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General Composite Structure: Fabrication, Inspection, Damage Assessment and Repair (SAE AIR4938 Part 1)

Course ID

ATS2071
Duration

10 days
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Persons who successfully complete this basic training program are considered to be able to perform bonded composite repairs to composite structures in compliance with the manufacturers’ repair documentation or other acceptable repair data. This curriculum should be considered a prerequisite for more advanced training.

This course is intended for technicians (about to be) involved with the maintenance and repair of aircraft- and component composite structures.

Prior composite training or experience is not required. Participant success will be in part based on the knowledge and skills possessed prior to course enrollment: Basic technical mathematics and reading comprehension.

This course includes

50 Practical Hours
25 Theoretical Hours
Theoretical Assignments
Practical Assessments

Personal Protection Equipment
Access to the ACRATS E-learning
Training Task Logbook
Certificate of Achievement

Training Calendar 2025

13 January until 24 January 2025
24 February until 07 March 2025
07 April until 18 April 2025
19 May until 30 May 2025
30 June until 11 July 2025
11 August until 22 August 2025
29 September until 10 October 2025
10 November until 21 November 2025

Full Trainings Calendar 2025 Outline

Learning Objectives And Topics

Objective:

Given discussion, lecture, and feedback, the participant will describe the basics of composite materials technology and their applications related to aerospace, marine, automotive, and civil, energy and consumer products. In addition, the participant will discuss the merits and general failure modes of composite materials to the extent that a material properties comparison can be established between metallic and composite structures.

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

Objective:

Given discussion, lecture, and feedback, the participant will explain the concept of “Human Factors” to the extent that a brief explanation of the “personal minimums” and a minimum of two factors that are likely causes of accidents and incidents be given.

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

Objective:

Given discussion, lecture, and feedback, the participant will visually recognize common composite fibers, list the properties, and associate the terms related to the fabric manufacturing process. In addition, the participant will describe the fiber placement levels used during manufacturing and repairing of composite structures to the extent that the fabric weaves, warp direction, and part warp clock can be referenced.

Topics:
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

Objective:

Given discussion, lecture, and feedback, the participant will state the difference between thermoplastic and thermosetting matrix materials, describe the roles and limitations of matrix materials, describe the storage and handling requirements, determine and calculate various mix ratios, describe the cure cycle, and describe the matrix cross-linking terminologies. In addition, the participant will describe and select appropriate filler materials to the extent that a given resin system mix ratio with filler materials can be calculated using an established ratio.

Topic:

A. Thermoplastics
B. Thermosets

C. Mixing and Mix Ratios

    i. Weight
    ii. Volume
    iii. Mixing Process

D. Curing of Resins

    i. A, B, and C Stages
    ii. Flow versus Gelation
    iii. Glass Transition
    iv. Viscosity
    v. Curing Reactions

E. Potting

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

Objective:

Given discussion, lecture, practice, and feedback, the participant will state the personal hazards working with polymeric materials and describe the four common paths of entry. The participant will evaluate a typical Safety Data Sheet (SDS) and demonstrate they can select proper personal protection equipment (PPE) and describe waste disposal procedures.

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

Objective:

Given discussion, lecture, and feedback, the participant will describe the pre-impregnation manufacturing levels and state the stages of the matrix material, storage and handling requirements, re-certification, and disposal procedures to the extent that the correct handling procedures are stated.

Topics:

A. Levels

    i. Resin Bath
    i. Hot Melt
    iii. Stages
B. Matrix Cure Temperatures

Objective:

Given discussion, lecture, and feedback, the student will explain the properties of adhesives and their usage, surface preparation levels, bond line control levels, and their common failure modes to the extent that adhesive materials can be selected given repair documentation as evaluated by the instructor.

Topics:
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
    i. Micro Beads
    ii. Carriers
        a. Scrim Cloth
        b. Knit
        c. Veil
H. Failure Modes
    i. Adhesion
    ii. Cohesion
I. Foams
    i. Core Splice

Objective:

Given discussion, lecture, and feedback, the student will describe the differences between sandwich structures and solid laminate structures (including monolithic structure) to the extent that the different materials used in construction will be described in detail as evaluated by the instructor.

