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Aircraft Composite Structural Bonded Repair, Part 2 Manufacturing, Inspection and Repair of Advanced Composites

Participants who successfully complete the "part 2" of this advanced aircraft composite training program are considered to be able to perform bonded composite repairs to composite structures in compliance with the manufacturers repair documentation or other acceptable repair data.

Course Information:

Training Locations: Netherlands, Singapore and Customer Location.

Course ID: CT020.

Course Duration: 10 Working days; 76 hours.


This course complies with guidelines of:

SAE Publications:

  • SAE AIR4938, Revision B, Revised 2017-06.

  • AIR4844,Composites and Metal Bonding Glossary.

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

  • ARP6262,Basic Composite Repair Technician Certification Standard.

EASA and FAA Certifcations:

  • 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.

Module Overview and Learning Goals:

After successful completion of each module, the student will be able to:

Module 1: Introduction to Aircraft Composites

  • Describe composite materials and their applications in aircraft structure. 
  • Discuss the merits and general failure modes of composite materials.


Module 2: Composite Structure Classification and Repair Categories

  • Identify team member skills, roles, and responsibilities as  related to composite repair processes. 
  • State the differences between structural classifications and repair categories.


Module 3: Aircraft-Specific Repair Material Requirements

  • Identify and verify that the repair material is the correct material called in the repair document.


Module 4: Matrix Systems

  • State the difference between thermoplastic and thermosetting matrix materials. 
  • Describe the roles and limitations of matrix materials, describe the storage and handling requirements.
  • Determine and calculate various mix ratios. 
  • Describe the cure cycle, and describe the matrix cross-linking terminologies. 
  • Describe and select appropriate filler materials to the extent that a given resin system mix ratio with filler materials can be calculated using an established ratio as evaluated by the instructor.


Module 5: Safety and Environment

  • Sate the personal hazards working with polymeric materials and describe the four common paths of entry. 
  • Evaluate a typical Safety Data Sheet (SDS) and demonstrate the select proper personal protection equipment (PPE).
  • Describe waste disposal procedures as evaluated by the instructor.


Module 6: Adhesives Review

  • Explain the properties of adhesives and their correct applications, surface preparation requirements, bond line control methods, common failure modes, and identify the adhesive materials required per the repair documentation.


Module 7: Aircraft Design Considerations

  • Describe the benefits and limitations of sandwich structures, solid laminate structures, solid laminate monolithic structure, and joint types. 
  • Describe EME, ply layup, protective coatings, and sealant requirements.


Module 8: Heat Transfer and Cure Cycle Management

  • Operate and control the heat application equipment to meet the repair cure cycle requirements. 
  • Describe the principles of heat transfer and how it affects the ability to meet the cure cycle requirements.


Module 9: Source Documents

  • Describe Air Transportation Association (ATA) specification 100 standardization.
  • State common OEM manuals used for repair of composite structures. 
  • Describe the manual revision process involving controlled documents.
  • State the need to follow written instructions when repairing composite structures to the extent that the chapter, section, and subject of a given aircraft composite part can be located as evaluated by the instructor.


Module 10: Repair Selection Considerations

  • Describe the differences between prepreg repairs, wet lay-up repairs, and bolted repairs. 
  • Explain the differences in sanding and ply stack-up techniques. 
  • Calculate the ply overlap dimension using 50:1 and 30:1 taper ratios for a four-ply face sheet and a six-ply face sheet using carbon and fiberglass plies.


Module 11: Inspection Techniques

  • List the various types of Non-Destructive Inspection (NDI) techniques and their limitations when used during manufacture and repair of composite structures. 
  • Perform a visual, tap test, and low-skill instrumented inspection of structures and correctly map the damaged area.


Module 12: Damage Mapping

  • Assess damage to identify the material type, size, and the number of plies and map the limits of damage using visual, tap test, or identify the required NDI method for the type of structure.


Module 13: Hands-on Exercise

  • Develop the skills necessary to repair fiber reinforced structures utilizing wet lay-up and prepreg materials, vacuum bagging techniques, and hot bond equipment. 
  • Must demonstrate the listed skills to the instructor and meet the criteria in the repair documentation.

At least two of the repair exercises will use 180 °C (350 °F) nominal cure temperature prepreg materials. For some of the repairs, foam cored parts are an alternative to honeycomb parts. At least one of the repairs must be a fiberglass  part. At least 50% of the repairs must use a hotbonder as the control method. At least one of the repairs must require restoration of the electromagnetic effects (EME) surface layer. At least one of the repairs is to be a part with a significant curvature.


Assessment Criteria:

  1. Core removed without causing additional damage to far side inner skin.
  2. Taper sanding meets repair document requirements.
  3. Correct material and orientation of original plies identified.
  4. Repair plies are positioned and oriented correctly.
  5. Cure cycle(s) meets repair document requirements.
  6. Repair meets post repair inspection requirements.


Module 14: Written Test

The written examination shall contain a minimum of 50 multiple choice questions.

The examination shall contain a minimum of 3 questions from each of the Topics listed in the outline for each Part. The examination will be closed book.


Module 15: Practical Assessment and Logbook Evaluation

The practical assessment will be a separate, hands-on repair.



Download Course Outline (PDF)
Aircraft Composite Structural Bonded Repair, Part 2 Manufacturing, Inspection and Repair of Advanced Composites


Participants who successfully complete this part 2 of this advanced composite training program are considered to be able to perform bonded composite repairs to composite structures in compliance with the manufacturers repair documentation or other acceptable repair data.


This course is designed for technicains, engineers, inspector and all other personal involved in the manufacture, maintenance and repair of composite structures.


To learn all about the basics principles and concept of reinforced fibers used in the aerospace industry. With this training, the (future) composite repair technician/ specialist will have a solid base to manufacture composite and perform inspections and repairs on aircraft components.

Sign up for: Aircraft Composite Structural Bonded Repair, Part 2