Aircraft Composite Structure: Fabrication, Inspection, Damage Assessment and Repair (SAE AIR4938 Part 2)
Composite Repair Level 2, Composites Level 2, SAE AIR4938 Part 2
Meets SAE AIR 4938 Standards and DOT/FAA AR-08/54
Course ID:
ATS2072
Level:
Level 2 / Intermediate
Duration:
10 days
Total Hours:
75 hrs
Classroom
17h
Practical
58h
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For Whom
This course is intended for engineers, technicians, inspectors, and other personnel involved with the maintenance and repair of aircraft- and component composite structures.
Prerequisites
SAE AIR4938: Composite and Bonded Structure Technician/Specialist, Part 1
Scope and Purpose
The ACRATS Level 2 Composites Training Program builds upon the foundational knowledge and skills acquired in Level 1. This curriculum, in conjunction with the Part 1 curriculum, is intended to meet the formal training requirement for individuals who intend to become certified as aircraft composite repair technicians. Participants who successfully complete this aircraft structural repair training program are considered able to perform composite bonded repairs to aircraft structures in compliance with the manufacturers’ repair documentation or other acceptable or approved repair data. Participants will gain advanced knowledge and practical expertise in various aspects of composite materials, repair processes, and inspection techniques, preparing them for more complex repair tasks in the aviation industry.
Course Includes
* 58 Practical Hours
* 17 Theoretical Hours
* Theoretical Assignments
* Practical Assessments
* Personal Protection Equipment
* Access to the ACRATS E-learning
* Task Logbook
* Certificate of Achievement
* 17 Theoretical Hours
* Theoretical Assignments
* Practical Assessments
* Personal Protection Equipment
* Access to the ACRATS E-learning
* Task Logbook
* Certificate of Achievement
Learning Outcomes
Perform bonded and bolted repairs on aircraft composite structures; Execute sandwich structure repairs to OEM/SRM standards; Assess and classify damage in composite components; Apply advanced inspection methods and repair design considerations
Selection Learning Goals
* Describe composite materials and their applications in aircraft structures
* Identify team member skills, roles, and responsibilities in composite repair processes
* Verify that repair materials match the specifications called for in the repair documentation
* Understand the differences between thermoplastic and thermosetting matrix materials, and describe their roles, limitations, and handling requirements
* State the personal hazards of working with polymeric materials and select the recommended personal protection equipment (PPE)
* Explain the properties and applications of adhesives, and identify the adhesive materials required per the repair documentation
* Describe the design considerations for aircraft structures, including benefits and limitations of sandwich structures, solid laminates, and joint types
* Operate and control heat application equipment to meet repair cure cycle requirements
* Describe common OEM manuals used for composite structure repairs and understand the limitations of these manuals
* Explain the differences between prepreg repairs, wet lay-up repairs, and bolted repairs, and calculate ply overlap dimensions
* List various Non-Destructive Inspection (NDI) techniques and perform visual, tap test, and low-skill instrumented inspections
* Assess damage to composite structures and map the limits of damage using appropriate inspection methods
* Perform hands-on repairs to fiber-reinforced structures using wet lay-up and prepreg materials, vacuum bagging techniques, and hot bond equipment
* Complete a practical assessment to demonstrate the ability to perform the entire repair process, from damage assessment to post-repair inspection, ensuring quality and compliance with repair documentation
* Identify team member skills, roles, and responsibilities in composite repair processes
* Verify that repair materials match the specifications called for in the repair documentation
* Understand the differences between thermoplastic and thermosetting matrix materials, and describe their roles, limitations, and handling requirements
* State the personal hazards of working with polymeric materials and select the recommended personal protection equipment (PPE)
