SAE AIR 4938B-2017 Composite and Bonded Structure Technician Specialist Training Document.pdf

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1、 _ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising ther

2、efrom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2017 SAE International All rights reserved. No part of this

3、publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-49

4、70 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/standards.sae.org/AIR4938B AEROSPACE INFORMATION REPORT AIR4938 REV. B Issued 1996-09 Revised 2017-06 Supersedin

5、g AIR4938A Composite and Bonded Structure Technician/Specialist Training Document RATIONALE This document is intended to outline the minimum training requirements deemed necessary for composite and/or metalbond technicians/specialists. TABLE OF CONTENTS 1. SCOPE 2 2. APPLICABLE DOCUMENTS 2 2.1 SAE P

6、ublications . 2 2.2 FAA and EASA Publications . 2 3. STUDENT PREREQUISITES . 3 4. EXAMINATIONS . 4 5. TEACHING LEVELS . 4 6. PART 1 - General Composite Structural Bonded Repair Curriculum . 5 6.1 Scope 5 6.2 Topics and Objectives . 6 7. PART 2 - Commercial Aircraft Composite Structure Bonded Repair

7、Curriculum . 17 7.1 Scope 17 7.2 Topics and Objectives . 17 8. PART 3 - Commercial Aircraft Composite Structure Bolted Repair Curriculum . 27 9. PART 4 - Commercial Aircraft Structure Metalbond Repair Curriculum . 28 9.1 Scope 28 9.2 Topics and Objectives . 29 10. NOTES 36 10.1 Revision Indicator 36

8、 SAE INTERNATIONAL AIR4938B Page 2 of 36 1. SCOPE This is a general curriculum that has been developed to identify the minimum knowledge and skill requirements of a composite and/or metal bond repair technician/specialist. This revision changes the document from an all-inclusive curriculum into a mo

9、dular set of curricula. Teaching levels have been assigned to the curriculum to define the knowledge, skills, and abilities graduates will need to make repairs to composite or metalbond structure. Minimum hours of instruction have been provided to ensure adequate coverage of all subject matter inclu

10、ding lecture and laboratory. These minimums may be exceeded and may include an increase in the total number of training hours and/or increases in the teaching levels. Each curriculum is a subpart of this document. Part 1 is the General Composite Structure Bonded Repair curriculum, independent of the

11、 application. Part 2 is the Commercial Aircraft Composite Structure Bonded Repair curriculum. Part 3 is the Commercial Aircraft Composite Structure Bolted Repair curriculum. (Under Development) Part 4 is the Commercial Aircraft Structure Metalbond Repair curriculum. This document contains ATA104 lev

12、el IV curricula. 2. APPLICABLE DOCUMENTS The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications shall apply. The applicable issue of other publications shall be the issue in effect on the date of the purchase order. In the event o

13、f conflict between the text of this document and references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 2.1 SAE Publications Available from SAE International, 40

14、0 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org. AIR4844 Composites and Metal Bonding Glossary AIR5719 Teaching Points for an Awareness Class on “Critical Issues in Composite Maintenance and Repair“ AIR6291 Guid

15、elines for Repair Process Evaluation of Aluminum Bonded Structure ARP6262 Basic Composite Repair Technician Certification Standard 2.2 FAA and EASA Publications Available from Federal Aviation Administration, 800 Independence Avenue, SW, Washington, DC 20591, Tel: 866-835-5322, www.faa.gov and from

16、European Aviation Safety Agency, Ottoplatz, 1, D-50679 Cologne, Germany, Tel: +49 221 8999 000, www.easa.europa.eu. Title 14 Code of Federal Regulations, Part 147 EASA AMC 20-29 Composite Aircraft Structure FAA AC 20-107B Composite Aircraft Structure FAA AC 65-33 Development of Training/Qualificatio

17、n Programs for Composite Maintenance Technicians FAA AC 43-214 Repairs and Alterations to Composite and Bonded Aircraft Structure SAE INTERNATIONAL AIR4938B Page 3 of 36 3. STUDENT PREREQUISITES Part 1 - General Composite Structure Bonded Repair Student success will be in part based on the knowledge

18、 and skills possessed prior to course enrollment: Basic technical mathematics Reading comprehension Part 2 - Commercial Aircraft Composite Structure Bonded Repair and Part 4 - Commercial Aircraft Structure Metalbond Repair Student success will be in part based on the knowledge and skills possessed p

