Engineering Professional Programs

Course Outline

1.0 Introduction (3.0 hrs.)

1.1 Difference between Metals and Composites (repairs to metal parts vs. repairs to composite parts)

1.2 CRC Composite Structures Awareness Video

1.3 Definitions, typical defect and damage types, and sources of damage

1.4 Potential for defects and damage in composite parts (ply collation, curing, adhesive bonding, machining, assembly, disassembly, handling, environment, impact, erosion, lightning strike, and during repair !)

1.5 Assessment of need for repair (no repair action, cosmetic or sealing repair, structural repair, repair not being economical)

1.6 Manufacturing assessment process

1.6.1 Process specifications (acceptance and rework criteria for minor defects)

1.6.2 Engineering review (repair of damage and major defects)

1.7 In-Service assessment process

1.7.1 Structural Repair Manual (SRM) (allowable damage and repair of most in-service damage incidents)

1.7.2 Original Equip. Manufacturer (OEM) (damages beyond the SRM as needed e.g. infrequently damaged parts, damages at joints)

1.8 Repair environments (Manufacturing: Composite Shop, Final Assembly, Flight Line. In-Service: Line Maintenance (at the gate), Line Maintenance (overnight), Base Maintenance, Composite Shop)

1.9 Design for Repairability

2.0 Inspection Techniques (3.0 hrs.)

2.1 Non-instrumented or low-skill inspection methods

2.2 Instrumented nondestructive test methods

2.3 Emergent nondestructive test technologies

2.4 Applicability of NDT methods vs. flaw type

2.5 Probability of Detection (POD)

2.6 In-service inspection vs. production inspection -- differences

2.7 Damage detection – methods used and rationale

2.8 Repair assessment – methods used and rationale

2.9 Test cases and examples

3.0 Basic Types of Repair and design criteria (4.0 hrs.)

3.1 Nonstructural Repairs

3.1.1 Sealing

3.1.2 Potting

3.1.3 Resin Injection

3.2 Structural Repairs

3.2.1 Bolted, external patches

3.2.2 Bolted, flush patches

3.2.3 Adhesively bonded, external patches

3.2.4 Adhesively bonded, flush patches

3.2.5 Wet lay-up, flush patches

3.2.6 Overlay repairs

3.2.7 Bolted and Bonded patches

3.4 Drivers that determine the type of repair

3.5 Repair Design considerations Criteria and Requirements

3.5.1 Allowable Damage Limits

3.5.2 External Bonded or Bolted Repairs

3.5.3 Scarf Repairs

3.5.4 Multiple Repairs

3.5.5 Aerodynamic Smoothness

3.5.6 Material Selection

3.5.7 Repair Classification

3.5.8 Repair Method Selection

3.6 SRM Repair Types

4.0 Repair Analysis and Validation (3.0 hrs.)

4.1 Shear stress distribution

4.2 Thermal influences

4.3 Stiffness match considerations

4.4 Damage Tolerance considerations

4.5 Strength and failure criteria

4.6 Adhesive joint analysis

4.7 Bolted repairs

4.8 Testing and Validation

4.8.1 Building Block approach

4.8.2 Testing

5.0 Bolted Repair Process (3.0 hrs.)

5.1 Geometric arrangement of the fastener pattern

5.2 Fastener type, material, head configuration, and shank diameter

5.3 Patch material, thickness, shape

5.4 Proper drilling procedures Hand Drilling through CFRP/Ti Issues/Concerns

5.5 Special considerations

5.6 Typical repair procedure

5.7 Examples of Bolted Repairs

5.8 Videos of Bolted Repair

6.0 Bonded Repair Process (4.5 hrs.)

6.1 Types (sandwich, external patch, scarf patch, step patch)

6.2 Removal of damage skin material

6.3 Removal of damaged core material

6.4 Typical Bonded Repair Procedures (1.5 hrs)

6.4.1 Wet Lay-up Repair Procedure

6.4.2 Pre-impregnated Repair Procedure

6.4.3 Add in other SRM Chapter 51 procedures

6.5 Examples of Bonded Repairs

6.6 Videos of Bonded Repairs

6.7 Role of pressure and heat

6.8 Effects of moisture on bonded repair

6.9 Thermal Considerations

6.10 Post-repair inspection

7.0 Bonded and Bolted repairs (1.5 hrs.)

7.1 Load sharing

7.2 Alternate load paths

7.3 Through thickness reinforcement/peel stress

7.4 Jigging and bonding advantages

8.0 Post-Repair Activities (3.0 hrs.)

8.1 Lightning and Electrostatic Protection Designs, Damage and Repair

8.1.1 Flame Spray

8.1.2 Aluminum and Copper Foil

8.1.3 Expanded oil Mesh

8.1.4 Diverter Strips

8.1.5 Picture Frames

8.1.6 Anti-Static and Conductive Coating

8.1.7 Damage at a Fastener and Surrounding Structure

8.1.8 Typical Lightning Strike Damage Scenarios

8.2 Repair Inspection and re-inspection

8.3 Analysis of Repair Deviations

9.0 Service History and Selected In-Service Issues (1.5 hrs.)

10.0 Heatcon Demo of Repair Techniques (3.0 hrs.)

Questions

If you have questions about this program, please call UW Educational Outreach Advising at 206-685-8936 in the greater Seattle area or 1-800-543-2320. If you have questions about registration for this program, please call the UW Educational Outreach Registration Department at 206-543-2310 or 1-800-543-2320.

For more information about Boeing initiatives in composites education,email Michael Richey, Boeing Learning Training and Development, Engineering & Operations Group.