Intermediate of Composite Structures Fabrication & Repair

 

Course code: TECH-010 (Stage II)

Course duration: 5 Days

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

This is our follow-up course for the EFC TECH-001 Basic Principles of Composite Structures Fabrication & Repair. This level 2 course is meant for Personnel of technical departments having successfully passed our Stage I course and want to go to the next level of composite repair and understanding of advanced composite materials and processes for repair.

Advised Pre Requisites

EFC TECH-001 course or equivalent level. Please contact us to assess your equivalent level.

Participants
Personnel of technical departments who want to become an Composite Repair technician who has full understanding of Advanced Composite Repair and is able to repair composite damage in accordance with the OEM manuals. 

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

Objectives
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 can recognize hazardous situations & materials
  • Will have the expert in-depth understanding of vacuum bag techniques
  • Can apply damage assessment and machining sequence
  • Knows how to work in accordance with several OEM repair manuals
  • Will be able to repair damage of Glass, Carbon and Aramid composites
  • Can taper sand excellently with various taper ratios and variations in overlaps as required by OEM
  • Can work in teams and fabricate a Carbon and Glass and Aramid fiber double curved panel with Nomex® honeycomb and / or polyurethane foam core
  • Can perform several damage repair methods including 'wet layup' and pre-preg repair
  • Can drill holes in edge band of composite panels with drill bushings
  • Must be able to understand criteria required in AIR 4838 (Latest revision)

Course Content Theory (Level 2)

  • O.E.M. comparison and other necessary manuals
  • O.E.M. Advanced Ply Lay-Up Blue print reading
  • O.E.M. Additional Repair manual Repair Damage assessment and record keeping by documentation and photography
  • Damage awareness  and incident reporting
  • Surface prep & different Repair type assessments and Composite fastener removal
  • Composite fastener holes, drilling , Reaming and fastener Installation
  • Use of Hot-Bonding equipment - ramp, dwell setting, TC placement and Heat sinks
  • Use of Wax sheets and offset thickness
  • Quick Repair Tooling fabrication and other Equipment
  • Application of 'Felt' for damage area support technique
  • Safety

Workshop exercises (Level 2)

Taper sand excellently with various taper ratios and variations in overlaps as required by OEM. Per group fabricate Carbon and Glass and Aramid fibre single curved panels with Nomex® honeycomb and / or foam core. Perform repair methods  in' Wet Lay-Up' and pre-preg. Pre-drill and drill holes in the edge band of panels with drill fixtures and bushings.

Perform the following skills on Composite panels:

  • Fabricate single curved Carbon fiber sandwich panel (pre-preg) according to Ply lay-up drawings
  • Trim panels & drill holes in Glass, Carbon and Ararmid fiber panels
  • Perform Step cutting by hand on Glass and Aramid fibre panels
  • Damage assessment by visual inspection and photography
  • Record keeping
  • Application of 'Felt' Technique for repair panels
  • Surface prep and Repair steps and determination of working order steps
  • Damage support techniques by vacuum
  • Edge Band and damage 
  • Repair type off materials and OEM chapter findings and printout
  • Damage removal, Scarf preparation
  • Performing skin core and edge band repair pre-preg layup materials and processes
  • Perform various taper sand exercises with different overlap ratios per OEM
  • Lay-Up choice of vacuum materials vacuum bag and vacuum leak checking
  • Curing with an oven and / or Hot-Bond repair equipment - heat blankets and heat blanket tester, Thermocouples, thermocouple welder and program cure cycles

Examination

  • Multiple choice questions from each of the teachings Level 1-2 
  • Successful completion is 75% correct answers (The examination will be closed book)
  • 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.

This course can also be held at our facility in, Bicester UK at the Bicester Banbury College. 
Minimum participants4  and Max. 12. See our Up coming course schedule
Contact our purchasing manager Rolf Hovener via e-mail at r.a.hover@efcomposites.com

Request for 'On-Site' Training
This course can be requested for an 'On-Site' training at your company under certain "Terms & Conditions"
It will involve additional cost such as: Instructor(s) Travel, lodging, daily allowance, shipping /ensuring material and bringing in equipment.

Note for companies only:

  • If required, our Training course 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.

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.