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Technicians of technical departments with no composite training who want to learn the General Basics of composite repair of aircraft components using the Boeing, Airbus, or other aircraft type Structural OEMs Repair manuals  

Our TECH-101 Part 1 General Composite training course is an advised prerequisite for the advanced PART 2 training as the EFC--TECH-102 -Part 2 Commercial Aircraft Composite Structure Bonded Repair course.
Participant success will be in part based on their  knowledge and skills possessed before course enrollment:

• Basic Technical Mathematics
• Reading comprehension in Technical English 
• Speaks and understands Technical English 

The follow-up for this course is the EFC-TECH-102  PART 2, which meets EASA-FAA & OEM SRM standards

• Aircraft sheet metal workers who want additional training in composites or conversion into composite technicians!
• Technicians / Shop leads / Engineers or those in technical departments with no composite training who want to learn the Basics of composite repair of aircraft components using the Boeing, Airbus, or other aircraft-type structural repair manuals from both OEMs.

Personnel with experience in composite fabrication & metal-bond repair are also welcome to participate in this course.
EFC will confirm that courses are running once sufficient applications from participants (minimum of 4) have been received.

Minimum required 4 and maximum 8 per course^*.

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

Participants who complete this "Part 1 General Composite Structural and Bonded Repair" training are considered to be able to perform composite repairs to composite structures in compliance with Boeing and Airbus repair documentation or other acceptable repair data.

• Or other bespoke types of aircraft 

The  EASA-FAA  approved TECH 102- Part 2 course curriculum is an advised prerequisite for more advanced follow-up repair training, as shown in the TECH-102 Part 2 training course (CLICK HERE )

Module 1 Introduction to Composites    (Level 1)     (1,5 hours)

Objective:
Given the discussion, lecture, and feedback, the participant will be able to describe the basics of composite materials technology and its applications related to aerospace, marine, automotive, civil, energy, and consumer products. The participant will also discuss the merits and general failure modes of composite materials to the extent that a comparison of material properties can be established between metallic and composite structures as evaluated by the instructor.

A.   Definition of Composites
B.   History of Composites
C.   Advantages/Disadvantages
D.   Conductivity
E.   Applications
F.   Product Forms

Module 2  Human Factors      NA               (level 1)         (0 hours)

Human factors are outside the scope of this course's training.

A.   Definition
B.   FAA / EASA Resources
C.   Personal Minimums

Module 3  Reinforcement Fibers                (Level 1)      (1 hour)

Objective:
Given the discussion, lecture, and feedback, the participant will be able to visually recognize standard composite fibers, list their properties, and associate the terms related to the fabric manufacturing process. The participant will also describe the fibre placement levels used during the 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.

A.   Materials

i.    Fiberglass
ii.   Aramid
iii.   Carbon
iv.  Ceramics
v.   Hybrids

B.   Forms Terminology

i.    Filament
ii.   Strand
iii.   Tow
iv.  Yarn

C.   Unidirectional Tape

D.   Non-Woven

i.    Mat
a.   Chopped
b.   Continuous Filament
ii.   Stitched

E.   Woven

i.    Plain
ii.   Twill
iii.   Harness Satin
iv.  Biaxial
v.   Triaxial

F.   Fiber Sizing and Finishes

G.  Balance and Symmetry

i.    Warp Clock
ii.   Tracers
iii.   Ply Orientation
iv.  Nesting

Module 4. Matrix Systems  Level 1  (1 hour)
Objective:
Given the discussion, lecture, 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, explain the storage and handling requirements, and determine and calculate various mix ratios. The participant will also explain the cure cycle and define the 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
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)

E.   Potting

i.    Fillers
ii.   Micro-Balloons
iii.   Chopped Fiber
iv. Fumed Silica

Module 5 Safety and Environment     (Level 1)  (1,5 hours)

Objective:
Through discussions, lectures, practice, and feedback, the participant will be able to identify the personal hazards associated with working with polymeric materials and describe the four common entry points. Finally, the participant will evaluate a typical Safety Data Sheet (SDS) and demonstrate the ability to select proper personal protection equipment (PPE) and describe waste disposal procedures, as assessed by the instructor.

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

Module 6 Pre-Impregnated Materials     (Level 1)     (1 hour)​

Objective
Given the discussion, lecture, and feedback, the participant will describe the pre-impregnation manufacturing levels and state the stages of the matrix material, including storage and handling requirements, recertification, and disposal procedures, to the extent that the instructor accurately evaluates the correct handling procedures.

