Aircraft Composite Structure: Inspection, Damage Assessment and Repair, Level 1 (SAE AIR4938 Part 1) Learn about the fundamentals of inspection and repairs of composite materials

This level 1 composite course has been developed as a starting point 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 a better understanding of advanced composite materials, basic manufacturing processes, wet-layup/lamination, vacuum bagging techniques, adhesive, material handling and storage of fibers and sandwich materials, adhesive, tooling and equipment, design of the composite repair facility, understanding of technical drawings, repair, and inspection methods and techniques. The participant will develop the skillset to safely work with reinforced plastic (use of glass, aramid and carbon fibers combined with high strength epoxy resin systems) and to perform inspection and repair on composite structure.

Course Information:

• Training Locations: Netherlands, Singapore or at Customer Location.
• Course ID: ATS1011.
• Course Duration: 5 Working days. 
• Prerequisites: Prior composites experience or training is not required.
• Learning Hours:
  • ​​Classroom: 4.5 hours.
  • Online Learning: 5.5 hours. 
  • Practical Hours: 34 hours

Course Module Overview:

• Introduction composites.
• Definitions and applications.
• Human factors.
• Reinforced Fibers.
• Health, safety and environment.
• Adhesives.
• Material Handling and Storage.
• Facilities and Equipment.
• Vacuum Bagging.
• Heating Devices.
• Reading Technical Drawings.
• Machining of Composites.
• Written Test.

Hands-on Exercises: 
Learning by Doing. 

• Introduction to composite repairs.
• Manufacturing and repair: monolithic panel lay-up using using dry glass cloth and liquid epoxy resin materials; symmetric and asymmetric laminates. Vacuum bagging with varied bleeder/breather sequences to evaluate resin bleed and flow characteristics.
• Modification according engineering drawing on monolithic panel.
• Sandwich panel layup, bagging and processing of nested glass and aramid fiber fabric foam and honeycomb core panel.
• Composite repair: damage removal, scarf preparation, core and skin repair using wet layup materials and processes.
• 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.