Topics:
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/Crush

Objective:

Given discussion, lecture, and feedback, the student will explain the importance of proper storage and handling of materials utilized 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.

Topics:
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

Objective:

Given discussion, lecture, and feedback, the student will list the various equipment needed to properly operate a composite facility to the extent that a detailed list of tools, dust extraction equipment, trim rooms, and Controlled Contamination Area (CCA) be discussed in detail as evaluated by the instructor.

Topics:
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

Objective:

Given discussion, lecture, and feedback, the student will explain the importance of vacuum bagging to the extent that an explanation be given on the principals of vacuum and how it affects laminate properties, and provide a detailed list of materials utilized in the vacuum bagging process.

Topics:

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

Objective:

Given discussion, lecture, and feedback, the student will explain the different types of heating devices utilized in the composite industry to the extent that an explanation be given on their primary uses, advantages/disadvantages, their limitations, and the concerns of the devices as evaluated by the instructor.

Topics:

A. Autoclave
B. Oven
C. Hot Bonders
D. Heat Blankets
E. Hot Air Blowers
F. Heat Lamps
G. Infrared
H. Heat Guns

Objective:

Given discussion, lecture, and feedback, the student will describe the use of repair documents and manuals for composite structures.

Topics:

A. ATA Specification 100
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

Objective:

Given discussion, lecture, and feedback, the student will discuss the protective coating requirements, their handling procedures involving fiber reinforced plastic structures, and determine the type, application, and restoration procedures using approved manuals.

Topics:
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

Objective:

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

Topics:
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
E. Repair Area Limitations

Objective:

Given discussion, lecture, practice, and feedback, the participant will list the various types of Non-Destructive Inspection (NDI) techniques and their limitations during manufacture 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 evaluated by the instructor.

Topics:

A. Types of Damage
B. Mapping of Damage
C. Pre- and Post-Repair Inspection
D. Visual
E. Tap Testing
F. Ultrasonic (Pulse-Echo, TTU, Bondtesters)
G. Thermography
H. X-Ray
I. Comparison of NDI Techniques for Metal and Composite Structure

Objective:

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

Topics:
A. Sanding
B. Drilling
    i. Speeds and Feeds
    ii. Types of Drills
    iii. Reamers
C. Tools and Equipment
D. Trimming
E. Core Machining

Objective:

Given discussion, lecture, practice, and feedback, the student will develop the basic skills necessary to repair fiber-reinforced structures utilizing wet-lay and prepreg materials, vacuum bagging techniques, and hot bond equipment to the extent that personal protective equipment is worn and the repairs are accomplished using approved documentation and deemed airworthy as evaluated by the instructor and approved acceptance criteria.

Topics:
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

1. Core removed without causing additional damage to far side inner skin;
2. Taper sanding meets repair document requirements;
3. Correct material and orientation of original plies identified;
4. Repair plies are positioned and oriented correctly;
5. Cure cycle(s) meets repair document requirements;
6. Repair meets post-repair inspection requirements.

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Composite

Sheet Metal Tools

Painting

Swaging

Flap Peening

Work Light

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Personal Protection

Cutting Mat

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Tools

Aviation Toolkits

Composite

Sheet Metal Tools

Painting

Swaging

Flap Peening

Work Light

Equipment & Storage

Personal Protection

Cutting Mat

Dust Extraction

General Composite Structure: Fabrication, Inspection, Damage Assessment and Repair (SAE AIR4938 Part 1)

This course includes

Training Calendar 2025

Learning Objectives And Topics

1. Introduction to Composites

2. Human Factors

3. Reinforcement Fibers

4. Matrix Systems

5. Safety and Environment

6. Pre-Impregnated Materials

7. Adhesives

8. Structural Design Considerations

9. Material Handling and Storage

10. Facilities and Equipment

11. Vacuum Bagging

12. Heating Devices

13. Source Documents

14. Protective Coatings and Finishes

15. Repair Selection Considerations

16. Inspection Techniques

17. Machining of Composites

18. Hands-On Exercises

Assessment Criteria Hands-On Exercises:

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