Standard

Posted.10/16/03

AST 109 – Composites and Bonded Structures

Course Description:

Emphasizes the development of knowledge and skills necessary to fabricate and repair bonded and composite aircraft parts.  Topics include: safety, terms, classification and characteristics, inspection techniques, and application

 

Competency Areas:

Hours:

 

 

 

Safety

Class

4

Terms

D. Lab

2

Classifications and Characteristics

P. Lab/O.B.I.

3

Inspection Techniques

Credit

6

Application

 

 
 

Prerequisite:

AST 104

Corequisite:

     

 

Course Guide

 

Competency

After completing this section, the student will:

Hours

Class

D. Lab

P. Lab/

O.B.I.

SAFETY

4

0

2

Fire hazards

Follow manufacturer’s recommendations for prevention of fire hazards.

 

 

 

Inhalation hazards

Follow manufacturer’s recommendations to prevent inhalation hazards.

 

 

 

Eye and skin irritants

Wear protective clothing and safety equipment during repair procedures.

 

 

 

 

Follow manufacturer’s directions to prevent and treat eye and skin irritation.

 

 

 

Environmental hazards

Read and follow MSDS in handling all environmentally hazardous materials.

 

 

 

 

Discuss Hazardous Duty Standards Act compliance.

 

 

 

TERMS

6

0

0

Identification

Identify materials commonly used in aircraft composite and bonded structures.

 

 

 

CLASSIFICATIONS AND CHARACTERISTICS

10

2

8

Fiber glass

Identify specific types of fiberglass.

 

 

 

 

Fabricate basic fiberglass panels.

 

 

 

 

Repair damaged fiberglass panels.

 

 

 

Honeycomb

Identify specific types of honeycomb.

 

 

 

 

Assess and classify damaged honeycomb structures.

 

 

 

 

Demonstrate proper repair procedures for various honeycomb structures

 

 

 

Composites

Identify specific types of composites.

 

 

 

 

Fabricate basic composite structures.

 

 

 

 

Assess and classify damaged composite structures.

 

 

 

 

Demonstrate proper repair procedures for various composite bonded materials.

 

 

 

INSPECTION TECHNIQUES

10

10

5

Inspection

Inspect aircraft for structural failures or malfunctions and classify damage

 

 

 

 

Inspect damaged area using approved techniques

 

 

 

Surface preparation

Clean repair surface

 

 

 

 

Remove the damaged area using approved techniques

 

 

 

 

Prepare and apply adhesives

 

 

 

APPLICATION

10

8

15

Special tools

Use special tools for common repairs to include a controller unit, vacuum system, heating blankets, and thermocouple assemblies.

 

 

 

Repair manuals

Research repair manuals for repair procedures.

 

 

 

Types of repairs

Perform ply-to-core delamination repairs.

 

 

 

 

Perform ply-to-ply disbond repairs

 

 

 

 

Perform minor surface damage repairs with structural adhesives.

 

 

 

 

Remove or replace complete structures.

 

 

 

 

Apply aerodynamic smoothing compounds for repair.

 

 

 

 

Cure repairs using approved techniques.

 

 

 
Suggested Resources

 

Books:

 

Busnell, A.R., & Kelly, A. (Eds.).  (1985).  Composite materials:  A directory of European research.  Stoneham, MA: Butterworth.

Cardon, A.H., & Verchery, G. (Eds.).  (1985). Mechanical characterization of load bearing fibre composite laminates:  Proceedings of the European Mechanics Colloquium 182, Mechanical characterization of load bearing fibre composite laminates, Brussels Belgium, August 29-31, 1984.  New York: Elsevier.

Cook, J.P.  (1985).  Composite construction methods.  New York: Krieger.

Green, W.A.  (1987). Mechanical behavior in composites and laminates.  New York: Elsevier.

Hoff, N.J.  (1986). Monocoque, sandwich and composite aerospace structures.  Lancaster, PA: Technomic

International Aviation Publishers Staff. (1977).  Aircraft bonded structure.  Casper, WY: Author.

Kawata, K., & Akasaka, T. (Eds.).  (1982).  Composite materials.  Hummelstown, PA: Elsevier.

Lambie, J., & Markowski, M.A. (1984).  Composite construction for homebuilt aircraft.  New York: Ultralight.

Marshall, I. H., @Demuts, E. (Eds.), (1988).  Supportability of composite airframes: Proceedings of a workshop, sponsored by US Air Force European Office of Aerospace Research and Development and Paisley College of Technology, held in Glasgow, Scotland, 3-4, August 1987, New York:  Elsevier.

Sanchez-Palencia, E., & Zaoui, A. (Eds.).  (1987), Homogenization techniques for composite media.  New York: Springer-Verlag.

Suresh, S. (Ed.). (1989).  Interfacial phenomena composites: Processing, characterization and mechanical properties.  New York: Elsevier.

U.S. Department of Transportation (F.A.A.). (1976). Airframe and powerplant mechanics: Airframe handbook.  Casper, WY: IAP.

Vinson, J.R., & Chou, T.W. (1975). Composite construction materials and their use in structures.  Lancaster, PA:  Elsevier.

Zweben, C., Hahn, H.T., & Chou, T.W. (1989). Delaware composite design encyclopedia (Vol. 1).  Lancaster, PA: Technomic.