Part 4 Structural Metal Bond Repair course

This SEA-FAA EASA-approved SAE-AIR4938 curriculum-Part 4  Commercial aircraft Structure Metal bonding course was developed for composite and metal-to metal bond Repair technicians and Engineers
ATA 104 Level IV objectives related to the SAE AIR4938 and AMC 20-29.

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This is an  EASA/FAA-approved SAE-4938 PART 4  Commercial Aviation Metal Bond  Repair course, which is aimed at Aircraft technicians and  Engineers
This composite course in advanced metal bonding is intended to meet the formal training requirement for technicians and Engineers who intend to become familiar with aircraft metal-to-metal bond repair 
You, as a technician or composite engineer, should attend this course given by the most experienced instructors in Aviation. 
Engineers who complete this aircraft structural composite repair training course are considered to damage assess, damage preparation, and monitor metal-bonded repairs for Aircraft metal-bonded structures in compliance with the manufacturer’s repair documentation, SRM, or other acceptable repair data.

Course ID: EFC-TECH 04-Derived from the SAE-PART 4- Commercial Aircraft Structure Metal Bond Repair course
Course duration:  5 DAYS (40 hours) training course.
Course schedule: See the schedule or request it.

Abbreviations used :

  • SAE: Society of Automotive Engineering
  • SAE- CACRC: Commercial Aircraft Composite Repair Committee (SAE-AIR4938 Doc.)
  • SAE- AIR: Aerospace Recommended Practices document
  • SAE- ARP: Aerospace Recommended Practices
  • FAA:  Federal Aviation Administration
  • EASA: European Union Aviation Safety Authority 
  • MRO:  Aircraft Maintenance, Repair & Overhaul center
  • EFC:   Earth & Flight Composites Training

Qualification to repair the structure to a serviceable condition will require additional experience, typically gained through on-the-job training under the supervision of a qualified individual.

This course complies with and is given according to the principles of the SAE-Int. PART 4  CACRC AIR4938,  EASA, and FAA standards

This course complies with de guidelines of:​

1- SAE Publications

  • AIR4938   Composite and Bonded Structure Technician/Specialist (This document contains the ATA104 level IV curricula)
  • AIR4844   Composites and Metal Bonding Glossary
  • AIR5719   Teaching Points for an Awareness Class on "Critical Issues in Composite Maintenance and Repair"
  • AIR6291   Guidelines for Repair Process Evaluation of Aluminum Bonded Structure
  • AIR/ARPs Produced by the repair technique task group

2-  FAA and EASA Certifications 

  • Title 14   Code of Federal Regulations, 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

The following definitions of minimum teaching levels are derived from Title 14 Code of Federal Regulations, Part 147, and may be exceeded.

Level 1
Level 1 requires knowledge of general principles and includes instruction through lectures, demonstrations, and discussions, but does not involve practical application or the development of manipulative skills. This teaching level generally refers to classroom discussion and does not require a practical application. Teaching aids or instructional equipment may include charts, books, diagrams, or other visual teaching aids. If a training organization chooses to teach Level 1 courses incorporating actual components, the components do not have to be operational. 

Level 2
Level 2 requires knowledge of general principles and includes instruction through lectures, demonstrations, discussions, and limited practical application; however, it does not involve the development of sufficient manipulative skills to perform basic operations. This teaching level requires some hands-on, manipulative skills and accompanying actual or simulated components/equipment, but may be taught primarily in the classroom environment.

Level 3
Level 3 requires knowledge of general principles and includes instruction through lectures, demonstrations, discussions, and a high degree of practical application to develop sufficient manipulative skills to return to service (normal operation). This teaching level requires hands-on skills and sufficient, appropriate instructional aides to train students to develop manipulative skills sufficient to simulate the return to service of mechanical skills. At this level, the teaching aids must be similar to or be the actual equipment items on which the student is expected to develop required skill levels. A Level 3 subject cannot be taught solely through a lecture in the classroom; appropriate training aids and hands-on experience must also be utilized.

