Basic mathematics - demonstrate the knowledge to use mathematical numbers in different forms to fabricate composite and assembly structure; ability to add, subtract, multiply, and divide; use of fractions and decimals. Aerodynamics - demonstrate the knowledge of basic aircraft aerodynamics; aircraft flight; concepts of aerodynamics; lift, eight, thrust, drag theories; axes of flight theories; demonstrate knowledge of aerospace manufacturing regulations; air regulations (DOT, FAA, Boeing compliance).
Identify types of care (materials, classes, grades); ability to trim core (rough trim, net trim, CNC trim); ability to chamfer core (includes chamfer radius); stabilize core; recognize and use potting compounds (BMS 5-28); ability to pot and bond splice; heat forming; identify core (label and buy-off).
Cloth kitting - identify prefab material matrix (low and high temp); storage and handling life specifications; calculate exposure hours; hand cut kits; CNC cutting and labeling. Composite fabrication - lay up and bagging techniques; applicable tooling; accurately complete all required paperwork; define required acronyms, abbreviations, and terminology. Cure - determine correct curing procedure (oven or autoclave); ability to debag.
Trim - identify tool setback; use hand rout fixtures and routers; recognize necessity for CNC fixtures and trimming; ability to deburr; ability to chamfer and edge radius. Inspection - receiving inspection; inspection methods (drawing, visual, dimensional, NDI); self inspection and acceptance; composite vs. metal detail inspection; close tolerance hole inspection; rejection tag process; material test and retest process (Lab); precision measurement (Q.C. specific).
Assembly - align and attach parts; use temporary fasteners; trim and fit parts; drill, ream and countersink holes; disassemble components and parts; dress and deburr parts; assemble parts and structural fasteners; remove parts/components from jigs or fixtures. Fastener installation - select fasteners, lay-out hole patterns; drill, ream, and countersink holes; install corrosion treated fastener holes (wet installation); set and buck rivets; install swage threadless collars; install panel and cowling fasteners; install blind nuts; install blind bolts and rivets.
Exterior finish - material matrix (primers, conductive coatings and enamel); application of coatings; curing of coatings; inspection of coatings. Corrosion control - apply water displacement compounds (Alodine/Anodize); apply leveling compounds; edge seal details (composite, metal, resin, primer). Surface Preparation - material matrix (conditioners and pinhole fillers); cure surface materials; finish product. Shipping - details of protective wrapping of parts or shipping; identify parts; airworthiness acceptance procedures.
Blueprint reading - define the content of automated parts lists and advanced drawing change notices; interpret drawings, dimensions, notes (detail, assembly, installation); types of drawings and views; types of lines and arrangements of views; blueprint arrangement; interpret dimension elements, systems, angles, purposes; types of tolerance; aerodynamic smoothness requirements; assigned engineering numbers and block numbers. Process specifications - define content of material specs (BMS); content of process spec (BAC); recognize and use standard specs; process specifications departures (PSD's); spec control (liaise with Manufacturing Engineering); familiarize with Quality Assurance Manual (purpose, content, control).
Safety Health & Environmental Affairs (SHEA) - awareness of Health & Safety hazards; how to handle hazardous materials (MSDS); compliance with safety regulations; use of personal protective equipment; operation of emergency safety equipment; knowledge of housekeeping practices (5S's); maintenance of tools and equipment; awareness of fire hazards. Tools and equipment - select and operate hand tools; select and operate power tools; select and operate shop equipment; maintain hand and power tools. Precision measurement - sue rulers; use dial calipers; use micrometers; feeler gauges; hole gauges. Tooling fabrication - define fabrication techniques (models vs. Catia); define types of tools; tool sustainment; lay-out and fabricate a cutting pattern.
This course will prepare the student to take the TOWES exam.
Approved repair instructions (D6-53900); clean damage by sanding, grinding, and routing; prepare patching by step/taper sanding; shape/size core for replacement; replace cored areas with potting compounds; bond core replacement; lay-up repair plies using pre-preg cloth; cure repairs.