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 theref
2、rom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2009 SAE International All rights reserved. No part of this publication ma
3、y 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: +1 724-776-4970 (outside US
4、A) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AIR5719AEROSPACEINFORMATIONREPORTAIR5719 Issued 2009-10Teaching Points for an Awareness Class o
5、n “Critical Issues in Composite Maintenance and Repair“ RATIONALEThis document was developed to fulfill the need for a standardized checklist regarding critical issue awareness for composite structure maintenance and repair. 1. SCOPE This document is to be used as a checklist by curriculum developer
6、s to create awareness training for critical composite repair and maintenance issues. This document will not take place of training requirements for specific job roles of a composite repair technician or engineer. 1.1 Purpose The purpose of this AIR is to establish a standard teaching checklist for a
7、n awareness course covering the critical technical issues associated with the maintenance and repair of composite aircraft structures. This document describes terminal course objectives (TCOs) and teaching points, which in combination serve as a course checklist for organizations developing this awa
8、reness course. 1.2 Field of Application The course is intended to address critical composite structural safety and certification issues as opposed to building specific skills among individual team members. Specific skill-building is outside the scope of this course and is not the intent of the conte
9、nts of this document.1.3 Product Classification The organization and structure of the teaching points presented in this AIR is unique and is not considered part of the public domain, and is subject to SAE copyright authority. The technical information contained in the teaching points of this AIR is
10、regarded as common practice, and therefore is available in the public domain. The Federal Aviation Administration (FAA) funded the assembly of this information and the development of training course details. It has published the technical information as part of a more complete treatment of composite
11、 maintenance course material. The FAA retains the right to grant permission to any outside party to access and utilize the technical information assembled under the government funded program and subsequent revisions. The FAA shall retain the right to reproduce the technical information contained in
12、this AIR document for its use and to exercise all the rights inherent with the information provided in this document without restriction. The FAA will not distribute copies of this AIR document to the public without prior approval from the SAE.SAE AIR5719 Page 2 of 291.4 Form TCOs, in addition to su
13、bordinate objectives which support the TCOs, indicate student learning expectations for each section of the course, while teaching points convey items that should be covered within each TCO. TCOs are listed at the second numbering sequence (e.g. 3.1) in this document. Teaching format is at the discr
14、etion of the teaching institution, and those objectives and teaching points which refer to laboratory learning environments are suggestions in teaching format only (e.g. section 6.2.4). In general, laboratory exercises are intended to reinforce objectives and teaching points listed in other sections
15、 of this AIR. 2. REFERENCES 2.1 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
16、 the event of conflict between the text of this document and references cited herein, the text of the referenced documents takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 2.1.1 SAE Publications Available f
17、rom SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org.AIR4844 Composites and Metal Bonding Glossary ARP4916 Masking and Cleaning of Epoxy and Polyester Matrix Thermosetting Composite Materials AI
18、R4938 Composite and Bonded Structure Technician/Specialist: Training Document ARP4977 Drying of Thermosetting Composite Materials ARP4991 Core Restoration of Thermosetting Composite Components ARP5089 Composite Repair NDT/NDI Handbook ARP5143 Vacuum Bagging of Thermosetting Composite Repairs ARP5144
19、 Heat Application for Thermosetting Resin Curing ARP5256 Mixing Resins, Adhesives and Potting Compounds AIR5278 Composite and Bonded Structure Engineers: Training Document AIR5279 Composite and Bonded Structure Inspector: Training Document ARP5319 Impregnation of Dry Fabric and Ply Lay-Up AE-27 Desi
20、gn of Durable, Repairable, and Maintainable Aircraft Composites R-336 Care and Repair of Advanced Composites, 2nd Ed. 2.1.2 Other Industry Publications AC145-6 Repair Stations for Composite and Bonded Aircraft Structure 14CFR Part 147 Aviation Technician Schools CMH-17 Composite Material Handbook 17
21、 SAE AIR5719 Page 3 of 293. BASE KNOWLEDGE Basic knowledge in the technology of composite materials is provided to those students having limited exposure and/or understanding of composite materials technology. Prior to the exposure to critical issues involved with the maintenance and repair of compo
22、site materials in commercial aerospace applications (Sections 4, 5, and 6 below), the student must understand the fundamentals of the technology to enhance learning. This subject will provide an overview of maintenance and repair, to be later reinforced in the main course outlined in Sections 4, 5,
23、and 6. Included in base knowledge is: (1) a description of basic materials technology and terms, (2) an introduction to maintenance and repair, (3) descriptions of other critical elements, such as coatings and selection criteria for bolted and bonded repairs, and (4) developments in materials resear
24、ch relating to composite maintenance and repair. Due to the overview nature of the base knowledge in Section 3, only TCOs and the corresponding subordinate objectives are listed. 3.1 After completing this unit, the student will understand the basics of composite materials technology. This material i
25、s intended to provide fundamental concepts and terminologies to the student who has had minimal exposure to composites technology. Terminologies, material applications, processing, and properties are covered at a summary level. For students requiring this level of knowledge, this content is best tau
26、ght as a first topic in the awareness course.3.1.1 The student will be able to distinguish among adhesive, resin, fiber and core applications and uses. 3.1.2 The student will be able to describe critical composite processing parameters. 3.1.3 The student will be able to describe composite material p
27、roperties, failure modes and effects of processing. 3.1.4 The student will be able to describe various composite machining, assembly and finishing processes. 3.1.5 The student will be able to describe stiffened laminate and sandwich applications and structural properties. 3.1.6 The student will be f
