EASA Part 4 Commercial Aircraft Structure Metal Bond Repair course

This EASA/FAA-approved Part 4 Commercial aircraft Structure Metal bonding course satisfies ATA 104 Level IV objectives related to the SAE AIR4938 and AMC 20-29.

Visit our EFC Facebook page for the latest composite News & information, and Like us! 

Visit our YouTube video page on Metal Bond Repair!

This is an EASA/FAA-approved Commercial Aviation Metal Bond  Repair course
This composite course in advanced metal bonding will meet the formal training requirement for individuals who intend to become certified aircraft metal bond repair technicians.
You should attend this course, taught by the most experienced aviation instructors. 
Persons who complete this aircraft structural composite repair training course are considered to perform metal-bonded repairs to aircraft-bonded structures in compliance with the manufacturer’s repair documentation or other acceptable repair data.

Course ID: EFC-TECH-104-SAE-PART 4- Commercial Aircraft Structure Metal Bond Repair course
Course duration:  5 DAYS (40 hours) training course.
Course Schedule: Please see the schedule or request a copy.

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 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 the guidelines of:​

1- SAE Publications

  • AIR4938   Composite and Bonding 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 useful 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 that incorporate actual components, those components do not have to be operational in nature. 

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 it may be taught primarily in the classroom environment.

Level 3
Level 3 requires knowledge of general principles and includes instruction through lectures, demonstrations, and discussions, with a high degree of practical application to develop sufficient manipulative skills to accomplish a service return (regular operation). This teaching level requires hands-on skill and appropriate instructional aides to train students to develop manipulative skills sufficient to simulate return-to-service 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 the required skill levels. A Level 3 subject cannot be taught solely through classroom lectures; appropriate training aids and hands-on experience must be used.

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

Since 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, such as:

  • Boeing drawing reading BDS 1330

  • FREE, Safety and Environment in working with Advanced Composites

  • FREE, Fiberglass quiz

  • Knowledge assessment test for composite Technicians and shop leads

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

 

 

Day(-s): 5 (days) / Tech code: TECH-104

Date Location Price Subscribe
2026-03-09

Frankfurt

 3495 Subscribe here
2026-03-16

frankfurt

 3495 Subscribe here
2026-03-30

Frankfurt

 3495 Subscribe here
2026-06-15

Frankfurt

 3495 Subscribe here

Advised prerequisites

  • Basic or equivalent knowledge in working with composites, and preferably some working experience with aluminum 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!

Don't hesitate to get in touch with us if you have any doubts or would like to discuss the current knowledge with us. You can contact us via info@efcomposites.com.
Student success will be in part based on the knowledge and skills possessed before course enrolment:
And including the following disciplines:

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

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


Personnel in technical departments,  MROs with some basic knowledge of composite Aircraft metal structures (aluminum honeycomb panels), who want to familiarize themselves with Aircraft Structural metal-bonded repairs, can read and understand OEM Repair manuals for repairing metal to a metal-bonded structure.

Sheet metal workers who want to have additional  training  in composite repair training


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 CACRC-EASA-SAE-approved curriculum is intended to meet the formal training requirement for individuals seeking certification as aircraft structure metal-bond repair technicians. Persons who complete this aircraft repair training program can perform repairs to aircraft metal structures in compliance with the manufacturer's documentation or other acceptable repair data.

The teaching levels listed are considered the minimum required for a given task. The hours for lectures 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 on-the-job experience. 

  • Must be able to work independently or in groups of two with minimum supervision
  • Must be able to keep a repair record of a student's logbook
  • Must be attentive to details
  • Will be able to repair adhesively bonded aluminium Aircraft structure components according to 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. Record various types of injury according to the OEM manual:
  • - half-depth core repair with septum placement
    - full depth core repair with aerodynamically flush
  • Can surface prep. aluminium structure repair area before bonding, following the OEM manual using Corrosion-Inhibiting primer—surface pre-treatment Sol-Gel AC130-2, and know about other surface treatments like Alodine, PACS, PANTA, and 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, install, and apply foam- and matt-supported film adhesives, and position Scrim cloth according to the repair manuals.
  • We will be able to monitor the total material, in-life cycle, and out-time of all frozen materials using a 'Freezer 'ut time form.'
  • Knows how to use the program and monitor heat and hot-bonding systems at 121 °C. curing
  • Has the knowledge of how to fabricate a quick composite reinforced support tooling 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 the SAE-Aerospace Composite Bonded glossary document SAE-AIR4844 (last revision)
  • Can perform a Post-Repair inspection using photography & recordkeeping

Module 1- Introduction to Part 4  Aircraft Metal Bond Structure        (Level 1)      ( 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
  • Critical Issues in Aircraft Metal Bond Maintenance, 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 versus Clad
  • Pre-Primed Sheet
  • Heat Treatments
  • Alu Core Material
  • Forms
  • Alloys
  • Surface Treatments
  • Discussion of Bonding Other Metals

Module 3-   Adhesion                                                                            (Level 1)       (1 hour)
Objective: After discussion, lecture, and feedback, the participant will be able to 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
  • Corrosion
  • Surface Prep and Contamination
  • Cohesion
  • Mixed Mode

Module 4   Safety and Environment                                                    (Level 1)       (1 hour)
Objective: After discussion, lecture, and feedback, the participant will demonstrate the proper use of Personal Protective Equipment (PPE) and describe the available data 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 listed surface preparation methods are taught at the Level 3 level.        

  • 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: After discussion, lecture, and feedback, the participant will be able to 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

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

Modul  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:

  • 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, form, and fit repair parts to 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, a visual inspection, and a polarized-light inspection to Level 3, as evaluated by the instructor.

  • Film Thickness Measurement
  • Bond Testers
     Harmonics Resonance
     Ultrasonic
  •  Tap Test
  •  Visual (Corrosion, Contaminants, Exposed Metal, Water Break Free Test)
  •  Polarized Filter Inspection
  •  X-Ray
  • Thermography
  • Eddy Current
  • Conductivity
  • Hardness

 

 


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

Objective:
Through discussion, lecture, practice, and feedback, the participant will demonstrate proper safety practices while exhibiting the skills necessary to repair metal bond structures utilizing pre-bond treatments, film paste adhesives, metal parts, vacuum bagging techniques, and hot bonding equipment. 
By the end of the training program, participants must demonstrate these skills by accomplishing a minimum of three repairs listed below, as verified by 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. 
A. Repairs 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. Prepared witness samples during this course 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 must 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 Test

  • Identify Failure Modes
  • Wedge Test
  • Climbing drum peel test
  • 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. Repair Preparation
  4. Repair Lay-up
  5. Vacuum Bagging
  6. Repair Cure
  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.

    Visit EFC and Like us on our  EFC Facebook page!

 

(Ref: SAE-AIR4938)
5. EXAMINATIONS 
  • EFC as Training Provider will be required to monitor the participant/participant's performance throughout the program. 
  • Participants will be administered a practical certification assessment following laboratory classes. A checklist is recommended 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 about 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.
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.
 
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.




Enroll for an EFC course
Card image

Download here..

Download the EFC course factsheetse

For which date do you want to enroll?

2026-03-09 2026-03-16 2026-03-30 2026-06-15
EFC Course overview
Course overview
Course schedule