Helicopter Structure: Modifications and Repair Manufacturing, Inspections, Modifications and Repair of Composite and Metallic Helicopter Structure and Components.

Participants who successfully complete this Helicopter Structure Training program are considered to be able to:

• Manufacture Metallic and Composite Components.
• Perform Inspections on Metallic and Composites Structures.
• Perform Modifications on Metallic and Composites Structures.
• Perform various types of Repairs on Composite and Metallic Helicopter Structures.

 

All the above mentioned task will be performed in compliance with the manufacturers repair documentation or other acceptable repair data.

 

Course Information:

Training Locations: Netherlands, Singapore or Customer Location.

Course ID: HS010.

Course Duration: 15 Working days; 120 working hours.

 

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". 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 Composites

• Discuss the merits and general failure modes of composite materials to the extent that a material properties comparison can be established between metallic and composite structures as evaluated by the instructor.

 

Module 2: Human Factors

• Explain the concept of “Human Factors” to the extent that a brief explanation of the “personal minimums” and a minimum of two factors that are likely causes of accidents and incidents be given.

 

Module 3: Reinforcement Fibers

• Visually recognize common composite fibers, list the properties, and associate the terms related to the fabric manufacturing process.
• Describe the fiber placement levels used during manufacturing and repairing of composite structures to the extent that the fabric weaves, warp direction, and part warp clock can be referenced as evaluated by the instructor.

 

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: Pre-Impregnated Materials

• Describe the pre-impregnation manufacturing levels and state the stages of the matrix material, storage and handling requirements, re-certification, and disposal procedures to the extent that the correct handling procedures are stated as evaluated by the instructor.

 

Module 7: Adhesives

• Explain the properties of adhesives and their usage, surface preparation levels, bond line control levels, and their common failure modes to the extent that adhesive materials can be selected given repair documentation as evaluated by the instructor.

 

Module 8: Structural Design Considerations

• Describe the differences between sandwich structures and solid laminate structures (including monolithic structure) to the extent that the different materials used in construction will be described in detail as evaluated by the instructor.

 

Module 9: Material Handling and Storage

• Explain the importance of proper storage and handling of materials utilized in the various composites industries to the extent that storage containers (refrigerators, freezers, cabinets, etc.), storage life, handling concerns, out times, recertification, and disposals will be discussed in detail as evaluated by the instructor.

 

Module 10: Facilities and Equipment

• List the various equipment needed to properly operate a composite facility to the extent that a detailed list of tools, dust extraction equipment, trim rooms, and Controlled Contamination Area (CCA) be discussed in detail as evaluated by the instructor.

 

Module 11: Vacuum Bagging

• Explain the importance of vacuum bagging to the extent that an explanation be given on the principals of vacuum and how it affects laminate properties.
• Provide a detailed list of materials utilized in the vacuum bagging process as evaluated by the instructor.

 

Module 12: Heating Devices

• Explain the different types of heating devices utilized in the composite industry to the extent that an explanation be given on their primary uses, advantages/disadvantages, their limitations, and the concerns of the devices as evaluated by the instructor.

 

Module 13: Source Documents

• Describe the use of repair documents and manuals for composite structures.

 

Module 14: Protective Coatings and Finishes

• Discuss the protective coating requirements, their handling procedures involving fiber reinforced plastic structures, and determine the type, application, and restoration procedures using approved manuals.

 

Module 15: Repair Selection Considerations

• Discuss the protective coating requirements, their handling procedures involving fiber reinforced plastic structures, and determine the type, application, and restoration procedures using approved manuals.

 

Module 15: Practical Assessment and Logbook Evaluation

• Describe the differences between prepreg repairs, wet lay-up repairs, and bolted repairs.

 

Module 16: Practical Assessment and Logbook Evaluation

• List the various types of Non-Destructive Inspection (NDI) techniques and their limitations during manufacture and repair of composite structures.
• Perform a visual and tap test inspection on a sandwich constructed part and correctly map the damaged area.

 

Module 17: Machining of Composites

• Able to select and safely operate air powered tools, including drill motors, die grinders, and dual orbital sanders.
• Determine recommended grinding materials along with speeds and feed for machining of carbon and fiberglass materials to the extent that a minimum of 10 holes are drilled to the correct size without fiber breakout damage and taper sand a four-ply face sheet without bond ply damage.

 

Module 18: Hands-On Exercises

Develop the basic skills necessary to repair fiber reinforced structures utilizing wet-lay and prepreg materials, vacuum bagging techniques, and hot bond equipment to the extent that personal protective equipment is worn and the repairs are accomplished using approved documentation and deemed airworthy as evaluated by the instructor and approved acceptance criteria.

 

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 19: 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 20: Practical Assessment and Logbook Evaluation

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

 

 

 

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