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Advised are

• Basic technical mathematics,
• Physics and chemistry are considered high at the school level or equivalent.

Evaluation of primary education can be accomplished by examining school transcripts, reviewing the training received through approved training providers, or by a pre-test by EFC.

Advised prerequisite: EFC-TECH-101 -SAE -PART 1 -  General Composite Structure Bonded Repair 
Student success will be in part based on the knowledge and skills possessed before course enrollment:

Personnel of technical departments /technicians who have attended:

• TECH-101 PART  1 - General Composite Structure Bonded Repair or the EFC TECH-001 Basic Composite course
  Participant success will be in part based on the knowledge and skills possessed before this course enrollment:

Personnel with composite fabrication & repair experience are also welcome to participate in this course.
EFC confirms that courses are running as soon as sufficient applications are received!

Participants who complete this basic composite Repair training are considered to perform composite repairs to composite structures in compliance with the Boeing, Airbus and other Aircraft type repair documentation or other acceptable repair data.

Aircraft type repairs, for example and not limited to this list:

• Boeing 777
• Boeing 747
• Boeing 737
• airbus A320
• airbus a350
• Or other bespoke aircraft types

If you plan to enrol in the TECH 102 Part 2 Advanced Composite Repair course, an intelligent choice is to register as a follow-up on our Metal Bonding course, SAE/CACRC and /or EASA approved.  
Our SAE-AIR4938- TECH-104 Part 4 Commercial Aircraft Structure Metal Bonded Repair course (click link). Watch a short Part 4 Metal Bond video on YouTube!! 

Minimum required 2 and maximum 8 per course^*.

* Courses will be confirmed as running by EFC as soon as sufficient applications are received!

Persons who complete this advanced training program are considered to perform more complex, in-depth composite repairs to composite structures.

This complies with the OEM's manufacturer’s repair documentation or other acceptable repair data.
This curriculum should be considered a prerequisite for more advanced training. Like the EFC-TECH-120 Radome Repair Training

1. Introduction to Aircraft Composite Structure Level 1  (1 hour)

Objective:
Given the discussion, lecture, and feedback, the participant will be able to describe composite materials and their applications in aircraft structures. The participant will also discuss the merits of composite materials and their general failure modes.

A. Advantages/Disadvantages
B. Electrical and Thermal Conductivity
C. Coefficients of Thermal Expansion (CTE)
D. Applications
E  Composite Structure Classification and Repair Categories and Repair Team

2.   Composite Structure Classification and Repair Categories and Repair Team   Roles and Responsibilities         Level 1        (1 hour)           

Objective:

Given the discussion, lecture, and feedback, the participant will be able to identify the skills, roles, and responsibilities of team members related to composite repair processes and state the differences between structural classifications and repair categories.

A.   Roles and Responsibilities

i.    Engineer (degree)

ii.    Inspector
iii.   Aircraft Maintenance Technician

B.   Structure Classifications

i.    Primary

ii.    Principal Structural Elements (PSE)

iii.   Fatigue Critical Baseline Structure (FCBS)

iv.   Secondary
v.   Interior
C.   Repair Categories

i.    Category A   – Permanent Repair – No additional inspections

ii.    Category B  – Permanent Repair – Supplemental inspections

iii.   Category C  – Time Limited

3.   Aircraft-Specific Repair  Material Requirements        Level 1   ( 1 hour)

Objective:
Given the discussion, lecture, and feedback, the participant will identify and verify that the repair material is the correct material specified in the repair document.

        A.   Repair Material Requirements 

.i     Aerospace Material Specifications
ii.    Material Certification Requirements
iii.   Receiving Inspection
iv.   Product Identification.  

4     Matrix Systems                                                       Level 2    (1 hour)
Objective:
Given discussion, lecture, practice, and feedback, the participant will be able to state the difference between thermoplastic and thermosetting matrix materials, describe the roles and limitations of matrix materials, identify the storage and handling requirements, determine and calculate various mix ratios, describe the cure cycle, and define matrix cross-linking terminologies. The participant will also describe and select appropriate filler materials so that a given resin system mix ratio with filler materials can be calculated using an established rate as evaluated by the instructor.

A.   Thermoplastics
B.   Thermosets
C.   Mixing and Mix Ratios
i.    Weight (accuracy of scales)
ii.    Volume
iii.   Mixing Process
iv.   Improper Mix Ratios

D.   Curing of Resins
i.    A, B, and C Stages
ii.    Flow versus Gelation
iii.   Glass Transition
iv.   Viscosity
v.   Curing Reactions
vi.   Effect of Mis-Cures (under-cured and over-cured)

5  Safety and Environment                                        Level 1          (0.5 hours)
Objective:
Given the discussion, lecture, and feedback, the participant will identify the personal hazards associated with working with polymeric materials and describe the four common entry points. The participant will evaluate a typical Safety Data Sheet (SDS) to the extent that the selection of recommended personal protection equipment (PPE) and waste disposal procedures is required.