* Explain the properties and applications of adhesives, and identify the adhesive materials required per the repair documentation
* Describe the design considerations for aircraft structures, including benefits and limitations of sandwich structures, solid laminates, and joint types
* Operate and control heat application equipment to meet repair cure cycle requirements
* Describe common OEM manuals used for composite structure repairs and understand the limitations of these manuals
* Explain the differences between prepreg repairs, wet lay-up repairs, and bolted repairs, and calculate ply overlap dimensions
* List various Non-Destructive Inspection (NDI) techniques and perform visual, tap test, and low-skill instrumented inspections
* Assess damage to composite structures and map the limits of damage using appropriate inspection methods
* Perform hands-on repairs to fiber-reinforced structures using wet lay-up and prepreg materials, vacuum bagging techniques, and hot bond equipment
* Complete a practical assessment to demonstrate the ability to perform the entire repair process, from damage assessment to post-repair inspection, ensuring quality and compliance with repair documentation
Additional Information
Standards
Meets SAE AIR 4938 Standards and DOT/FAA AR-08/54
Focus
advanced bonded repairs; sandwich structure repair; bolted joint repairs; damage assessment techniques; heat/cure cycle management; inspection of complex structures
Modules & Topics
| Module & Hours | Title & Description |
|---|---|
|
Module 1
Class: 1.00h
|
Introduction to Aircraft Composite Structure
Level:
1
In Module 1, you'll learn about composite materials and their applications in aircraft structures. You will discuss the advantages and disadvantages of composite materials, their electrical and thermal conductivity, and coefficients of thermal expansion (CTE). Additionally, you will explore various applications of composite materials in the aviation industry.
Topics:
•
* 1. Advantages/Disadvantages
•
* 2. Electrical and Thermal Conductivity
•
* 3. Coefficients of Thermal Expansion (CTE)
•
* 4. Applications
|
|
Module 2
Class: 1.00h
|
Composite Structure Classification, Repair Categories and Repair Team Roles and Responsibilities
Level:
1
In Module 2, you'll learn about the classification of composite structures, repair categories, and the roles and responsibilities of team members involved in composite repair processes. You will identify the skills and responsibilities of engineers, inspectors, and aircraft maintenance technicians. Additionally, you'll understand the differences between primary, secondary, and critical structural elements, and the various categories of repairs.
Topics:
•
* 1. Roles and Responsibilities
•
a. Engineer (degreed)
•
b. Inspector
•
c. Aircraft Maintenance Technician
•
* 2. Structure Classifications
•
a. Primary
•
b. Principal Structural Elements (PSE)
•
c. Fatigue Critical Baseline Structure (FCBS)
•
d. Secondary
•
e. Interior
•
* 3. Repair Categories
•
a. Category A – Permanent Repair
•
b. Category B – Permanent Repair
|
|
Module 3
Class: 1.00h
|
Aircraft-Specific Repair Material Requirements
Level:
1
In Module 3, you'll learn about aircraft-specific repair material requirements. You will identify and verify that the repair material matches the specifications called for in the repair documentation. This includes understanding aerospace material specifications, material certification requirements, and the process of receiving inspection, and product identification.
Topics:
•
* 1. Repair Material Requirements
•
a. Aerospace Material Specifications
•
b. Material Certification Requirements
•
c. Receiving Inspection
•
d. Product Identification
|
|
Module 4
Class: 1.00h
|
Matrix Systems
Level:
2
In Module 4, you'll deepen your understanding of matrix systems used in composite materials. You will learn about the differences between thermoplastic and thermosetting matrix materials, their roles and limitations, and their storage and handling requirements. You will also determine and calculate various mix ratios, describe the cure cycle, and understand matrix cross-linking terminologies. Additionally, you'll learn to select appropriate filler materials and calculate resin system mix ratios with fillers.