Levels, i. Resin Bath, ii. Hot Melt, iii. Stages
Matrix Cure Temperatures

Module 7 Adhesives                              (Level 1)       (1 hour)
Objective:
Given the discussion, lecture, and feedback, the participant will explain the properties of adhesives and their usage, surface preparation levels, bond line control levels, and standard failure modes, ensuring that adhesive materials can be selected based on repair documentation evaluated by the instructor.

A.   Film
B.   Liquid
C.   Paste
D.   Supported/Unsupported
E.   Chemical Bonding Compared to Mechanical Bonding
F.   Surface Preparation, i.    Surface Energy
G.  Bond Line Control,  Micro Beads ii  Carriers,
       a. Scrim, Cloth,  b. Knit, c.   Veil
H.   Failure Modes,
i.    Adhesion,
ii.   Cohesión, 
iii    ​Foams,

H  Core Splice

Module 8 Structural Design Considerations       ( Level 1)         (1 hour)
Objective:
Given the discussion, lecture, and feedback, the participant will be able to describe the differences between sandwich structures and solid laminate structures (including monolithic structures) to the extent that the different materials used in construction are described in detail, as evaluated by the instructor.

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

E.   Wood
F.   Foam
G.  Honeycomb

 i.    Material Types
ii.   Densities
iii.   Cell Shapes and Sizes
iv.  Ribbon Direction
v.   Filleting
vi.  Cleanliness
vii.  Splices
a.   Septum
b.   Peg/Crus

9.  Material Handling and Storage                       (Level 1)                    (2 Hours)

Objective:
Given discussion, lecture, and feedback, the participant will explain the importance of proper storage and handling of materials utilised 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.

A.   Flammable Storage Cabinets
B.   Refrigerators/Freezers
C.   Shipping: Handling and Temperature Requirements
D.   Storage Temperatures
E.   Thawing
F.   Kitting
G.  Out Time
H.   Storage Life (Shelf Life)
I.    Mechanical Life and Handling Life
J.   Handling of Polymeric Materials
K.   Handling of Dry Goods
L.   Recertifying of Polymeric Materials
M.  Disposal

10. Facilities and Equipment                                      (Level 1)                (2 hours)

Objective:
Based on the discussion, lecture, and feedback, the participant will compile a detailed list of the various equipment required to properly operate a composite facility, including tools, dust extraction equipment, trim rooms, and a Controlled Contamination Area (CCA), as evaluated by the instructor.

A.   Trim Rooms

B.   Dust Extraction Levels

i.    Booths
ii.   Vacuums
iii.   Downdraft Tables

C.   Controlled Contamination Area (CCA)

D.   Resin Mixing Areas

i.    Mixing Booth
ii.   Disposal Equipment

E.   Vacuum Equipment

i.    Ports
ii.   Pumps
iii.   Hoses
iv.  Gauges

11.  Vacuum Bagging                                ( Level 1)                  (1.5 hours)

Objective:
Given discussion, lecture, and feedback, the participant will explain the importance of vacuum bagging to the extent that an explanation is given on the principles of emptiness and how it affects laminate properties, and provide a detailed list of materials utilised in the vacuum bagging process as evaluated by the instructor.

A.   Theory

i.    Vacuum/Pressure
ii.   Altitude

B.   Materials

i.    Peel Ply
ii.   Bleeders/Breather
iii.   Release Films
iv. Bagging Films
v.   Bag Sealant
vi. Cauls

C.   Types of Bags

i.    Bag to Part
ii.   Bag to Tool
iii.   Envelope

D.   Bleeding

i.    Fiber Resin Ratio
ii.   Void Content
iii.   Thickness

E.   Ply Compaction Requirements

12. Heating Devices                               ( Level 1 )                   (1,5 hours)

Objective:
Given the discussion, lecture, and feedback, the participant can explain the different types of heating devices used in the composite industry, explaining their primary uses, advantages, disadvantages, limitations, and the concerns evaluated by the instructor.

A.   Autoclave
B.   Oven
C.   Hot Bonders & programming  Dual-zone Hot-bonders 

D.   Heat Blankets
E.   Hot Air Blowers
F.   Heat Lamps
G.  Infrared
H.   Heat Guns

13  Source Documents                            (Level 1)                    ( 2,5 hours)

Objective:
Given discussion, lecture, and feedback, the participant will describe the use of repair manuals and documents for composite structures and explain the service's limitations.

