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DMSC58 Composite Repair - Stage 1



This course provides comprehensive training, understanding and application of a full range of repair techniques to composite mouldings, from cosmetic through to structural repairs. Emphasis is on understanding failure modes, recognising materials and production process, and correct use of tools, abrasives and dust extraction in order to apply effective repairs.


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

Structure

30% theory, 70% practical, 8 delegates maximum, no experience required.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 Nov 2020
23-27 Nov 2020
12-16 Apr 2021
8-12 Nov 2021
Price per Delegate
£ 1,740.00    (£ 1,450.00 plus £290.00 VAT)


Composite repair 1 course content
DMSC58 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
Health & Safety

Theory

Introduction to composites theory, materials & processes
Theory & Discussion
Damage detection
Repair of composites overview

Theory, Discussion & Demo
Dust generation, risk assessment & capture
Theory & Discussion
Material removal tools & abrasives

Theory, Demo & Practical
Non-structural cosmetic & temporary repairs
Theory, Demo & Practical
Wet lay-up laminating
Matrix preparation, application, curing & exotherm control
Application of cosmetic gel coat repairs
Application of temporary repairs
Tuesday Demo & Practical
Sanding and polishing of cosmetic gel coat repairs
Re-filling of cosmetic gel coat repairs
Assessment of temporary repairs
Theory, Practical & Discussion
Failure modes & predicting failure
Impacts & assessment of damage

Theory
Minor and major structural laminate repairs
Demo & Practical
Removal of temporary repair
Preparation of tapered/scarf surfaces
Preparation of single & double sided repair surfaces
Theory, Demo & Practical
Temporary backing structures
Process & material matching & preparation
Wednesday Theory, Demo & Practical
Wet lay-up laminating of single & double sided, minor & major structural repairs
Theory & Demo
Structural sandwich panel repairs
Core preparation & splicing

Practical
Preparation of type A, B & C structural sandwich panel repair surfaces & materials for infused & pre-preg panels
Theory & Demo
Vacuum bagging & materials
Caul plates

Demo & Practical
Wet lay-up & vacuum bagging of type A/B structural repairs
Thursday Demo & Practical
Recognition & orientation of pre-preg materials
Laminating of type B/C structural pre-preg sandwich panel repairs
Theory & Practical
Curing pre-preg repairs
Temperature & pressure profiles
Tg points
Use of hot bonder for curing pre-preg repairs
Discussion & Practical
Inspection, evaluation and review of repairs completed
Destructive testing of repairs
Assessed Practical
Assessment of damage
Complete a repair strategy
Preparation of repairs
Friday Assessed Practical
Completion of repairs to a range of test piece components, including step sanded surface preparation, identification of laminate plies, preparation & application of orientated materials, vacuum bagging, curing, surface finishing, blending and polishing
Reinstate Workshop
Written test
Equipment return
Summary / Feedback
dmsc58 composite repair stage 1.pdf
File Size: 1061 kb
File Type: pdf
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Composites repair 1 course content:
This course will give you the knowledge and skills you need to get you started with composite repairs. It is aimed at anyone involved with repairs to composite materials, including repair technicians, supervisors, engineers, designers, researchers and managers. No previous experience is required
 
The course will cover approximately 28 hours of practical throughout the week and 12 hours theory and practical demonstrations.
making composites repair blanks
 
All the components for repair will be supplied to you, ready made as this ensures consistency of the components, maximising your time repairing various forms and working with a selection of materials.
 
You will damage these parts and then complete 8 composite repairs, ranging from cosmetic through to structural repairs where damage has gone through the component.  These include working with gel coat repairs for a perfect finish, sandwich panel repairs, pre preg, temporary and then permanent repairs.

We will look at the reasons why composite components fail, for example; delamination, disbonds and fibre breakage and the types of damage including impact and puncture damage. You will cover material identification, the type of fabric and fibre being used, identifying the production method and working out how best to go about the repair.

Before you begin the assessment task, all the training tasks completed will be reviewed and discussed in the group. Destructive testing will be carried out on the structural repairs to inspect their integrity.
Composites repair training
repair blank layup

 
Each task is designed to convey a new technical detail, building on from the previous task. Feedback is given from our tutors throughout the course and discussion is encouraged. At the end of the training course, conclusions are discussed as a group which will show which techniques work best.
UPCOMING COURSES

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