AVM 260 - Aircraft Composite Repair II

• Completion of the Aircraft Airframe Mechanics Certificate   or 
• Documentation of FAA Airframe Certification or 
• Transcript showing completion of airframe curriculum from a FAA accredited AMTS

1. Recall proficient knowledge of materials, processes and equipment used in advanced composites. 
2. Recall proficient knowledge of basic design considerations for monolithic laminate panels and sandwich structures. 
3. Demonstrate common processes/procedures associated with how to fabricate and repair fiber reinforced structures utilizing wet-lay and prepreg materials.

1. Introduction to Composites
   1. Definition of Composites
   2. History of Composites
   3. Advantages/Disadvantages
   4. Conductivity
   5. Applications
   6. Product Forms
2. Human Factors
   1. Definition
   2. FAA Resources
   3. Personal Minimums
3. Reinforcement Fibers
   1. Materials
   2. Forms Terminology
   3. Unidirectional Tape
   4. Non-Woven
   5. Woven
   6. Fiber Sizing and Finishes
   7. Balance and Symmetry
4. Matrix Systems
   1. Thermoplastics
   2. Thermosets
   3. Mixing and Mix Ratios
   4. Curing of Resins
   5. Potting
5. Safety and Environment
   1. Fumes, Vapors, and Dust
   2. Skin Contact
   3. Safety Data Sheet (SDS)
   4. Personal Protective Equipment (PPE)
   5. Exothermic Reactions
   6. Waste Disposal
   7. Flammability
6. Pre-Impregnated Materials
   1. Levels
   2. Matrix Cure Temperatures
7. Adhesives
   1. Film
   2. Liquid
   3. Paste
   4. Supported/Unsupported
   5. Chemical Bonding Compared to Mechanical Bonding
   6. Surface Preparation
   7. Bond Line Control
   8. Failure Modes
   9. Foams
8. Structural Design Considerations
   1. Advantages/Disadvantages
   2. Typical Sandwich Design
   3. Solid Laminate and Monolithic Design
   4. Joint Types
   5. Wood
   6. Foam
   7. Honeycomb
9. Material Handling and Storage
   1. Flammable Storage Cabinets
   2. Refrigerators/Freezers
   3. Shipping: Handling and Temperature Requirements
   4. Storage Temperatures
   5. Thawing
   6. Kitting
   7. Out Time
   8. Storage Life (Shelf Life)
   9. Mechanical Life and Handling Life
   10. Handling of Polymeric Materials
   11. Handling of Dry Goods
   12. Recertifying of Polymeric Materials
   13. Disposal
10. Facilities and Equipment
    1. Trim Rooms
    2. Dust Extraction Levels
    3. Controlled Contamination Area (CCA)
    4. Resin Mixing Areas
    5. Vacuum Equipment
11. Vacuum Bagging
    1. Theory
    2. Materials
    3. Types of Bags
    4. Bleeding
    5. Ply Compaction Requirements
12. Heating Devices
    1. Autoclave
    2. Oven
    3. Hot Bonders
    4. Heat Blankets
    5. Hot Air Blowers
    6. Heat Lamps
    7. Infrared
    8. Heat Guns
13. Source Documents
    1. ATA iSpec 2200/S1000D
    2. Original Equipment Manufacturer (OEM)
    3. Engineering Orders
    4. SAE AMS-CACRC ARPs
    5. Regulatory Documents
    6. Drawing Systems
    7. Process Specifications
    8. Material Specifications
    9. Data Sheets
    10. Vendor Manuals
14. Protective Coatings and Finishes
    1. Sealants
    2. Primers
    3. Finishes
    4. Conductive
15. Repair Selection Considerations
    1. Repair Design
    2. Taper Sanding and Step Sanding
    3. Part Drying Requirements
    4. Ply Stack Up
    5. Repair Area Limitations
16. Inspection Techniques 
    1. Types of Damage
    2. Mapping of Damage
    3. Pre- and Post-Repair Inspection
    4. Visual
    5. Tap Testing 
    6. Ultrasonic (Pulse-Echo, TTU, Bondtesters)
    7. Thermography
    8. X-Ray
    9. Comparison of NDI Techniques for Metal and Composite Structure
17. Machining of Composites
    1. Sanding
    2. Drilling
    3. Tools and Equipment
    4. Trimming
    5. Core Machining