NEW: EFC Online Distance elearning website (Click here  https://elearning.edutech.efcomposites.com/)

Sins 2020, we have set up our NEW Online e-learning WEBSITE  with LOTS of information about Advanced Composites on our Technical BLOG page
and FREE and paid theoretical courses about advanced composites like:

  • Boeing drawing reading (BDS) Boeing Drafting System

  • FREE, Safety and Environment in working with Advanced Composites

  • Knowledge assessment test for composite Technicians and shop leads

  • How to fabricate a Boeing 787 Radome repair Tool/Mold, and many more courses you need to have  (Click here)

  • EFC BLOG  with all Composite-related info

 

 

Day(-s): 5 / Tech code: ENG-104-EASA/FAA Part 4

Advised prerequisites

  • Basic or equivalent knowledge in working with composites and preferably some experience of working with aluminium materials will be advantageous.
  • Preferably  attend our new TECH-101 Part 1-General Structural Bonded  Composite Repair Course."
  • Aircraft sheet metal workers who want to receive additional training in composites or convert into composite technicians!

Please contact us if you are in doubt to discuss the current knowledge with us. You can reach us at info@efcomposites.com.
Student success will be in part based on the knowledge and skills possessed before course enrolment:
And including the following disciplines:

  • Technical mathematics
  • Reading comprehension
  • Fundamentals of engineering and technical drawings
  • General shop and hand tool usage
  • Use of precision measurement tools

Aircraft health and regulatory safety awareness
(Need for PPE - Personal Protection Equipment) 


Boeing or Airbus dedicated Composite Repair Technicians, Engineers of technical departments, or MROs with some basic knowledge of composite Aircraft metal structure (aluminium honeycomb panels) who want to get familiar with Aircraft Structural Metal Bonded Repairs can perform damage asesment, can assist technicians in repair sequences, surface prep., read and perform post-repair checks, and can interpret OEM Repair manuals Boeing or Airbus SRM in repair of metal to a metal bonded Aircraft structure.
If necessary, we will be happy to educate other types of Aircraft SRMs in the repair of metal-bonded structures. Please ask us.

 


Minimum required 4 and maximum 8 per course*.

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

SCOPE
This curriculum is designed to meet the formal training requirements for Technicians and Engineers who intend to become more familiar with metal-bond repair of aircraft structures. Engineers who complete this aircraft repair training program are considered to have a better understanding of aircraft metal structures in compliance with the manufacturer’s repair documentation, Boeing or Airbus SRMs, or other acceptable Engineering repair data.

The teaching levels listed are considered the minimum required for a given task. The hours for lecture and hands-on repair projects are the minimum required for each. Many of the subjects need reinforcement through practical exercises.
Qualification to repair the structure to a serviceable condition will require additional experience in the form of the job 
The engineer:

  • Must be able to keep repair records in a logbook and make engineering notes
  • Must be attentive to details and have an understanding of all materials used, including surface prep methods needed to get a strong structural repair for return to service.
  • Will be able to repair adhesively bonded aluminium Aircraft sandwich structure components by the OEM manual of the specific type of aircraft
  • Can work according to Safety regulations and can recognize hazardous materials & situations
  • Is familiar with Human factors 
  • Can assess metal-bonded damage by NDI, photography, & Recordkeeping 
  • Can assess various types of damages according in acordans with the OEM manuals of Boeing and Airbus:
    - half-depth core repair with septum placement
    - full depth core repair with aerodynamically flush
  • Has a good understanding of surface preparation of  aluminium bonded structure repair area before bonding, following the OEM manual, using Corrosion Inhibiting primer - Surface pre-treatment Sol-Gel AC130-2, and has knowledge of other surface treatments like Alodine,  PACS, PANTA, and other HF methods
  • Can successfully bond aluminium ASTM D test coupons (witness samples) along with the repairs, such as Lap shear test,  Climbing Drum peel test, and Wedge test.
  • Will be able to handle and install foam adhesive, matt-supported film adhesives, and positioning of Scrim cloth acc. to repair manuals
  • Will be able to monitor total material, in life cycle, and out of time for all frozen materials using a 'Freezer Out Time Form.'
  • Knows how to use and program, and monitor different heat and hot bonding systems for hot 121 °C. cures
  • Has the knowledge of how to fabricate a quick composite reinforced support tool for an Aircraft aluminum-bonded structure
  • Must be able to read and understand Technical English and read and understand the criteria required as written in SAE- Aerospace Composite Bonded glossary document AIR4844 (last revision)
  • Can perform pre- and Post-Repair inspection using photography & recordkeeping 

Module 4- Introduction to Aircraft Metal Bonded Structure       ( 0,5 hour)
Objective: After discussion, lecture, and feedback, the participant will be able to describe the metal bond application and identify critical elements as evaluated by the instructor.

