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DMSC59
Composite Repair - Stage 2

This progression course addresses more advanced composite repair techniques and issues in respect to more extensive and complex structural repairs. Repairs are conducted on solid laminates and sandwich panels using advanced repair tooling, step sanding routers and jigs, standard repair patches and more extensive heat mat/lamp curing of materials. Emphasis is on refinement of the repair techniques and methodologies and working with on-tool extraction and dust containment/control.

Typical Attendees
This course is suitable for anyone involved with repairs to composite materials, including repair technicians, supervisors, engineers, designers, researchers and managers.

Pre-requisite
Attendees must have previously completed the course DMSC58, Composite Repair - Stage 1

Structure
25% theory, 75% practical, 12 delegates maximum
Special Notice
As training providers it is our responsibility to ensure training is up to date and taught to the highest standard. To assist with this we have aligned our repair courses with the requirements of the SAE’s AIR4938 standard, 'Composite and bonded structure technician/specialist training document'.  This standard was produced by the worldwide 'Commercial Aircraft Composite Repair Committee' (CACRC) and defines the foundation content and structure for composite repair training that is applicable to all industry sectors.
Our stage 1 and 2 composite repair courses already covered cross sector repair techniques with a full range of materials, processes, tools and techniques and were already 90% in line with the AIR4938 standard.  As all our courses are already in line with the UK’s National Occupational Standards for composites and fully documented to the UK’s Qualifications and Curriculum Authority requirements, it was a relatively easy task to cross reference to the AIR4938 standard and add 10% more technical content to our repair courses.  The end result is that all our customers benefit from the work we do for aerospace.



Course Dates
16-20 October 2023
Price per Delegate
£ 2,220.00  (£ 1,850.00 plus £370 VAT)


Composite repair 2 course content
DMSC59 Session 1
09:00 - 11:00
Session 2
11:15 - 13:15
Session 3
13:45 - 15:45
Session 4
16:00 - 18:00
Monday Introduction

Equipment issue

Theory & Discussion

Advanced composite repairs
Co-bonding & secondary bonding structural repairs
Structural repair design and processes
Theory, Demo & Practical
Refresh of composite,materials & processes
On tool extraction, dust containment and capture strategies
Advanced dust control & dust free material removal
Theory, Demo & Practical
Pre-preg material life,
storing & defrosting
Ply orientation standards
notation & Variations
Nesting & kitting
Spring back, distortion
Balanced & un-balanced
orientated plies
Theory
Adhesion & release
Release agents
Adhesive Bonding
Peel plies

Demo & Practical
Production of a pre-preg panel to production documentation
Tuesday Theory, Demo & Practical
Sandwich panels & multistage processing
Core materials & tracer films
Preparation & application of honeycomb core
Second stage curing of pre-preg panel
Theory, Demo & Practical
Human Factors
Damage inspection & evaluation
Damage reporting
Structural repair design considerations
Theory, Demo & Practical
NDT inspection overview & techniques
Setting up and using NDT equipment
NDT inspection of undamaged parts
Practical
NDT Inspection of
damaged parts
Production of inspection
report
Design of standard step
sanded repair scheme
Wednesday Theory, Demo & Practical
Conducting laminate discovery activities using ‘Step Sanding Tool Kit’
Fibre, fabric, orientation & thickness records
Theory, Demo & Practical
Prepare step sanded repair surface for type B wet lay-
up part using Step Sanding Tool Kit
Theory, Demo & Practical
Fibre to resin ratios
Ply thickness calculations and variation
De-bulk factors
Bleed variation
Calculation of bleed plies
Thursday Theory, Demo & Practical
Prepare and apply materials to the repair surface
Wet lay-up laminate repair using double membrane vacuum bag with bleeder plies
Theory, Demo & Practical
Tg point of parts
Using infra-red lamps & temporary ovens for curing
Positioning of thermocouples
Recording of cure profile
Theory, Demo & Practical
Producing and using standard repair patches
Pressure de-bulk of repair patch
Practical
Prepare step sanded repair surface for type A pre-preg part using Step Sanding Tool Kit
Friday Theory, Demo & Practical
Selection and sequence of vacuum bagging consumables

Theory, Demo & Practical
Apply standard repair patch & vacuum bag
Theory, Demo & Practical
Using hot bonders &
heat mats, for on part curing
Positioning of thermocouples
Determination & monitoring of cure profile
Discussion & Practical
Inspection, evaluation and review of repairs completed
Completion of repair reports
Destructive testing and inspection of repairs completed
Reinstate Workshop

Written test

Equipment return

Summary / Feedback
DMSC59 Composites Repair Stage 2.pdf
File Size: 517 kb
File Type: pdf
Download File

Composite Repair – Stage 2  course details:

This is aimed at anyone involved with repairs to composite materials, including repair technicians, supervisors, engineers, designers, researchers and managers.

Attendees must have previously completed the course DMSC58, Composite Repair - Stage 1. At the start of the stage 2 course we begin with a 30 minute recap of what was covered on the Composites Repair – Stage 1 and then cover approximately 30 hours of practical and 10 hours of new theory and technical demonstrations.
composites repair course
using a woodpecker for composites inspection
You will produce one component yourself in line with the SAE’s AIR4938 standard, 'Composite and bonded structure technician/specialist training document'.  This standard was produced by the worldwide 'Commercial Aircraft Composite Repair Committee' (CACRC). Your second component will be supplied by us to ensure that everyone attending the course has consistent components to work with.
 
You will begin by inspecting your composite components using a range of Non Destructive Testing (NDT) techniques. These include tap test using a wood pecker, moisture meter and ultrasonic inspection.
 
The composite parts are inspected before and after applying controlled damage.  This is designed to mimic the real life damage a component might incur during normal service. You will be shown what to expect to find when inspecting a composite component and how the various types of damage are categorised.
 
Working with the Step Sander Repair Kit, you will complete discovery exercises (investigating damage and ply lay-up) and then learn how to effectively remove damaged composite material prior to repair.
 
The Step Sander Repair Kit has been developed to improve the quality and consistency of the repair surface by working with jigs, offering a high level of accuracy (0.05mm in depth). As you become more familiar with the equipment, your speed will increase. It will allow you to produce a higher quality step sanded repair, in a shorter period of time, than with alternative tools.
 
We will cover laminate calculations to give accurate resin to fibre ratios. This will ensure material consistency through the parent material and the repaired area, maintaining material thickness and fibre content, essential in good quality repair.

Various curing methods are used through the week, demonstrating their effectiveness and advantages in various situations. Surface and envelope vacuum bagging techniques are used with a range of curing methods. These curing methods include using a hot bonder with heat blankets and infrared lamps, autoclave and oven.
step sander repair
The repaired components are checked using the NDT equipment and then physically tested to ensure the repairs have been completed effectively. As a group, conclusions are discussed highlighting improvements that could be made, and areas of the repair that have gone well. Feedback is given throughout the course and discussion is encouraged.
UPCOMING COURSES


27th Feb - 3rd March 2023 - DMSC61

6th-10th March 2023 - DMSC58

27th - 31st March 2023 - DMSC53

17th-21st April 2023 - DMSC54

15th -19th May 2023 - DMSC51

click here for composite training  information

dark matter composites ltd
Tel/Fax:  +44 (0)1582 791001
email: 
info@darkmattercomposites.co.uk
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