Structural Metal Bonding Repair (Stage I)

Course code: TECH-100 (Stage I)
Course duration: 5 Days


This a hands-on metalbond repair training in repair of metal aircraft structure damage with Aluminum honeycomb core.
All EFC courses comply SAE-CACRC, FAA, CAA and EASA standards.

Advised pre-requisites

Personnel Technical Departments, having basic knowledge of composite and/or completed the EFC TECH-001-(Stage I), or equivalent level. Please contact us to review your or your company’s Technician equivalent training level.
This is a Basic hands-on Training level 3 course (compliant with Level 3, Part 147 R Teaching levels).


Personnel of technical departments with None or Basic knowledge of composites who want to get  familiar with Aircraft of Metal Bonded Structural Repair & damage assessment and will be able to repair metal bonded structure damages in accordance with the OEM structural repair manuals.


At the end of this most Hands-on  Structural metal bonding course the participants:

  • Must be able to work in groups of two with minimum supervision
  • Must be attentive to details
  • Will be able to repair adhesively bonded aluminum structure components in accordance with the OEM manual of the specific type of aircraft
  • Can work according to Safety regulations and can recognize hazardous materials & situations
  • Can assess type of damage by NDI, photography & Record keeping
  • Can perform various types of damage according to the OEM manual:
    – half dept core repair with septum placement
    – full  dept core repair with aerodynamical flush
  • Can surface prep. aluminium structure repair prior to bonding in accordance with the OEM manual using Corrosion Inhibiting  primer – Surface pre treatment Boegel / Sol Gel AC130-2
  • Can successfully fabricate aluminium ASTMD test coupons (witness samples) alongside  the repairs such as: Floating Roller Peel, Lap shear, Climbing Drum peel and Wedge test
  • Will be able to handle and install foaming adhesives, film adhesives and positioning cloth
  • Will be able to monitor total material,Life cycle, ‘Out time’ of all frozen materials using a ‘Freezer Out time form’.
  • Knows how to use and / or program and monitor different heat and hot bonding systems for curing
  • Can and is able to fabricate quick composite reinforced support tooling for aluminum bonded structure
  • Must be able to understand criteria required in SAE- Aerospace Info Report AIR-4838 (last revision)
  • Can perform a Post-Repair inspection, photography of repair & Record keeping

Course content theory (Level 2-3)

  • Fundamentals of structural bonding techniques
  • ASTM test coupons & fabrication of ASTM ‘Witness’ samples
  • Aluminium honeycomb hexagonal core materials and cell types
  • O.E.M. manuals (SRM) and other necessary documents
  • Damage Awareness & damage incidents reporting
  • O.E.M. Additional Repair manual chapters Repair Damage assessment scratches,dents e.a
  • Record keeping through documentation and photography
  • PACS, PANTA, HFL Alodine and Sol-Gel (AC-130-2 )processes
  • Destructive and non-destructive testing of aluminium bonded structures
  • Surface preparation & different Repair type assessment
  • Use of hot-bonding equipment, pros and cons of different heating devises
  • Possible Heat sinks & Insulation in metallic structure
  • Application of Quick Repair Support Tooling for metal bonded structure
  • Safety General

Workshop exercises (Level 3)

The participants will :

  • Fabricate test coupons (witness samples) alongside repairs in environmental conditions and analyze failure methods
  • Perform damage assessment by inspection and photography and perform record keeping
  • Perform vacuum leak checks on every repair and keep record
  • Apply Surface preparation and repair steps to be taken
  • Perform metal bond repairs on aluminum honeycomb sandwich structure per the OEM manual
  • Program and monitor hot bonding equipment, change programs and parameters during curing
  • Learn the importance of thermocouple placement on adhesively bonded structure
  • Learn about insulation of metallic structure and of heat sink prevention by insulating methods
  • Perform Post-Repair inspection on all repairs and keep record
  • All record keeping will be evaluated by the instructor(s)


  • Multiple choice questions from each of the teachings Level 2-3
  • Successful completion is 75{63753f107260f26306864167adcf73e00445e84c75013824deb98cc0ddc15287} correct answers (The examination will be closed book)
  • The practical mark will be the average of all marks gained from the practical exercises including the outcome of the destructive testing of the fabricated test coupons and personal logbook per student
  • All grades will be recorded in the participant individual training records and kept on record at EFC and your company for unlimited time (compliant with Reference EASA Commission Regulation (EU)No 1321/2014)
  • A certificate of accomplishment is handed out to each participant.

Tailor made

Note for companies only:

  • If required, our Training courses can be tailored made to meet your specific needs. 
  • Course dates as noted on our course schedule can be adjusted on request to meet your required starting date.
  • If you have a requirement for this, please contact our business development manager, Rolf Hovener, via his personal page.

On site

This currency competence assessment can be hold 'On-Site' at your company under certain conditions. 

It will involve additional cost such as: Travel, lodging, daily allowance, shipping / ensuring material and equipment plus 25%. If we do hold this course 'On-Site', there are specific requirements per course regarding the equipment of your company workshop and training material availability. 

For information & requirements, contact our business & purchasing manager Rolf Hovener via his personal page.

Bicester, UK

This course can also be held at our facility in Bicester in the UK at the Bicester Banbury College.  If you have a need for this, please contact our purchasing manager Rolf Hovener via his personal page.

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.


Enroll for this course?
Cost for this course:  2.295,00 EUR

Training data:

Course overview