Topics:
•
* 1. Thermoplastics
•
* 2. Thermosets
•
* 3. Mixing and Mix Ratios
•
a. Weight (accuracy of scales)
•
b. Volume
•
c. Mixing Process
•
d. Improper Mix Ratios
•
* 4. Curing of Resins
•
a. A, B, and C Stages
•
b. Flow versus Gelation
•
c. Glass Transition
•
d. Viscosity
•
e. Curing Reactions
•
f. Effect of Mis-Cures (under-cured and
•
over-cured)
|
|
Module 5
Class: 0.50h
|
Safety and Environment
Level:
1
In Module 5, you'll learn about safety and environmental considerations when working with polymeric materials. You will understand the personal hazards, describe the four common paths of entry, and evaluate a typical Safety Data Sheet (SDS). You will also learn to select the recommended personal protection equipment (PPE) and understand proper waste disposal procedures.
Topics:
•
* 1. Fumes, Vapors, and Dust
•
* 2. Skin Contact
•
* 3. Safety Data Sheet (SDS)
•
* 4. Personal Protective Equipment (PPE)
•
* 5. Exothermic Reactions
•
* 6. Waste Disposal
•
* 7. Flammability
|
|
Module 6
Class: 0.50h
|
Adhesives Review
Level:
1
In Module 6, you'll review the properties and applications of adhesives used in composite repairs. You will learn about the correct applications of adhesives, surface preparation requirements, bond line control methods, and common failure modes. Additionally, you will identify the adhesive materials required per the repair documentation.
Topics:
•
* 1. Film
•
* 2. Liquid
•
* 3. Paste
•
* 4. Supported/Unsupported
•
* 5. Surface Preparation
•
* 6. Bond Line Control
•
a. Micro Beads
•
b. Carriers
•
c. Scrim Cloth
•
d. Knit
•
e. Veil
•
* 7. Failure Modes
•
a. Adhesion
•
b. Cohesion
•
* 8. Foams
•
a. Core Splice
|
|
Module 7
Class: 2.00h
|
Aircraft Design Considerations
Level:
1
In Module 7, you'll learn about the design considerations for aircraft structures. You will explore the benefits and limitations of sandwich structures, solid laminate structures, and solid laminate monolithic structures. Additionally, you'll understand different joint types, electromagnetic effects, ply layup, protective coatings, and sealant requirements. The module will also cover impact resistance, balance and symmetry, and other critical factorsin aircraft design.
Topics:
•
* 1. Typical Sandwich Design
•
* 2. Solid Laminate and Monolithic Design
•
* 3. Advantages/Disadvantages of Solid Laminates
•
versus Sandwich Structures
•
* 4. Joint Types
•
a. Bolted
•
b. Bonded
•
* 5. Impact Resistance
•
* 6. Balance and Symmetry
•
* 7. Electromagnetic Effects (EME)
•
* 8. Conductive Layers
•
* 9. Sealants
•
* 10. Primers
•
* 11. Finishes
•
* 12. Acoustic Properties
•
* 13. Sonic Fatigue
•
* 14. Elevated Surface Temperature Requirements
•
* 15. Erosion Protection
•
* 16. Galvanic Compatibility
•
* 17. Transmissivity
|
|
Module 8
Class: 2.00h
|
Heat Transfer and Cure Cycle Management
Level:
3
In Module 8, you'll learn about heat transfer and cure cycle management for composite repairs. You will operate and control heat application equipment to meet repair cure cycle requirements. Additionally, you'll understand the principles of heat transfer and how they affect the ability to meet these requirements. The module will cover the usage of various heat application equipment, thermocouple placement, and insulation and airflow control.
Topics:
•
* 1. Heat Transfer Basics
•
* 2. Equipment Usage
•
a. Autoclave
•
b. Oven
•
c. Hot Bonders
•
d. Heat Blankets
•
e. Hot Air Blower
•
f. Infrared
•
g. Heat Lamps
•
* 3. Thermocouple Placement
•
* 4. Insulation and Airflow Control
|
|
Module 9
Class: 2.00h
|
Source Documents Review
Level:
2
In Module 9, you'll review common OEM manuals and documents used for repairing composite structures. You will learn about the limitations of these documents and the importance of following written instructions during repairs. Additionally, you will locate appropriate maintenance data for a given aircraft composite part and understand the various types of source documents and their specific purposes.
