U79 Composite structures Repair process 1

Topic outline

• Composite Structures Repair Process 45h
  

  Composite Structures Repair Process 45h

  This unit of learning is part of the following learning pathways:

  • Curriculum on Composite Materials - Composite repair technician

  
  

  • Announcements Forum
  • Readings:
    

  • Advanced Composite Materials File
  • Composite Repair File
  • Guidelines for the Development of a Critical Composite Maintenance and Repair Issues Awareness Course File
  • Essentials of Advanced composite repair File
  • Book: ENGINEERING COMPOSITE MATERIALS File
  • The challenge of composite fuselage repair File
  • Repair of Composite Laminates File
  • Meeting the challenge of wind turbine Repair File
  • Repair of FRP File
  • Video: Inside the Airbus A350 XWB File
  • Video: Aerospace Composite Repair Concepts by AGFM File
  • Animation: Automatic Fiber Placement Airplane Spar Manufacture File
  • Video: NASA Marshall Curved Panel Layup File
  • youtube: Composite repair link URL
  • useful links youtub File
  • Video: How To Do Perfect Vacuum Resin Infusion of a Carbon Fibre (Fiber) Part - Basic Tutorial File
  • References,books, links, video,.. on Composites URL
• Learning outcome:
  

  Learning outcome:

  Select and execute on advanced composite structural repairs using required tools and machines and propose the optimal repair solution.

  Competences

  • To distinguish between the different ways of handling the composite material and doing it according to the safety requirements
    
  • To select and execute the right repairs method for failures eliminating according to technical manuals, and design organisation technical instruction.
    
  • To evaluate personal competence and skill limits, and where to receive assistance during maintenance.
    

  Knowledge

  • To know the advanced composite materials repair (types, methods, processes…)
    
  • To know the machines and tools for composite repairing workshop.
    
  • 3. To know about the basic relevant chemistry for composite structures.
    
  • To know the basic electrical and measurement instruments for composite structures.
    
  • To know the technical terminology
    

  Skills

  • To handle and store different types of composite materials to standards.
    
  • To apply hands skills (sensory and physical demands).
    
  • To perform all composite structures repair works (patch repair, bonded and bolted repair, scarf and step sanded ...)
    
  • To use appropriate hand tools, instruments, and machines during repairing processes (drilling, cutting, curing equipment….)
    
• Syllabus:
  

  Syllabus:

  Title	Composite structures Repair process
  Topics	Classroom hours	Laboratory and practical hours
  1. Introduction to composite structures repair	1	-
  2. Composite repair process 2.1. Adhesives 2.2. Wet lay-up General 2.3. Prepreg General	2.5	10
  3. Handling and storing materials	1	1
  4. Equipment and facilities	1	1.5
  5. Vacuum bagging	1	1
  6. Heating devices	1	1
  7. Machining of composite materials	1	3.5
  Unit assessment	1
  Duration – hours	8.5	18.5
  Total unit duration	28 hrs. = 4 days
  Main hands-on content	Monolithic structural repair, Build up monolithic structure and wet lay-up, sandwich construction structural repair. Perform sandwich panel repair with core replacement and perform edge matrix closing. Vacuum bagging different shapes procedure. Environment condition, tools use, hot bonder, basic heating devices, and facilities.
• References ,textbook, and manuals:
  

  References ,textbook, and manuals:

  1. Structural composites: Advanced composites in aviation, 2013, book by Avotek Information Resources, LLC. USA, www.avotek.com
  2. Essentials of advanced composite fabrication & repair, by ABARIS training staff, 291 pages, published 2009 by Aviation Supplies & Academics ASA, Inc. www.asa2fly.com 
  3. AviationMaintenanceTechnicianHandbook –Airframe, volume 1, chapter 07,FAA – 2012.
  4. ARP5143: Vacuum Bagging of Thermosetting Composite Repairs
  5. ARP5256: Mixing Resins, Adhesives and Potting Compounds
  6. ARP5319: Impregnation of Dry Fabric and Ply Lay-Up
  7. ARP5701: Lay-Up of Pre-Preg Composite Materials
  8. Structural Repair Manuals SRM
  9. The Boeing Company DVDs, Advanced composite repair.
  10. ARP 5089 Composite Repair NDT/NDI Handbook
  11. ARP 5144 Heat Application for Thermosetting Resin Curing
  12. AMS 2980A Technicial Specification: Carbon Fiber Fabric and Epoxy Resin Wet Lay-Up Repair Material
  13. AMS 3970 Carbon Fiber Fabric Repair Prepreg.

  
  

  
  
• Unit Assessment
  

  Unit Assessment

  Assessment sample of Unit-4:

  https://docs.google.com/forms/d/1yIQPkzzlme4BzK5rxucu6LJujpiaeKbwJpU6Vm-yAuA/edit?usp=sharing