28、amiliar with information sources that have a glossary of terms for reference. 3.2 After completing this unit, the student will understand the basics of composite materials maintenance and repair. This material is an introduction to composite materials maintenance and repair. It previews the basic ma
29、intenance procedures which will be considered in more depth later in the course, and includes processing materials, tooling and equipment. This content is best taught following the composites materials technology summary presentation, and prepares the student for later teaching materials which focus
30、 on safety issues and maintenance and repair processes. 3.2.1 The student will be able to list the basic steps in maintenance procedures from damage detection through repair completion.3.2.2 The student will be able to list key composite and expendable materials needed for simple laminate structure
31、repair including storage requirements. 3.2.3 The student will be able to list the necessary tooling and equipment to accomplish a simple laminate structural repair.3.2.4 The student will understand personal and equipment safety requirements. 3.2.5 The student will be able to describe the differences
32、 between repairing composite and metal structures, including discussions on the special issues related to composite and metal bonding. 3.2.6 The student will be able to describe the process of metal bonding. 3.2.7 The student will be able to discuss the importance of approved data, methods and proce
33、dures used in product-specific, composite maintenance and repair. SAE AIR5719 Page 4 of 293.3 After completing this unit, the student will understand other critical elements of composite maintenance and repair. While having an overview of composite materials technology and related maintenance and re
34、pair is a necessary part of a students preparation for more in depth study, there are other considerations, including the selection of repair methodology, electromagnetic effects and surface finishing and re-finishing, waste disposal, and trends in development of repair technology. Understanding ski
35、ll limitations and the importance of utilizing source documentation is introduced. This content is best taught following the composites materials technology summary presentation and repair overview, and prepares the student for later teaching materials which focus on safety issues along with mainten
36、ance and repair processes.3.3.1 The student will be able to discuss basic issues affecting the selection of bonded or bolted repairs. 3.3.2 The student will be able to describe various electrical requirements and effects, including prevention of corrosion, hazards of electromagnetic interference and
37、 electrostatic discharge (lightning protection systems) and how they need to be considered during repair processes. 3.3.3 The student will understand the need for protective coatings and surface finishing steps used for composite aircraft structure. 3.3.4 The student will be able to describe typical
38、 paint and surface layer removal techniques for finished composite parts. 3.3.5 The student will know the issues related to the proper disposal of wastes from the composite repair process. 3.3.6 The student will know why understanding personnel skill limits and where to receive assistance during mai
39、ntenance is essential. 3.3.7 The student will be able to discuss the importance of documenting and sharing information about damage scenarios discovered in service between OEM, maintenance and repair organizations and regulators. 3.4 At the end of this unit the student will be aware of composite mai
40、ntenance research and industry developments. As a relatively new technology, composite material development and practice continues to evolve. This unit will provide an overview of some of the key advances and stimulate further research into these advances. 3.4.1 The student will explain the general
41、lack of standards available for composite engineering practices and realize that composite maintenance and repair requires special acquired skills. 3.4.2 The student will discuss emerging advances in repair process technologies that may appear for bonded and bolted repair and quality control. The ne
42、ed for industry to properly substantiate emerging repair process technology before it can be applied to certified products will be introduced. 3.4.3 The student will discuss emerging damage and repair inspection technologies, such as bond testing, moisture meters, interferometer (3D characterization
43、). The need for industry to properly substantiate emerging inspection process technology before it can be applied to certified products will be introduced. 3.4.4 The student will discuss advances in composite repair analysis and design, which may be used by engineers to develop a repair for aircraft
44、 structure. 3.4.5 The student will be able to outline the process for repair structural substantiation and approval to meet regulatory requirements.SAE AIR5719 Page 5 of 294. TEAMWORK AND DISPOSITION This section of the class is organized to highlight the importance of teamwork in the disposition of
45、 damaged composite structure during maintenance and repair. Each member of the team must have training that qualifies them for the specific tasks he or she will perform. The training would start with an awareness of critical composite maintenance and repair issues, such as provided by the current co
46、urse. Additional training is needed to develop specific skills and perform tasks on the structural components of a given aircraft type, which have unique repair design, process and inspection details. It is unlikely that one person will attain all the special skills needed for engineering dispositio
47、n, inspection and repair of damage to a given structure. Instead, trained engineers, inspectors and technicians will work as a team from the time of damage detection until an approved repair is properly executed. Approval of a new repair design and process for critical composite structures will requ
48、ire an interface with engineers having the necessary skills and data to substantiate structural integrity of the repair per regulations. 4.1 After completing this unit, the student will understand roles and responsibilitiesThis part of the class will help students understand the roles and responsibi
49、lities of engineers, inspectors and technicians involved in composite maintenance and repair. It also discusses a vital interface between personnel trained in composites with pilots, operations and line maintenance personnel that may first become aware of a need for damage disposition. The content introduces several subjects covered in greater depths by other sections of the class. These include an overall view of the composite inspection, da
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