Basic Principles of Composite Structures Fabrication & Repair

Course code: TECH-001 (Stage I)

Course duration: 5 Days

Introduction:
All EFC courses comply SAE-CACRC, FAA, CAA and EASA standards.

This is a Training 'level 1-2' composite repair course. It is our most "Basic" composite course designed to meet the requirements of a wide range of participants / technicians from beginner to intermediate technician who want to have a better understanding of advanced composites .

Advised Pre-requisites
"None Required" 
This composite course is an advised  prerequisite for EFC courses such as the TECH-010 Intermediate and TECH-020 Advanced Repair course.

Participants
Personnel of technical departments having no prior experience or training with Fiber Reinforced Composites and wanting to gain a better understanding of advanced composite materials and processes such as, lay-up, laminate different materials, vacuum bagging, fabrication and repair. Personnel with some composite fabrication & repair experience are also welcome to participate in this basic course. 

Number of participants: Minimum required 4 and Maximum 16 per course*.
* Courses will be confirmed as running by EFC as soon as sufficient applications are received! 

Objectives
To provide participants with theoretical knowledge and practical Hands-On skills necessary to carry out basic fabrication and repair.

At the end of the course the participants:

  • Must be able to work independently with minimum supervision
  • Must be attentive to details
  • Can work according to Safety regulations and recognize hazardous situations & materials
  • Knows material properties and is familiar with "Handling & Storage" of frozen materials
  • Can work safely with pre-preg Carbon fiber, UNI Carbon tape material and is familiar with the effects of orientation and 'Balance' and 'symmetry' in a laminate
  • Knows how work with dry glass fabric and liquid Epoxy resin to impregnate wet in wet (Wet Lay-Up)
  • Can apply fundamental vacuum bagging, bleeder & breather concepts
  • Can taper sand taper ratios as required by OEM
  • Fabricate Carbon and Glass fibre single curved panels with Nomex® honeycomb and foam core
  • Performs basic 'Wet Lay Up' repair 
  • Must be able to understand criteria as required in the SAE- CACRC AIR 4838 Training Document

Course Content Theory  (Level 1-2)

  • Health and Safety (MSDS)
  • History of composites, recent developments and terminology
  • Handling & Storage of Frozen materials
  • Material Forms: dry cloth and wet resins vs. pre-preg, weave styles
  • Fundamentals of Fabrication: dry cloth and pre-preg handling, ply orientation, layup procedures, vacuum bagging techniques
  • Introduction to advanced composite materials / structures
  • Resin, adhesive systems: thermosets vs. thermoplastics, mix ratios, viscosity, service temperature limits, cold storage requirements / shelf life limits, pot life, etc.
  • Material Data Sheet (MDS) reading to determine Open time, Shelf life, and material Cure cycles 
  • Composite awareness & reporting damage incidents
  • Minor Damage assessment, dents scratches and others 
  • Sanding techniques, scarf angels, step repairs, ply cutting

Workshop exercises: (Level 1-2)

Participants will be intensively monitored while fabricating reinforced fiber laminates from Carbon UD, sandwich parts from Aramid and Glass Fiber prep-preg and dry fiber material using various ply lay-Up directions. Lay-Up of vacuum materials and perform vacuum leak checking and curing.

Determine ply directions in Glass, fiber laminates by sanding.
Damage assessment and reporting
Damage removal, scarf preparation for repair using a Wet Lay-Up and pre-preg repair process.
Introduction to oven and Hot Bond repair consoles and their equipment.

 Examinations

  • Multiple choice questions from each of the teachings Level 1-2 
  • Successful completion is 75% correct answers
  • The examination will be closed book and  can be conducted by a Part 147 approved Examiner
    on request 
  • The practical mark will be the average of all marks gained from the practical exercises
    Assessment activities are built into our courses, to give feedback on the achievement and personal potential and kept record in a personal logbook per student.  
  • All grades will be recorded in the participant individual training records and kept on record at EFC for unlimited time (compliant with Reference EASA Commission Regulation (EU) No 1321/2014)
  • A certifcate of accomplishment is handed out to each participant.

Note for companies only:

  • If required, our Training courses can be tailored made to meet your specific needs. 
  • Course dates as noted on our schedule can be adjusted on request to a required starting date.

This course can also be held at our facility in, Bicester, UK at the Bicester Banbury College. 
Minimum participants: 4 and max. 12. See our course schedule
Contact our purchasing manager Rolf Hovener via e-mail at r.a.hover@efcomposites.com or info@efcomposites.com

Request for 'On-Site' Training
This course can be requested for an 'On-Site' training at your company under certain "Terms & Conditions"

For information & requirements, contact our business & purchasing manager Rolf Hovener via e-mail at r.a.hover@efcomposites.com or Owner / Founder Bert Groenewoud via e-mail at info@efcomposites.com

Course Pricing
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.