  • Common Metal Bond Applications on Commercial Aircraft
  • Critical Issues and damage types found in Aircraft Metal bonded structure for Repair, and Overhaul
  • AIR6291, Guidelines for Repair Process Evaluation of Aluminum Bonded Structure

Module 2- Metal bond-Specific Repair Material Requirements        Level 1  (1 hour)
Objective: After discussion, lecture, and feedback, the participant will be able to describe and identify the correct aluminum alloy and core for a specific repair, as evaluated by the instructor.

Aluminum Alloy Selection 

  • Bare Aluminum versus Clad Aluminium
  • Pre-Primed Alu Sheets
  • Heat Treatments of aluminum and their stages
  • Alu Core Materials and densities
  • Forms
  • Aluminium Alloys
  • Surface Treatments
  • Discussion of Bonding Other Metals

Module 3-   Adhesion                                                                             Level 1   (1 hour)
Objective: Given discussion, lecture, and feedback, the participant will describe the factors of adhesion as evaluated by the instructor.

  • Chemical Bonding Compared to Mechanical Bonding
  • Surface Tension and Surface Energy
  • Types of Failure
  • Adhesion
  • Cohesion
  • Corrosion
  • Surface Prep and Contamination
  • Mixed Mode

Module 4   Safety and Environment                                                    Level 1      (1 hour)
Objective: After discussion, lecture, and feedback, the participant will demonstrate proper use of Personal Protective Equipment (PPE) and describe the data available to safely use and dispose of hazardous materials, as evaluated by the instructor.

  • SDS (Safety Data Sheet)
  • Waste Disposal
  • Personal Protection Equipment (PPE)

Module 5.    Surface Preparation and Time Limitations        Level 3     (2 hours)
Objective: Through discussion, lecture, practice, and feedback, the participant will be able to describe and prepare the metal surface as required by the repair document, including the removal of prior surface treatments, surface cleaning, chemical treatment, and correct primer application, as evaluated by the instructor. Two of the surface preparation methods listed below are taught at Level 3.        

  • Solvent Cleaning
  • Anodizing
    Phosphoric Acid
    • Phosphoric Acid Non-Tank Anodizing (PANTA)
    • Tank Method
    • Phosphoric Acid Containment System (PACS)
    • Boric/Sulphuric Acid
    • Chromic Acid
  • Chemical Conversion-Hydrofluoric Acid/Alodine
    Sol-Gel 
    • Boe-Gel / Sol-Gel AC 130-2
    • Pasa Gel
    • Grit Blast Silane
    • FPL Etch (improved)
    • Alodine
       
  •  Mechanical Abrasion Primers
  • Primer Thickness Requirements
  • Time Limits
  • Proper Handling and Storage of Prepared Surfaces
  • Acceptance Criteria
    Water Break Free Test
    Use of Polarizing Filter

Module 6.   Adhesives  Level 1  (0,5 hour)
Objective: Given discussion, lecture, and feedback, the participant will describe and identify the correct adhesive, its application, handling, and storage requirements as evaluated by the instructor.

  • Film & Foam Adhesives
  • Paste Adhesives
  • Core Splice Adhesive
  • Proper Handling and Storage

Module 7. Metal bond-Specific Design Considerations (Level 1) 1 hour
    Objective: After discussion, lecture, and feedback, the participant will be able to describe the metal bond part design requirements as evaluated by the instructor.

  • Impact Shields
  • Corrosion Resistance
    • Interfacial Hydration (Moisture Ingression)
  • Drainage Paths
  • Isolation Layers
  • Acoustical Treatments and Layers
  • Electromagnetic Concerns
  • Aerodynamic Considerations

Module 8.  Heat Transfer and Cure Cycle Management  Level 3  (1 hour)

Objective: Through discussion, lecture, practice, and feedback, the participant will be able to describe and control the cure cycle to meet the repair document requirements, as evaluated by the instructor. At least two types of equipment listed below will be trained at  Level 3.