19、rior to course enrollment: Successful completion of Part 1 - General Composite Structure Bonded Repair Course or demonstrated mastery (bypass exam of Part 1) AND including the following disciplines: o Basic technical mathematics o Reading comprehension o Fundamentals of engineering and technical dra

20、wings o General shop and hand tool usage o Use of precision measurement tools o Basic physics o Basic chemistry o Aircraft health and safety regulatory awareness (need for PPE (Personal Protection Equipment) Part 3 - Commercial Aircraft Composite Structure Bolted Repair Student success will be in pa

21、rt based on the knowledge and skills possessed prior to course enrollment: Basic aircraft sheet metal skills o Knowledge of heat treatment o Proper forming and bending of aluminum alloys and titanium alloys Basic technical mathematics Reading comprehension Fundamentals of engineering and technical d

22、rawings General shop and hand tool usage Use of precision measurement tools Basic physics Basic chemistry Aircraft health and safety regulatory awareness (need for PPE (Personal Protection Equipment) SAE INTERNATIONAL AIR4938B Page 4 of 36 Basic technical mathematics, physics, and chemistry are cons

23、idered to be high school level courses. Evaluation of prior education can be accomplished by examination of school transcripts, by review of the training received through approved training providers, or by a pre-test. 4. EXAMINATIONS Training Providers will be required to monitor student performance

24、 throughout the program. Students will be administered a written exam following lecture classes and practical assessments in laboratory classes. The minimum passing grade for all written exams shall be 75% and all grades shall be recorded in the individuals training records. It is recommended to use

25、 a checklist to evaluate the practical assessment. The examination and assessment will cover the principles of the applicable curriculum and consist of: i. Written examination: The written examination shall contain a minimum of 50 multiple choice questions for 2 week courses and a minimum of 25 mult

26、iple choice questions for 1 week courses. The examination shall contain a minimum of 3 questions from each of the Topics listed in the outline for each Part. The examination will be closed book. ii. Practical assessment: The student must demonstrate to the approved training provider that they can pe

27、rform the basic tasks required to perform the applicable repairs. iii. Reexamination: If the student fails the written examination, they may request to retake a written examination. The written examination must not contain more than 20% of the questions that were on the failed examination. 5. TEACHI

28、NG LEVELS The following definitions of minimum teaching levels are derived from Title 14 Code of Federal Regulations, Part 147 and may be exceeded. a. Level 1 Level 1 requires knowledge of general principles and includes instruction by lecture, demonstration, and discussion, but does not include pra

29、ctical application or development of manipulative skill. This teaching level generally refers to classroom discussion and does not require practical application. Teaching aids or instructional equipment may include charts, books, diagrams, or other visual teaching aids. If a training organization ch

30、ooses to teach Level 1 courses incorporating actual components, the components do not have to be operational. b. Level 2 Level 2 requires knowledge of general principles and includes instruction by lecture, demonstration, discussion, and limited practical application, but does not include developmen

31、t of sufficient manipulative skill to perform basic operations. This teaching level requires some hands-on manipulative skills and their accompanying actual or simulated components/equipment, but still may be taught primarily in the classroom environment. c. Level 3 Level 3 requires knowledge of gen

32、eral principles and includes instruction by lecture, demonstration, discussion, and a high degree of practical application to develop sufficient manipulative skill to accomplish return to service (normal operation). This teaching level requires hands-on skill, as well as sufficient and appropriate i

33、nstructional aides to train the students to develop manipulative skills sufficient to simulate return to service mechanical skill. At this level, the teaching aids must be similar to or be the actual items of equipment on which the student is expected to develop required skill levels. A Level 3 subj

34、ect cannot be taught solely by lecture in the classroom; the appropriate training aids and hands-on experience must be used. SAE INTERNATIONAL AIR4938B Page 5 of 36 6. PART 1 - General Composite Structural Bonded Repair Curriculum 6.1 Scope Persons who successfully complete this basic training progr

35、am are considered to be able to perform bonded composite repairs to composite structures in compliance with the manufacturers repair documentation or other acceptable repair data. This curriculum should be considered a prerequisite for more advanced training. Outline for Initial Composite Certificat