A.   Fumes, Vapours, and Dust
B.   Skin Contact
C.   Safety Data Sheet (SDS)
D.   Personal Protective Equipment (PPE)
E.   Exothermic Reactions
F.   Waste Disposal
G.   Flammability

6  Adhesives Review                                                  Level 1           ( 0.5 hours)
Objective:
Given the discussion, lecture, and feedback, the participant will be able to explain the properties of adhesives and their correct applications, surface preparation requirements, bond line control methods, and standard failure modes, and identify the adhesive materials required according to the repair documentation.

A.   Film
B.   Liquid
C.   Paste
D.   Supported/Unsupported
E.   Surface Preparation
F.   Bond Line Control
i.    Micro Beads
ii.    Carriers
a.   Scrim Cloth
b.   Knit
c.   Veil

G.   Failure Modes
i.    Adhesion
ii.    Cohesion

H.   Foams
i.    Core Splice

7.   Aircraft Design Considerations                               Level 1                 (2 hours)
Objective:
Given discussion, lecture, and feedback, the participant will describe the benefits and limitations of sandwich structures, solid laminate structures, solid laminate monolithic structures, and joint types.

A.   Typical Sandwich Design
B.   Solid Laminate and Monolithic Design
C.   Advantages/Disadvantages of Solid Laminates versus Sandwich Structures
D.   Joint Types
i.    Bolted
ii.    Bonded

E.   Impact Resistance
F.   Balance and Symmetry
G.  Electromagnetic Effects (EME)
H.   Conductive Layers
I.    Sealants
J.   Primers
K.   Finishes
L.   Acoustic Properties
M.  Sonic Fatigue
N.   Elevated Surface Temperature Requirements
O.   Erosion Protection
P.   Galvanic Compatibility
Q.   Transmissivity

8.   Heat Transfer and Cure Cycle Management                Level 3               (2 hours)
Objective:
Given discussion, lecture, practice, and feedback, the participant will be able to operate and control the heat application equipment to meet the repair cycle requirements. The participant will describe the principles of heat transfer and how it affects the ability to meet the cure cycle requirements.

A.   Heat Transfer Basics
B.   Equipment Usage
i.    Autoclave (optional Level 1)
ii.    Oven (optional Level 1)
iii.   GMI Aero Hot Bonder's Go to GMI AERO France
iv.   Heat Blankets
v.   Hot Air Blower (optional Level 1)
vi.   Infrared (optional Level 1)
vii. Heat Lamps

C.   Thermocouple Placement
D.   Insulation and Airflow Control

9.   Source Documents Review                                         Level 2                  (2 hours)
Objective:
Given discussion, lecture, practice, and feedback, the participant will describe standard OEM manuals used to repair composite structures and explain the limitations of their use.
The participant will state the need to follow written instructions when repairing composite structures to the extent that the instructor can evaluate the appropriate maintenance data of a given aircraft composite part.

1. ATA iSpec2200/S100D
2. Structural Repair Manuals
   1. Allowable Damage Limits (ADL)
   2. Repair Limits
3. Component Maintenance Manual
4. Engineering Orders
5. Maintenance Organisation-Specific Documents
6. SAE AMS-CACRC ARPs
7. Regulatory Documents
   1. Airworthiness Directives
   2. Service Bulletins
   3. Advisory Circulars
   4. Rule-Making Task
8. Material and Processes Specifications

i.    OEM
ii.    Vendor
iii.   Internal

10. Bonded Repair Design Considerations                       Level 2                   (1 hour)
Objective:
Given the discussion, lecture, practice, and feedback, the participant will be able to describe the differences between prepreg, wet lay-up, and bolted repairs. The participant will be able to explain the differences in sanding and ply stack-up techniques. Using carbon and fibreglass plies, the participant will 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.

A.   Repair Design

i.    Prepreg
ii.    Wet Lay-Up
iii.   Support Tooling Requirements
iv.   Doubler Overlay
v.   Pre-Cured Patch
vi.   Bolted
vii. Nonstructural (cosmetic)
B.   Taper Sanding and Step Sanding
C.   Part Drying Requirements
i.    Physical Water
ii.    Absorbed Moisture
D.   Ply Stack-Up
i.    Small Ply Down
ii.    Large Ply Down (optional)
E.   Repair Area Limitations

11. Inspection Techniques                                             Level 2               ( 2 hours)
Objective:
Through discussions, lectures, practice, and feedback, participants will be able to identify the various Non-Destructive Inspection (NDI) techniques and their limitations in manufacturing and repairing composite structures. Finally, the participant will perform a visual, tap, and low-skill instrumented inspection of structures and correctly map the damaged area.

A.   Types of Damage
B.    Pre- and Post-Repair Inspection
C.   Visual
D.   Tap hammer usage in damage testing (this tap hammer method is taught at Teaching Level 3).  Go to the Tap hammer 

E.   Low-skill Inspection Instrument (this method is to be taught to teaching Level 3)
F.   Ultrasonic (Pulse-Echo, TTU, Bondtesters)
G.   Thermography
H.   X-Ray
I.    FT-IR (Fourier Transform Infrared for heat damage)
J.   Comparison of NDI Techniques for Metal versus Composite Structure

12. Damage Assessment                                         Level 3                      (2 hours)
Objective:
Given discussion, lecture, practice, and feedback, the participant will assess damage to identify the material type, size, and the number of plies and map the damage limits using visual, tap test, or place the required NDI method type structure.

