PROCESSING, INSPECTION AND REPAIR, LEVEL 1 - acrats

This content is ACRATS Proprietary Composite Education Program, Level 1

1

ADVANCEDCOMPOSITES:PROCESSING,INSPECTIONANDREPAIR,LEVEL1

DEVELOPED IN COLLBORATION WITH OUR PARTNER AM&TS

CourseTitle:ADVANCEDCOMPOSITES:PROCESSING,INSPECTIONANDREPAIR,LEVEL1

Course Code: CA001

Date: 2018-04

Developed by: Rick van Opdorp

Signature:

Composite Education Program, Level 1


2


TABLE OF CONTENTS

SCOPE ............................................................................................................................................... 3

DURATION ........................................................................................................................................ 3

LOCATION ......................................................................................................................................... 3

APPLICABLE DOCUMENTS ............................................................................................................. 3

EXAMINATIONS ................................................................................................................................ 4

TEACHING LEVELS .......................................................................................................................... 5

MODULE 1 – Advanced Composite: Processing ............................................................................... 6 Scope ................................................................................................................................................. 6 Topics and Objectives ........................................................................................................................ 6

MODULE 2 – Advanced Composite: Inspection ................................................................................ 7 Scope ................................................................................................................................................. 7 Topics and Objectives ........................................................................................................................ 7

MODULE 3 – Advanced Composite: Repair .................................................................................... 8 Scope ................................................................................................................................................ 8 Topics and Objectives ........................................................................................................................ 8


3


SCOPE This is a standard curriculum that has been developed according SAE CACRC publications. Teaching levels have been assigned to the curriculum to define the knowledge, skills, and abilities, graduates will need to manufacture composite components with failure. After the manufacturing, the students will perform NDT inspection on the manufactured components. After the inspection, the students will perform composite repairs on the components. After a minimum hour of instruction have been provided to ensure adequate coverage of all subject matter including lecture and laboratory. Each curriculum module is a subpart of this document: Module 1 is Advanced Composites: Processing Module 2 is Advanced Composites: Inspection Module 3 is Advanced Composites: Repair This document contains ATA104 level IV curricula. DURATION 5 working days, 40 hours Start 08:00 Break 12:00 / 13:00 End 17:00 LOCATION ACRATS Training Services B.V. Aviolandalaan 35, Building 42A 4631RV, Hoogerheide Netherlands Or Customers Site APPLICABLE DOCUMENTS The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications shall apply. The applicable issue of other publications shall be the issue in effect on the date of the purchase order. In the event of conflict between the text of this document and references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.


4


SAE Publications 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 ARP6262 Basic Composite Repair Technician Certification Standard FAA and EASA Publications 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 EXAMINATIONS It will be required to monitor student performance throughout the program. Students will be administered a written exam following lecture classes and practical assessments in laboratory classes. The minimum passing grade for all written exams shall be 75% and all grades shall be recorded in the individual’s training records. The examination and assessment will cover the principles of the applicable curriculum and consist of: Written examination: The written examination shall contain multiple choice questions. The examination shall contain questions from each of the Topics listed in the outline for each Part. The examination will be closed book. Practical assessment: The student must demonstrate to the Instructor that they can perform the basic tasks required to perform the applicable repairs. Reexamination: If the student fails the written examination, they may request to retake a written examination. The written examination must not contain more than 20% of the questions that were on the failed examination. CERTIFICATION Certificated covered by EASA 147 approved training school “Aircraft Maintenance and Training School”.


5


TEACHING LEVELS 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 by lecture, demonstration, and discussion, but does not include practical application or development of manipulative skill. This teaching level generally refers to classroom discussion and does not require practical 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 incorporating actual components, the components do not have to be operational.

Level 2 Level 2 requires knowledge of general principles and includes instruction by lecture, demonstration, discussion, and limited practical application, but does not include development of sufficient manipulative skill to perform basic operations. This teaching level requires some hands-on manipulative skills and their accompanying actual or simulated components/equipment, but still may be taught primarily in the classroom environment.