  • Heat Transfer 
  • Equipment Limitations
  • Autoclave
  • Oven
  • Hot Bonders
  • Heat Blankets
  • Hot Air Blowers
  • Heat Lamp
  • Infrared Heaters
  • Thermocouple Placement
  • Insulation and Airflow Control
  • Heatsinks

Module 9. Pressure Requirements  Level 3 (1 hour)

Objective: Through discussion, lecture, practice, and feedback, the participant will be able to describe pressure requirements, place the correct core vent materials, and control pressure to meet the repair document requirements as evaluated by the instructor.

  • Vacuum Levels
  • Positive Pressure
  • Core Venting
  • Air Entrapment

Module 10. Source Documents  Level 2  (1 hour)
Objective: Through discussion, lecture, practice, and feedback, the participant will be able to identify, describe, and comply with repair documents as evaluated by the instructor.

ATA Spec 2200/S1000 
Structural Repair Manuals Boeing and or Airbus:

  • Allowable Damage Limits (ADL)
  • Repair Limits

Component Maintenance Manual
Engineering Orders
Maintenance Organization Specific Documents
SAE AMS-CACRC ARPs
Regulatory Documents:

  • Airworthiness Directives
  •  Service Bulletins
  •  Advisory Circulars
  • Rule-Making Task

Material and Processes Specifications

  •  OEM
  •  Vendor
  •  Internal

Module 11. Repair Considerations   Level 3   (3 hours)

Objective: Through discussion, lecture, practice, and feedback, the participant will be able to identify damage, evaluate repair considerations, select the appropriate form, and verify that the repair parts meet the requirements of the repair document as assessed by the instructor.

Damage Assessment and Limitation of Corrosion

  • Contamination
  • Dents
  • Dis-bonds
  • Scratches, Nick's, and Gouges
  • Punctures
  • Crack
  •  Lightning Strike/Heat Damage
  • Proximity to Other Damage and Repairs
  • Material Selection and Substitution
  • Repair Part Sizing
  • Very film Check
  • Core Selection and Sizing
  • Septum
  • Bondline Thickness Control
  • Tooling Requirements
  • Contour Management/Material Forming
  • Damage Removal/Previous Repair Removal
  • Contaminant Removal/Prevention
  • Thermal Management
  • Effect of Vacuum Levels on Film Adhesives
  • Vacuum Bagging Techniques
  • Contact Materials

Module 12. Inspection Techniques  Level 1   (1 hour)

Objective: Through discussion, lecture, practice, and feedback, the participant will be able to describe inspection methods and conduct at least a tap test, visual inspection, and polarised light inspection to Level 3, as evaluated by the instructor.

  • Film Thickness Measurement
  • Bond Tester/Ramp damage checker
     Harmonics Resonance
     Ultrasonic
  •  Tap Testing using Statuscope
  •  Visual (Corrosion, Contaminants, Exposed Metal, Water Break Free Test)
  •  Use of Polarized Filter Inspection during surface prep.
  •  X-Ray
  • Thermography
  • Eddy Current
  • Infrared camera/Thermal head
  • Conductivity
  • Hardness

 

 


Module 13. Hands-On Exercises Level 3 ( 25.5 hours)

Objective:
Given discussion, lecture, practice, and feedback, the participant will demonstrate proper safety practices while exhibiting the skills necessary to repair metal bond structures utilizing pre-raid damage assessment, ADLs pre-bond treatments, application of film and paste adhesives, metal parts surface treatment and handling, vacuum bagging techniques, and hot bonding equipment. and cure techniques, hot-sinks in metal bond structures
By the end of the training program, participants must demonstrate these skills by completing the tasks listed below for the instructor and meeting the criteria outlined in the repair documentation.
The participant must also destructively test one of the repairs listed below and identify the failure mode, in addition to the wedge test, lap shear test, Floating roller peel test, and Peel test. 
An Assess Repair on an Aluminium honeycomb panel
Dent Repair
Skin and Core Repair or One Side Flush Repair/Half-depth core repair with Alu. septum
Skin Crack Repair
All participants must fill out their personal logbook, noting all steps and OEM manual chapters as they perform the actual repairs.