Topics:
•
* 1. ATA iSpec2200/S100D
•
* 2. Structural Repair Manuals
•
a. Allowable Damage Limits (ADL)
•
b. Repair Limits
•
* 3. Component Maintenance Manual
•
* 4. Engineering Orders
•
* 5. Maintenance Organization Specific Documents
•
* 6. SAE AMS-CACRC ARPs
•
* 7. Regulatory Documents
•
a. Airworthiness Directives
•
b. Service Bulletins
•
c. Advisory Circulars
•
d. Rule Making Task
•
* 8. Material and Processes Specifications
•
a. OEM
•
b. Vendor
•
c. Internal
|
|
Module 10
Class: 1.00h
|
Bonded Repair Design Considerations
Level:
2
In Module 10, you'll learn about the design considerations for bonded repairs. You will understand the differences between prepreg repairs, wet lay-up repairs, and bolted repairs. Additionally, you'll learn about various sanding and ply stack-up techniques. The module will also cover how to calculate ply overlap dimensions using 50:1 and 30:1 taper ratios for different ply face sheets using carbon and fiberglass plies.
Topics:
•
* 1. Repair Design
•
a. Prepreg
•
b. Wet Lay-Up
•
c. Support Tooling Requirements
•
d. Doubler Overlay
•
e. Pre-Cured Patch
•
f. Bolted
•
g. Nonstructural (cosmetic)
•
* 2. Taper Sanding and Step Sanding
•
* 3. Part Drying Requirements
•
a. Physical Water
•
b. Absorbed Moisture
•
* 4. Ply Stack-Up
•
a. Small Ply Down
•
b. Large Ply Down
•
* 5. Repair Area Limitations
|
|
Module 11
Class: 2.00h
|
Inspection Techniques
Level:
2
In Module 11, you'll learn about various Non-Destructive Inspection (NDI) techniques and their limitations when used in the manufacture and repair of composite structures. You will practice performing visual inspections, tap tests, and low-skill instrumented inspections. Additionally, you'll learn how to correctly map damaged areas and understand different types of damage and inspection methods.
Topics:
•
* 1. Types of Damage
•
* 2. Pre- and Post-Repair Inspection
•
* 3. Visual
•
* 4. Tap Testing (this method is to be taught to
•
teaching Level 3)
•
* 5. Low-skill Inspection Instrument (this method is to be taught to teaching Level 3)
•
* 6. Ultrasonic (Pulse-Echo, TTU, Bondtesters)
•
* 7. Thermography
•
* 8. X-Ray
•
* 9. FT-IR (Fourier Transform Infrared for heat damage)
•
* 10. Comparison of NDI Techniques for Metal versus
•
Composite Structure
|
|
Module 12
Class: 2.00h
|
Damage Assessment
Level:
3
In Module 12, you'll learn how to assess damage to composite structures. You will identify material types, sizes, and the number of plies, and map the limits of damage using visual inspections, tap tests, or appropriate NDI methods. This module will cover part identification, material identification, ply identification, damage mapping, and understanding SRM repair zones.
Topics:
•
* 1. Part Identification
•
* 2. Material Identification
•
* 3. Ply Identification
•
* 4. Damage Mapping (Sizing)
•
a. Visible Damage
•
b. Non-visible Damage
•
c. Inspection Techniques
•
* 5. SRM Repair Zones
|
|
Module 13
Practical: 46.00h
|
Hands-on Exercises and Assessment Criteria
Level:
3
In Module 13, you'll engage in extensive hands-on exercises to develop the skills necessary for repairing fiber-reinforced structures using wet layup and prepreg materials, vacuum bagging techniques, and hot bond equipment. You will perform various repairs on honeycomb sandwich parts, foam-cored parts, and parts with significant curvature. This module will ensure you can meet the criteria outlined in repair documentation, including damage assessment, material identification, and proper cure cycles.
