Composite Awareness

The use of composite materials in aviation has been increasing rapidly over the last decade, this is due to the materials characteristics of high strength and flexibility at a low weight. It is these value’s that have seen the material developed into fuselage structure on aircraft such as the Boeing 787 and the Airbus A350. 

Composite awareness and the ability to know how damage can be recognised, assessed, or can remain hidden is vital for all who deal physically with the aircraft or deal with the structure and design of repairs and modifications where composite materials are utilised. 

Target audience 

FAA, EASA and UK CAA Part 145, Part CAMO, Part 21 or other personnel including ground handling staff working on or in an aircraft environment where the composite materials can feature. 

Course Contents

Composite Awareness

• Inspection of Carbon Fibre / Glass Fibre Reinforced Polymer Composite Components & Honeycomb Sandwich Parts
• Inspection Techniques and Tap Testing
• Composite Materials Introduction

Definition of Composite Materials

• Glass Fibre Reinforced Polymer (GFRP)
  • Structure and Formation: Woven fabric, chopped strand mat
  • Uses and Advantages: Strength, lightweight, non-conductive
• Carbon Fibre Reinforced Polymer (CFRP)
  • Formation and Uses: Unidirectional sheets, moulding, repair
  • Characteristics: Lighter, more rigid than GFRP, conductive
• Quartz Fibre Reinforced Polymer (QFRP)
  • Stability and Use: Higher temperature stability, excellent insulator, limited use due to cost

Composite Materials and Construction

• Various Applications: B787 fuselage, A350 window frames, floorboards, flap track fairings, etc.
• Structural Awareness: Floor beams, control surfaces, panels, doors, flooring, and cabin furniture

Composite Inspection Methods

• Tap Test: Recognizing damage through sound changes
• Light Inspection: Shadows and deflections to identify damage
• Non-Destructive Tests (NDT): Ultrasonic inspection devices

Tap Testing

• Procedures: General tap test for damage and repair inspection, specific methods for Boeing and Airbus
• Tooling and Preparation: Tap hammers, visual inspection, understanding structure around test areas

Tap Testing Accomplishment

• Steps: Visual inspection, tapping method, interpretation of sounds
• Structural Examination: Incremental scanning, contour following, comparison with known good areas

Boeing 787 Composite Awareness

• Damage Evaluation: Philosophy and tools available (SRM, AMM, NDTM, MEL/CDL/DDG)
• Damage Inspection Process: Following AMM for various incidents (bird strike, lightning strike, etc.)
• Quick Composite Repair (QCR) Patch: Temporary repairs
• Current Return Network (CRN): Awareness of electrical return paths in composite structures
• Evaluation and Repair: SRM guidelines for visual inspection, tap test, and non-destructive testing

Airbus A350 Composite Aircraft

• Design Concept: Four-panel fuselage construction
• Damage and Inspections: Electric Structure Network (ESN) and Metallic Bonding Network (MBN)
• Inspection by Non-Specialist NDT Personnel: Ensuring dispatchability

Specifications course taught to: 

Course designed to meet requirements working with composite technologies as specified in

• EASA Part 145.A.35(a)
• UK CAA Part 145.A.35(a)
• FAA ATA Specification 104 Level IV (4) where special maintenance tasks may require additional specific training. 

Notes 

This course includes 2 videos with audio to demonstrate practical examples. 

Duration 

Suggested duration for completion is 3 hours. 

Interval for continuation 

There is no requirement to have interval training for this course – we recommend if you have not dealt with or had training on composite materials in 24 months you should consider this course. 

Method of Delivery 

Online via Computer Based Training; for classroom or instructor lead training please contact us info@oat.aero 

Click here to download the course syllabus.