A.    ATA iSpec 2200/S1000D
B.   Original Equipment Manufacturer (OEM)

i.    Structural Repair Manuals

ii.   Component Maintenance Manual

C.   Engineering Orders
D.   SAE AMS-CACRC ARPs
E.   Regulatory Documents
F.   Drawing Systems
G.  Process Specifications
H.   Material Specifications
I.    Data Sheets
J.   Vendor Manuals

14 Protective Coatings and Finishes        (level 1)                        (1 hour)

Objective:
Given the discussion, lecture, and feedback, the participant will discuss protective coating requirements, handling procedures involving fibre-reinforced plastic structures, and determine the type, application, and restoration procedures using approved manuals.

A.   Sealants
B.   Primers
C.   Finishes
D.   Conductive

i.    Metal Foil
ii.   Flame Spray
iii.   Metal Coated Fabrics
iv. Metal Meshes
v.   Anti-Static Paint
vi. Interwoven-Wire

15 Repair Selection Consideration           (Level 1)                          (1,5 hours)

Objective:
Given the discussion, lecture, and feedback, the participant will be able to describe the differences between prepreg repairs, wet lay-up repairs, and bolted repairs.

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 Limitation

16 Inspection                                                (Level 1 )                       (1 hour ) 

Objective:
Through discussions, lectures, practice, and feedback, participants will be able to identify various Non-Destructive Inspection (NDI) techniques and their limitations in the manufacturing and repair of composite structures. The participant will perform a visual and tap test inspection on a sandwich-constructed part and correctly map the damaged area as the instructor evaluates it.

A.   Types of Damage
B.   Mapping of Damage
C.  Pre and Post-Repair Inspection
D.   Visual
E.   Tap hammer usage in damage testing (this tap hammer method is taught at teaching Level 3). Go to the Tap hammer 
F.   Ultrasonic (Pulse-Echo, TTU, Bondtesters)
G.  Thermography
H.   X-Ray
I.    Comparison of NDI Techniques for Metal and Composite Structures

17. Machining of Composites                        ( Level 2 )                        (2 hours)

Objective:
Given discussion, lecture, practice, and feedback, the participant will select and safely operate air-powered tools, including drill motors, die grinders, and dual orbital sanders. Additionally, the participant will determine the recommended grinding materials, along with speeds and feed, for machining carbon and fibreglass materials to the extent that a minimum of 10 holes is drilled to the correct size without fibre breakout damage and taper, and sand a four-ply face sheet without bond ply damage, as evaluated by the instructor.

A.   Sanding
B.   Drilling

i.    Speeds and Feeds
ii.   Types of Drills
iii.   Reamers

18 Hands-On Exercises                                              ( Level 3)                                     (50 hours) 
Objective:
Given discussion, lecture, practice, and feedback, the composite technician will develop the essential skills to repair fibre-reinforced structures using wet-lay and prepreg materials, vacuum bagging techniques, and hot-bond equipment. To the extent that personal protective equipment is worn, repairs are accomplished using approved documentation and deemed airworthy, as evaluated by the instructor and accepted according to the agreed-upon criteria.

A.   Symmetrical/Asymmetrical Lay-Up Exercise

B.   Wet Lay-Up

i Resin Mixing
ii.   Bleeder Exercise

C.   Prepreg Lay-Up
i.      Panel Build
D.   Core Repair

i.    Foaming Adhesives
ii.   Film Adhesive
iii.   Potting

E.   Scarf Repairs - Fiberglass, Hybrid, or Carbon

i.    Wet Lay-Up
ii.   Prepreg

Assessment Criteria:

1. Tap hammer usage in damage testing (this tap hammer method is taught at Level 3). Go to the Tap hammer 

2. The core was removed without causing additional damage to the inner skin on the far side.

3. Taper sanding meets repair document requirements.

4. Correct material and orientation of original plies identified

5. Repair plies are positioned and oriented correctly.

6. Cure cycle(s) meet repair document requirements.

7. Repair meets post-repair inspection requirements.

8. Hot bonding equipment, programming & monitoring 

9. Use Dual-zone  Hot-bonder 

10. Use of proper quick-repair tooling

• EFC as Training Providers will monitor the participants' performance throughout the program. 
• Following laboratory classes, participants will be administered a practical certification assessment. A checklist is recommended for evaluating the functional certification assessment.
• The written certification examination and practical certification assessment will cover the principles of the applicable curriculum and consist of:
• The 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 the use of three or four alternative answers per question
• The examination shall contain questions from each of the Topics listed in the outline for each Part.
• The examination will be a closed-book examination.
• Successful completion is 75% correct answers.
• Reexamination: If a participant fails the written examination, they may request to retake it. 
• ​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 are conducted by a training provider following the guidance outlined in this AIR.

• OR complete the required exams and assessments based on this AIR curriculum without completing a training program. Attempting the exam and evaluation without prior training is not recommended for personnel without experience in composite repair.

 

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.