“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.”
|
|
Module 14
Class: 1.00h
|
Written Exam
The written examination consists of 50 multiple choice questions. The examination contains questions from each of the topics listed in the outline for each part. The examination will be closed book.
|
|
Module 15
Practical: 12.00h
|
Practical Assessment
The practical assessment will be a separate, hands-on repair. The practical assessment will be similar to one of the hands-on exercises. This practical assessment will test your ability to perform the entire repair process, from damage assessment to post-repair inspection, ensuring that you can apply the skills and knowledge gained throughout the course.
|
Module 1
Class: 1.00h
Introduction to Aircraft Composite Structure
Level: 1In Module 1, you'll learn about composite materials and their applications in aircraft structures. You will discuss the advantages and disadvantages of composite materials, their electrical and thermal conductivity, and coefficients of thermal expansion (CTE). Additionally, you will explore various applications of composite materials in the aviation industry.
Topics:
•
* 1. Advantages/Disadvantages
•
* 2. Electrical and Thermal Conductivity
•
* 3. Coefficients of Thermal Expansion (CTE)
•
* 4. Applications
Module 2
Class: 1.00h
Composite Structure Classification, Repair Categories and Repair Team Roles and Responsibilities
Level: 1In Module 2, you'll learn about the classification of composite structures, repair categories, and the roles and responsibilities of team members involved in composite repair processes. You will identify the skills and responsibilities of engineers, inspectors, and aircraft maintenance technicians. Additionally, you'll understand the differences between primary, secondary, and critical structural elements, and the various categories of repairs.
Topics:
•
* 1. Roles and Responsibilities
•
a. Engineer (degreed)
•
b. Inspector
•
c. Aircraft Maintenance Technician
•
* 2. Structure Classifications
•
a. Primary
•
b. Principal Structural Elements (PSE)
•
c. Fatigue Critical Baseline Structure (FCBS)
•
d. Secondary
•
e. Interior
•
* 3. Repair Categories
•
a. Category A – Permanent Repair
•
b. Category B – Permanent Repair
Module 3
Class: 1.00h
Aircraft-Specific Repair Material Requirements
Level: 1In Module 3, you'll learn about aircraft-specific repair material requirements. You will identify and verify that the repair material matches the specifications called for in the repair documentation. This includes understanding aerospace material specifications, material certification requirements, and the process of receiving inspection, and product identification.
Topics:
•
* 1. Repair Material Requirements
•
a. Aerospace Material Specifications
•
b. Material Certification Requirements
•
c. Receiving Inspection
•
d. Product Identification
Module 4
Class: 1.00h
Matrix Systems
Level: 2In Module 4, you'll deepen your understanding of matrix systems used in composite materials. You will learn about the differences between thermoplastic and thermosetting matrix materials, their roles and limitations, and their storage and handling requirements. You will also determine and calculate various mix ratios, describe the cure cycle, and understand matrix cross-linking terminologies. Additionally, you'll learn to select appropriate filler materials and calculate resin system mix ratios with fillers.
Topics:
•
* 1. Thermoplastics
•
* 2. Thermosets
•
* 3. Mixing and Mix Ratios
•
a. Weight (accuracy of scales)
•
b. Volume
•
c. Mixing Process
•
d. Improper Mix Ratios
•
* 4. Curing of Resins
•
a. A, B, and C Stages
•
b. Flow versus Gelation
•
c. Glass Transition
•
d. Viscosity
•
e. Curing Reactions
•
f. Effect of Mis-Cures (under-cured and
•
over-cured)
Module 5
Class: 0.50h
Safety and Environment
Level: 1In Module 5, you'll learn about safety and environmental considerations when working with polymeric materials. You will understand the personal hazards, describe the four common paths of entry, and evaluate a typical Safety Data Sheet (SDS). You will also learn to select the recommended personal protection equipment (PPE) and understand proper waste disposal procedures.
