The goal for this workshop was to achieve consensus for composites maintenance and repair.
Objective: The objective of the workshop was to provide terminal course objectives (TCOs) for a 5-day survey course and laboratory workshop regarding composites repair with the following vision:
Students at the end of the course will have a common foundation of understanding of the maintenance, repair and handling of composite materials, exposing them to simple repairs and preparing them for more advanced training. Students at the end of the course will be able to:
- Understand the basic art of composite maintenance and repair, including the design issues associated with airframe structure.
- Understand the roles, responsibilities and relationship of technician, inspector and engineer in the composite repair process.
- Produce composite laminate, damage it under controlled conditions, and make proper repair procedures.
- Identify differences in critical damage types, inspection methods and repair procedures for composite & metal structures.
- Perform damage inspection on a composite part produced by student
- Assess effectiveness of the student-repaired composite part.
- Describe the materials, processes and key quality controls used for bonded and bolted repair methods.
- Distinguish between proper procedures for repairs that are and are not included in source documentation.
Overview: More than 60 individuals, selected for invitation because of their extensive backgrounds in composites repair, attended the workshop. They represented academia, industry (OEMs, airlines and MROs), the FAA and U.S. Air Force, and professional training organizations, originating from a wide geographic spectrum. The workshop was sponsored by the FAA, AMTAS, and the Boeing Company. The workshop was sub-divided into three smaller work groups which represented Engineers, Technicians, and Inspectors. Each of the three work groups was facilitated by Boeing professionals, who provided critical expertise to the workshop process.
Outcomes: Each of the three work groups provided vital information for the successful development of the curriculum: 1) draft Terminal Course Objectives (TCOs) and 2) a list of 130 to 150 essential skills. Equally important, the broad representation of personnel in the workshop provided a sense of ownership and responsibility to a broad spectrum of the industry for the resulting curriculum development. Educational resources were identified for potential incorporation into the class, and included, for example, videos on composites repair from the U.S. Air Force, Alteon and Heatcon, with the following video titles:
- Prevention and Reporting of Damage
- Basics of Composites
- Mishap and Post-Crash Handling
- Operation of Hot Bonder
Next Steps: The draft TCOs are being categorized and tested through the AMTAS advisory group for completeness and consistency, and this report will be made available to the workshop attendees for comment. Team coordination meetings within Edmonds and Everett Community Colleges are being initiated. TCOs will be finalized in the first quarter 2005. A progress update will be delivered to the Commercial Aircraft Composite Repair Committee (CACRC) in May 2005, to be held in Bremen, Germany, where it is expected that additional European input will further refine the development.
The initial course materials will be developed and the first class will be conducted at Edmonds Community College under an FAA grant. A final report for the project and a review of the curriculum will be delivered to FAA and industry personnel in Chicago for final comment and to support further training development directions. Coinciding with these activities, a review of major training resources that would either enhance the curriculum development or provide directions for students seeking more advanced training will be conducted. A database is being established which will provide a guide to aerospace regulations, information sheets, policies, and advisory circulars regarding the maintenance and repair of composite materials on commercial aircraft.