phase 2 - Advanced Composite Structures Fabrication and Damage Repair


Class Dates

23 February 2009 18 May 2009 20 July 2009
21 September 2009 9 November 2009  

This class has a pre-requisite, the Fabrication and Damage Repair - Phase 1 course, or equivalent practical and theoretical training and experience.

Most of this class is devoted to handson repair practice, and little time is spent in the classroom. Students will be given a variety of damaged parts and structures to perform repairs.

Determining the extent of the damage, evaluating the ply orientation and layup of an unknown structure, and removing internal contamina-tion (such as water, fuel, etc.) are fundamental parts of this course. Preparation of both composite and aluminum surfaces for bonding is discussed at length.

Determining the best repair method and actually carrying out the complete repair follow classroom discussions.

Three different parts will be repaired by each team of participants, with different materials and challenges within each repair scenario.

Programming “hot-bonders” to carry out these repairs is an integral part of this course as well. Our facility has many types of HEATCON® Composite Systems “hot-bonders” to work with. The advantages of each will become familiar to the students as they have the opportunity to work with several of them individually throughout the week. Vacuum bagging of complex shapes is another challenge presented to students.


This course is designed as a follow-up to the Fabrication and Damage Repair
Phase 1. The two courses are best taken in succession, but can be taken
separately if necessary. The class assumes the students have the knowledge
gained in the first course, and concentrates on more difficult and realistic
repair situations. It is designed for those who will actually be performing or
inspecting repairs.


Key Lecture Elements

Damage Assessment and Classification

Paint RemovalRepair Instructions

Determining Unknown Lay-ups

Drying Moisture-Contaminated Honeycomb Cores

Bagging Techniques for On- and Off- Aircraft Repairs

Programming and Use of Composite Repair Sets

Dealing with Contaminated Structures

Handling Heat Blanket and Thermocouple Problems

Repair Design Considerations