Topics:
•
* 1. Fumes, Vapors, and Dust
•
* 2. Skin Contact
•
* 3. Safety Data Sheet (SDS)
•
* 4. Personal Protective Equipment (PPE)
•
* 5. Exothermic Reactions
•
* 6. Waste Disposal
•
* 7. Flammability
Module 6
Class: 0.50h
Adhesives Review
Level: 1In Module 6, you'll review the properties and applications of adhesives used in composite repairs. You will learn about the correct applications of adhesives, surface preparation requirements, bond line control methods, and common failure modes. Additionally, you will identify the adhesive materials required per the repair documentation.
Topics:
•
* 1. Film
•
* 2. Liquid
•
* 3. Paste
•
* 4. Supported/Unsupported
•
* 5. Surface Preparation
•
* 6. Bond Line Control
•
a. Micro Beads
•
b. Carriers
•
c. Scrim Cloth
•
d. Knit
•
e. Veil
•
* 7. Failure Modes
•
a. Adhesion
•
b. Cohesion
•
* 8. Foams
•
a. Core Splice
Module 7
Class: 2.00h
Aircraft Design Considerations
Level: 1In Module 7, you'll learn about the design considerations for aircraft structures. You will explore the benefits and limitations of sandwich structures, solid laminate structures, and solid laminate monolithic structures. Additionally, you'll understand different joint types, electromagnetic effects, ply layup, protective coatings, and sealant requirements. The module will also cover impact resistance, balance and symmetry, and other critical factorsin aircraft design.
Topics:
•
* 1. Typical Sandwich Design
•
* 2. Solid Laminate and Monolithic Design
•
* 3. Advantages/Disadvantages of Solid Laminates
•
versus Sandwich Structures
•
* 4. Joint Types
•
a. Bolted
•
b. Bonded
•
* 5. Impact Resistance
•
* 6. Balance and Symmetry
•
* 7. Electromagnetic Effects (EME)
•
* 8. Conductive Layers
•
* 9. Sealants
•
* 10. Primers
•
* 11. Finishes
•
* 12. Acoustic Properties
•
* 13. Sonic Fatigue
•
* 14. Elevated Surface Temperature Requirements
•
* 15. Erosion Protection
•
* 16. Galvanic Compatibility
•
* 17. Transmissivity
Module 8
Class: 2.00h
Heat Transfer and Cure Cycle Management
Level: 3In Module 8, you'll learn about heat transfer and cure cycle management for composite repairs. You will operate and control heat application equipment to meet repair cure cycle requirements. Additionally, you'll understand the principles of heat transfer and how they affect the ability to meet these requirements. The module will cover the usage of various heat application equipment, thermocouple placement, and insulation and airflow control.
Topics:
•
* 1. Heat Transfer Basics
•
* 2. Equipment Usage
•
a. Autoclave
•
b. Oven
•
c. Hot Bonders
•
d. Heat Blankets
•
e. Hot Air Blower
•
f. Infrared
•
g. Heat Lamps
•
* 3. Thermocouple Placement
•
* 4. Insulation and Airflow Control
Module 9
Class: 2.00h
Source Documents Review
Level: 2In Module 9, you'll review common OEM manuals and documents used for repairing composite structures. You will learn about the limitations of these documents and the importance of following written instructions during repairs. Additionally, you will locate appropriate maintenance data for a given aircraft composite part and understand the various types of source documents and their specific purposes.
