composite Structure Classification and Repair Categories, Aircraft-Specific Repair Material Requirements, Structural Design Considerations, Repair Selection Considerations, Resin Infusion Techniques, Heat Transfer and Cure Cycle Management, Protective Coatings and Finishes, Mould Making.

Course Information:

• Training Locations: Netherlands, Singapore or Customer Location.
• Course ID: ATS1013.
• Course Duration: 5 Working days. 
• Prerequisites: Advanced Composite Program Level 2 or equivalent.
• Learning hours:
  • Classroom: 8 hours.
  • Online Learning: 7 hours.
  • Practical: 31 hours.

Module Overview:

• Source Documents Review.
• Composite Structure Classification and Repair Categories.
• Aircraft-Specific Repair Material Requirements.
• Structural Design Considerations.
• Repair Selection Considerations.
• Resin Infusion Techniques.
• Heat Transfer and Cure Cycle Management.
• Protective Coatings and Finishes.
• Mould Making.
• Written Test.

Hands-on Exercises: 27 hours.
Practical: Learning by Doing.

• Repair to honeycomb sandwich part, with both skins and core damage, using prepreg materials. This repair can use either single sided or double sided heating method. The repair is to be performed from one side access. The repair can be either a one or two stage repair method. The cure cycle heat application can be any of the listed methods in this document.
• Repair to the edge band of honeycomb sandwich part, the damage is to extend into the core and have ply drop offs. This repair can use either single sided or double sided heating methods. The repair can use either a one or two stage repair method. The cure cycle heat application can be any of the listed methods in this document.
• Repair to a solid laminate part with a minimum of six plies, using wet layup or prepreg materials. This repair can use either single sided or double sided heating method. The cure cycle heat application can be any of the listed methods in this document.
• Repair to honeycomb sandwich part, with both skins and core damage, using wet layup or prepreg materials. This repair can use either single sided or double sided heating method. The repair is to be performed from one side access. The repair can be either a one or two stage repair method. The cure cycle heat application can be any of the listed methods in this document.
• Vacuum bagging using non-autoclave bleeder/breather schedules. Installation of pleats to minimize bridging in high-angle core transitions. Vacuum debulking, leak checking, and identification of other potential bagging problems.

This course complies with guidelines of:

SAE Publications:

• AIR4844: Composites and Metal Bonding Glossary.

• AIR5719: Teaching Points for an Awareness Class on "Critical Issues in Composite Maintenance and Repair".

• AIR629: Guidelines for Repair Process Evaluation of Aluminum Bonded Structure.

• ARP6262: Basic Composite Repair Technician Certification Standard.

FAA and EASA Publications:

• Part 147 EASA.
• AMC 20-29: Composite Aircraft Structure.
• FAA AC 20-107B: Composite Aircraft Structure.
• FAA AC 65-33: Development of Training/ Qualification Programs for Composite Maintenance Technicians.
• FAA AC 43-214: Repairs and Alterations to Composite and Bonded Aircraft Structure.

Download the detailed course outline below.