36、ion Topic Teaching Level Classroom Hours Lab Hours 1 Introduction to Composites 1 1.5 2 Human Factors 1 1 3 Reinforcement Fibers 1 1 4 Matrix Systems 1 1 5 Safety and Environment 1 1 6 Pre-Impregnated Materials 1 1 7 Adhesives 1 1 8 Structural Design Considerations 1 1 9 Material Handling and Storag

37、e 1 1.5 10 Facilities and Equipment 1 2 11 Vacuum Bagging 1 1.5 12 Heating Devices 1 1.5 13 Source Documents 1 2.5 14 Protective Coatings and Finishes 1 1 15 Repair Selection Considerations 1 1.5 16 Inspection Techniques 2 1 17 Machining of Composites 2 2 18 Hands-on Exercises 3 50 19 Written Test 2

38、 20 Practical Assessment Checklist Total Hours 25 50 Course Length (Minimum) 75 hours SAE INTERNATIONAL AIR4938B Page 6 of 36 6.2 Topics and Objectives 1. Introduction to Composites Level 1 1.5 hour Objective: Given discussion, lecture, and feedback, the student will describe the basics of composite

39、 materials technology and their applications related to aerospace, marine, automotive, and civil, energy and consumer products. In addition, the student will discuss the merits and general failure modes of composite materials to the extent that a material properties comparison can be established bet

40、ween metallic and composite structures as evaluated by the instructor. A. Definition of Composites B. History of Composites C. Advantages/Disadvantages D. Conductivity E. Applications F. Product Forms 2. Human Factors Level 1 1 hour Objective: Given discussion, lecture, and feedback, the student wil

41、l explain the concept of “Human Factors” to the extent that a brief explanation of the “personal minimums” and a minimum of two factors that are likely causes of accidents and incidents be given. A. Definition B. FAA/EASA Resources C. Personal Minimums 3. Reinforcement Fibers Level 1 1 hour Objectiv

42、e: Given discussion, lecture, and feedback, the student will visually recognize common composite fibers, list the properties, and associate the terms related to the fabric manufacturing process. In addition, the student will describe the fiber placement levels used during manufacturing and repairing

43、 of composite structures to the extent that the fabric weaves, warp direction, and part warp clock can be referenced as evaluated by the instructor. A. Materials i. Fiberglass ii. Aramid iii. Carbon iv. Ceramics v. Hybrids SAE INTERNATIONAL AIR4938B Page 7 of 36 B. Forms Terminology i. Filament ii.

44、Strand iii. Tow iv. Yarn C. Unidirectional Tape D. Non-Woven i. Mat a. Chopped b. Continuous Filament ii. Stitched E. Woven i. Plain ii. Twill iii. Harness Satin iv. Biaxial v. Triaxial F. Fiber Sizing and Finishes G. Balance and Symmetry i. Warp Clock ii. Tracers iii. Ply Orientation iv. Nesting 4.

45、 Matrix Systems Level 1 1 hour Objective: Given discussion, lecture, and feedback, the student will state the difference between thermoplastic and thermosetting matrix materials, describe the roles and limitations of matrix materials, describe the storage and handling requirements, determine and cal

46、culate various mix ratios, describe the cure cycle, and describe the matrix cross-linking terminologies. In addition, the student will describe and select appropriate filler materials to the extent that a given resin system mix ratio with filler materials can be calculated using an established ratio

47、 as evaluated by the instructor. SAE INTERNATIONAL AIR4938B Page 8 of 36 A. Thermoplastics B. Thermosets C. Mixing and Mix Ratios i. Weight ii. Volume iii. Mixing Process D. Curing of Resins i. A, B, and C Stages ii. Flow versus Gelation iii. Glass Transition iv. Viscosity v. Curing Reactions E. Pot

48、ting i. Fillers ii. Micro-Balloons iii. Chopped Fiber iv. Fumed Silica 5. Safety and Environment Level 1 1 hour Objective: Given discussion, lecture, practice, and feedback, the student will state the personal hazards working with polymeric materials and describe the four common paths of entry. The

49、student will evaluate a typical Safety Data Sheet (SDS) and demonstrate they can select proper personal protection equipment (PPE) and describe waste disposal procedures as evaluated by the instructor. A. Fumes, Vapors, and Dust B. Skin Contact C. Safety Data Sheet (SDS) D. Personal Protective Equipment (PPE) E. Exothermic Reactions F. Waste Disposal G. Flammability SAE INTERNATIONAL AIR4938B Page 9 of 3