Topics:
•
* 1. ATA iSpec2200/S100D
•
* 2. Structural Repair Manuals
•
a. Allowable Damage Limits (ADL)
•
b. Repair Limits
•
* 3. Component Maintenance Manual
•
* 4. Engineering Orders
•
* 5. Maintenance Organization Specific Documents
•
* 6. SAE AMS-CACRC ARPs
•
* 7. Regulatory Documents
•
a. Airworthiness Directives
•
b. Service Bulletins
•
c. Advisory Circulars
•
d. Rule Making Task
•
* 8. Material and Processes Specifications
•
a. OEM
•
b. Vendor
•
c. Internal
Module 10
Class: 1.00h
Bonded Repair Design Considerations
Level: 2In Module 10, you'll learn about the design considerations for bonded repairs. You will understand the differences between prepreg repairs, wet lay-up repairs, and bolted repairs. Additionally, you'll learn about various sanding and ply stack-up techniques. The module will also cover how to calculate ply overlap dimensions using 50:1 and 30:1 taper ratios for different ply face sheets using carbon and fiberglass plies.
Topics:
•
* 1. Repair Design
•
a. Prepreg
•
b. Wet Lay-Up
•
c. Support Tooling Requirements
•
d. Doubler Overlay
•
e. Pre-Cured Patch
•
f. Bolted
•
g. Nonstructural (cosmetic)
•
* 2. Taper Sanding and Step Sanding
•
* 3. Part Drying Requirements
•
a. Physical Water
•
b. Absorbed Moisture
•
* 4. Ply Stack-Up
•
a. Small Ply Down
•
b. Large Ply Down
•
* 5. Repair Area Limitations
Module 11
Class: 2.00h
Inspection Techniques
Level: 2In Module 11, you'll learn about various Non-Destructive Inspection (NDI) techniques and their limitations when used in the manufacture and repair of composite structures. You will practice performing visual inspections, tap tests, and low-skill instrumented inspections. Additionally, you'll learn how to correctly map damaged areas and understand different types of damage and inspection methods.
Topics:
•
* 1. Types of Damage
•
* 2. Pre- and Post-Repair Inspection
•
* 3. Visual
•
* 4. Tap Testing (this method is to be taught to
•
teaching Level 3)
•
* 5. Low-skill Inspection Instrument (this method is to be taught to teaching Level 3)
•
* 6. Ultrasonic (Pulse-Echo, TTU, Bondtesters)
•
* 7. Thermography
•
* 8. X-Ray
•
* 9. FT-IR (Fourier Transform Infrared for heat damage)
•
* 10. Comparison of NDI Techniques for Metal versus
•
Composite Structure
Module 12
Class: 2.00h
Damage Assessment
Level: 3In Module 12, you'll learn how to assess damage to composite structures. You will identify material types, sizes, and the number of plies, and map the limits of damage using visual inspections, tap tests, or appropriate NDI methods. This module will cover part identification, material identification, ply identification, damage mapping, and understanding SRM repair zones.
Topics:
•
* 1. Part Identification
•
* 2. Material Identification
•
* 3. Ply Identification
•
* 4. Damage Mapping (Sizing)
•
a. Visible Damage
•
b. Non-visible Damage
•
c. Inspection Techniques
•
* 5. SRM Repair Zones
Module 13
Practical: 46.00h
Hands-on Exercises and Assessment Criteria
Level: 3In Module 13, you'll engage in extensive hands-on exercises to develop the skills necessary for repairing fiber-reinforced structures using wet layup and prepreg materials, vacuum bagging techniques, and hot bond equipment. You will perform various repairs on honeycomb sandwich parts, foam-cored parts, and parts with significant curvature. This module will ensure you can meet the criteria outlined in repair documentation, including damage assessment, material identification, and proper cure cycles.
“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.”
Module 14
Class: 1.00h
Written Exam
The written examination consists of 50 multiple choice questions. The examination contains questions from each of the topics listed in the outline for each part. The examination will be closed book.
Module 15
Practical: 12.00h
Practical Assessment
The practical assessment will be a separate, hands-on repair. The practical assessment will be similar to one of the hands-on exercises. This practical assessment will test your ability to perform the entire repair process, from damage assessment to post-repair inspection, ensuring that you can apply the skills and knowledge gained throughout the course.
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