A.   Part Identification
B.   Material Identification
C.   Ply Identification
D.   Damage Mapping (Sizing) 

Tap hammer usage in damage testing (this tap hammer method is taught at Level 3). Go to Tap Hammer. Learn to use a Tap Hammer and grid for mapping
i.   Visible Damage: Photographing the area and locations
ii. Non-visible Damage
iii. Inspection Techniques: Tap hammer, Steel Taphammer rod and Boeing tap hammer as noted in the SRM
E.   SRM Repair Zones

13. Hands-On Exercises                                            Level 3              (46 hours)
Objective:
Given discussion, lecture, practice, and feedback, the student will develop the skills to repair fibre-reinforced structures utilising wet layup and prepreg materials, vacuum bagging techniques, and hot bond equipment. By the end of the training program, the student must demonstrate the EFC instructor's listed skills and meet the criteria in the repair documentation.
For some of the repairs, foam-cored parts are an alternative to honeycomb parts. At least one of the repairs must be a fibreglass part. At least 50% of the repairs must use a hot bonder as the control method. At least one of the repairs must require electromagnetic effects (EME) surface layer restoration. At least one of the repairs is to be a part of significant curvature.

I.    Repair the honeycomb sandwich part with skins and core damage. The skin repairs shall be performed using a wet layup. This repair is to be performed from one side access. The repairs shall be cured using any of the listed methods in this document

Assessment:
a.   Damage Assessment using Tap hammer NDI method 
b.   Core removed without causing additional damage to far side inner skin
c.   Taper sanding meets repair document requirements
d.   Correct material and orientation of original plies identified
e.   Repair plies are positioned and oriented correctly
f.    Cure cycle(s) meets repair document requirements
g.   Repair meets post-repair inspection requirements

II.    Repair honeycomb sandwich parts with both skins and core damage. The skin repairs shall be performed with prepreg. The repairs shall be cured with heat blankets and hot bonders

Assessment:
a.   Damage Assessment
b.   Core removed without causing additional damage to far side inner skin
c.   Taper sanding meets repair document requirements
d.   Correct material and orientation of original plies identified
e.   Repair plies are positioned and oriented correctly
f.    Cure cycle(s) meets repair document requirements
g.   Repair meets post-repair inspection requirements

III.   Repair the edge band of the honeycomb sandwich part; the damage extends into the core and has ply drop-offs. Both skins shall be repaired.
       Edgeband repair can use either single-sided or double-sided heating methods. It will use a one- and two-stage repair method.
       The cure cycle heat application can be any of the listed methods in the OEM documents.

Assessment:
a.   Damage Assessment 
b    Core was removed without causing additional damage to the far side of the inner skin

. c.   Taper sanding meets repair document requirements
d.   Correct material and orientation of original plies identified. Repair plies are positioned and oriented correctly}
f.    Cure cycle(s) meets repair document requirements
g.   Repair meets post-repair inspection requirements. Tap hammer usage in post-repair testing (this tap hammer method is taught at the teaching Level. Go to Tap hammer 

• As Training Providers, EFC will be required to monitor the participants' performance throughout the program. 
• Following laboratory classes, participants are administered a practical certification assessment. A checklist is recommended for evaluating functional certification assessments.
• The written certification examination and practical certification assessment will cover the principles of the applicable curriculum and consist of:
• The following written examination for certification shall contain approximately. Eight (8) multiple-choice questions per course day with a maximum of fifty (50)* per exam.
• The number depends on using three or four alternative answers per question.
• The examination shall contain questions from each Topic listed in the outline for each Part.
• The examination will be a closed-book examination.
• Successful completion is 75% correct answers.
• Reexamination: If the participant fails the written examination, they may request to retake the written test. 
• ​The written examination must not contain more than 20% of the questions from the failed exam.

• A repair training program, the required exams, and assessments based on this AIR curriculum and conducted by a training provider, follow the AIR guidance.
• OR complete the required exams and assessments based on this AIR curriculum without completing a training program. Attempting the exam and evaluation without training is not recommended for personnel without composite repair experience.

This course can also be held at our facility in Leipzig Germany at the facilities of our partner HEICO. If you have a need for this, please contact our purchasing manager Rolf Hovener via his page. For your company to benefit, this course can be held 'On-Site' at your facility under certain conditions.
Click on this link to the Onsite information webpage!

Courses as noted on our course schedule page can be run on request to meet your required start and end date. All listed course prices are Excl VAT. (Dutch VAT is 21%). EFC complies with Dutch tax laws. On request, companies can be sent an invoice instead of paying direct On-line with PayPal, IDEAL or credit card.

Payment is securely arranged via Mollie.nl . More information can be found on the website of Mollie.