B. Participant must prepare Alu bonded witness samples during this course, which are destructively tested according to ASTM American standard testing methods to Identify Failure Modes. The following test samples will be assembled during this course and have to reach their minimum failure mode to pass the actual practical examination:
  • Wedge Test
  • Lap Shear test
  • Floating Roller Drum peel test
  • Peel test

C.   Destructive Tests

i.    Identify Failure Modes
ii.   Wedge Test
iii   Climbing drum peel test
iv   Lap shear test

15. Practical Assessment                                                                                                                                          

The practical assessment will be a different, hands-on repair. The practical evaluation shall be similar to one of the hands-on exercises
Assessment:

  1. Damage Assessment
  2. Damage Removal
  3. Pre-Repair inspection and surface Preparation
  4. Repair build-up sequences
  5. Vacuum Bagging Methods
  6. Repair, Cure, and heatsink prevention
  7. Post Repair Inspection
  8. Record Keeping

​Assessment Criteria:

  1.   Damage was removed without causing additional damage.
  2.   Surface preparation meets repair document requirements.
  3.   Correct repair materials identified
  4.   The repair patch is positioned correctly
  5.   Cure cycle(s) meet repair document requirements
  6.   Oven cure or Hot bonder cure
  7.   Repair meets post-repair inspection requirements.

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(Ref: SAE-AIR4938)
5. EXAMINATIONS 
  • EFC as Training Providers will be required to monitor the participant/participant's performance throughout the program. 
  • Participants will be administered a practical certification assessment following laboratory classes. It is recommended to use a checklist to evaluate the practical 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 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.
Practical certification assessment: 
The participant must demonstrate to the approved training provider that they can perform the necessary tasks to complete the applicable repairs. 
  • All grades will be recorded in the participant's individual training records and kept on file at EFC for an unlimited period (compliant with EASA Commission Regulation (EU) No 1321/2014 and GDPR rules).
  • A certificate of accomplishment is handed out to each participant
  • Assessment activities are built into our courses to provide feedback on achievement and personal potential, and to keep a record in their logbook.
  • The outcome of the participant's examination, assessment document, and logbook per participant will be digitally sent to you or your company's responsible manager or HR department.​
6. CERTIFICATION
Part 1 certification shall  consist of documentation of successful completion of: 
  • A repair training program, the required exams and assessments based on the curriculum of this AIR4938 document, and conducted by a training provider following the guidance outlined in this AIR.
  • OR successful completion of the required exams and assessments based on the curriculum of this AIR without completion of a training program. Attempting the exam and evaluation without prior training is not recommended for personnel without experience in composite repair.
  • EFC SAE-AIR 4938C Part 2, Part 3, and Part 4 certification shall consist of successful completion of a repair training program, the required exams, and assessments based on the curriculum of this AIR and conducted by a training provider following the guidance outlined in this AIR. 
     
    CURRENCY AND RECURRENT TRAINING RECOMMENDATIONS
    Currency: Personnel should demonstrate continued competence every three years by performing a repair or by performing a practical assessment under the direct supervision of an examiner authorized and designated by the organization or by having participated in or completed at least six repairs applicable to the specific certification (i.e., Part 1, Part 2, etc.) in the three years.
    Don't hesitate to contact us for our currency or recurrent training program EFC TECH-022.
     
    Recurrent Training: A training program should include provisions for recurrent training to continually update personnel on technology, materials, and other changes related to composite and metal-bond maintenance and repair. The organization and the individual should maintain records of recurrent training.
     
    7. RECORDS
    The certifying agency or its designee shall maintain certification records for as long as certification is in effect and a minimum of 5 years after the certificate has expired. Such records shall be available for audit by authorized personnel. 
    The training agency shall maintain training records for a minimum of 5 years. Such records shall be available for audit by authorized personnel. 
    As an approved training provider, EFC complies with the European AVG/GDPR rules, effective as of May 25, 2018, concerning the storage of training records and private information of participants who attend our courses. Participants sign their first-day Administration entry form for approval to store their training records.
 
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.




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