Level 3 Level 3 requires knowledge of general principles and includes instruction by lecture, demonstration, discussion, and a high degree of practical application to develop sufficient manipulative skill to accomplish return to service (normal operation). This teaching level requires hands-on skill, as well as sufficient and appropriate instructional aides to train the students to develop manipulative skills sufficient to simulate return to service mechanical skill. At this level, the teaching aids must be similar to or be the actual items of equipment on which the student is expected to develop required skill levels. A Level 3 subject cannot be taught solely by lecture in the classroom; the appropriate training aids and hands-on experience must be used.


6


Module 1- Advanced Composites: Processing: Scope After completion of this processing module the technician is able to understand the techniques to design and fabricate composite parts. Outline for Composite Processing

Topic Teaching Level

Hours Theoretical

Hours Practical

1 Introduction to Advanced Composites 1 4 2 Manufacturing Monolithic Panel 3 6 3 Manufacturing Sandwich Panel 3 1 4 Technical Drawings 1 1 1 5 Vacuum Bagging (Manufacturing) 3 1 Total Hours 5 9

Topics and Objectives

Composite Processing Objective: Given discussion, lecture, practice, and feedback, this module is specially designed to allow technicians and engineers to manufacturer monolithic and sandwich panels. The course will give the participants the basic understanding of composite materials and build up the skills how to use and read technical drawings.

Topic: Level Introduction to Advanced Composites 1 Manufacturing Monolithic Panel 3 Manufacturing Sandwich Panel 3 Technical Drawings 1 Vacuum Bagging (Manufacturing) 3


7


Module 2 – Advanced Composites: Inspection Outline for Composite Inspection Scope After completion of this inspection module the technician is able to understand the inspection techniques, is able to perform damage assessments and make a damage rapport.


Hours Theoretical

Hours Practical

1 Introduction Inspections Techniques 1 2,5

2 Types of Damages on Composites 2 2 3 Inspection on the Manufactured panel 1 0.5 5 Tap-Testing on the manufactured

panel 3 1.5 1

6 Thermographic Inspection 1 1 7 Use of NTM combination with SRM 3 1 1,5 Total Hours 6 2,5

Inspection Techniques Objective: Given discussion, lecture, practice, and feedback, the student will list the various types of Non-Destructive Inspection (NDI) techniques and their limitations during manufacture and repair of composite structures. The student will perform tap test techniques on a monolithic and a sandwich constructed part and correctly map the damaged area as evaluated by the instructor.

Topic: Level Introduction Inspections Techniques 1 Types of Damages on Composites 2 Inspection on the Manufactured panel 1 Tap-Testing (hand and by automated tap tester) 3 Thermographic Inspection 1 Use of NTM combination with SRM 3


8


Module 3 – Advanced Composites: Repair Outline for Composite Repair Scope After completion of this repair Module the technician is able to understand the Structural Repair Manual and perform repairs on the structure and components of the aircraft according the technical documentation. Outline for Composite Manufacturing and Repair


Hours Theoretical

Hours Practical

6 Vacuum bag Procedures Repair 1/3 0,5 1,5 7 Perform Monolithic Repair Scarf 3 5,5 8 Perform Sandwich Repair Scarf 3 5,5 9 Principles of Tooling 1 0,5 Total Hours 1 12,5

Topics and Objectives

Composites Repair Objective: Given discussion, lecture, practice, and feedback, the student will develop the basic skills necessary to perform a scarfed repair on fiber reinforced structures utilizing wet-lay, pre-preg and sandwich materials, vacuum bagging techniques, and 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.

Topic: Level Vacuum bag Procedures Repair 1/3 Perform Monolithic Repair Scarf 3 Perform Sandwich Repair Scarf 3 Principles of Tooling 1

Examination

Examination Written 1 hour The written examination shall contain multiple choice questions for 1 week courses. The examination shall contain questions from each of the Topics listed in the outline for each Part. The examination will be closed book.

Examination Practical 3 hours

The student must demonstrate to the approved training provider that they can perform the basic tasks required to perform the applicable repairs.

PROCESSING, INSPECTION AND REPAIR, LEVEL 1 - acrats

Documents