sheetmetal; fabrication, inspection and repair. level 3

This content is ACRATS Proprietary Sheetmetal Education Program, Level 3

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SHEETMETAL: FABRICATION, INSPECTION AND REPAIR LEVEL 3

Course Title: Sheet Metal: Fabrication, Inspection and Repair, LEVEL 3

Course Code: SM003

Date: 2018-04

Developed by: Rick van Opdorp

Signature:

Sheetmetal Education Program, Level 3


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TABLE OF CONTENTS

SCOPE ................................................................................................................................................ 3

DURATION .......................................................................................................................................... 3

LOCATION .......................................................................................................................................... 3

APPLICABLE DOCUMENTS .............................................................................................................. 3

EXAMINATIONS.................................................................................................................................. 4

TEACHING LEVELS ........................................................................................................................... 5

MODULE 1 – Sheetmetal: Fabrication ................................................................................................ 6 Scope ................................................................................................................................................... 6 Topics and Objectives ......................................................................................................................... 6

MODULE 2 – Sheetmetal: Inspection .................................................................................................. 7 Scope ................................................................................................................................................... 7 Topics and Objectives ......................................................................................................................... 7

MODULE 3 – Sheetmetal: Repair ...................................................................................................... 8 Scope ................................................................................................................................................... 8 Topics and Objectives ......................................................................................................................... 8


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SCOPE This is a standard curriculum that has been developed according EASA and FAA publications. Teaching levels have been assigned to the curriculum to define the knowledge, skills, and abilities, graduates will need to manufacture and repair metal components. After the manufacturing, the student will perform inspection on the manufactured components. After the inspection, the student will perform repairs on the components. After a minimum hour of instruction have been provided to ensure adequate coverage of all subject matter including lecture and laboratory. Each curriculum module is a subpart of this document: Module 1 is Sheetmetal: Fabrication Module 2 is Sheetmetal: Inspection Module 3 is Sheetmetal: Repair This document contains ATA104 level IV curricula. DURATION 10 working days, 80 hours Start 08:00 Break 12:00 / 13:00 End 17:00 LOCATION ACRATS Training Services B.V. Aviolandalaan 35, Building 42A 4631RV, Hoogerheide Netherlands Or on Customers site


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APPLICABLE DOCUMENTS The following publications form a part of this document to the extent specified herein. The latest issues s shall apply. The applicable issue of other publications shall be the issue in effect on the date of the purchase order. In the event of conflict between the text of this document and references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. FAA and EASA Publications Part 145 EASA AMC-GM Acceptable means of compliance and Guidance Material to Part-145 AC43.13 1B Acceptable Methods, Techniques and Practices – Aircraft Inspection and Repair AC43.13 2B Acceptable Methods, Techniques and Practices – Aircraft alterations AC43.18 Fabrication of Aircraft Parts by Maintenance Personnel EXAMINATIONS It will be required to monitor student performance throughout the program. Students will be administered a written exam following lecture classes and practical assessments in laboratory classes. The minimum passing grade for all written exams shall be 75% and all grades shall be recorded in the individual’s training records. The examination and assessment will cover the principles of the applicable curriculum and consist of: Written examination: The written examination shall contain multiple choice questions. The examination shall contain questions from each of the Topics listed in the outline for each Part. The examination will be closed book. Practical assessment: The student must demonstrate to the Instructor that they can perform the basic tasks required to perform the applicable repairs. Reexamination: If the student fails the written examination, they may request to retake a written examination. The written examination must not contain more than 20% of the questions that were on the failed examination. CERTIFICATION Certificated covered by EASA 147 approved training school “Aircraft Maintenance and Training School”.


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TEACHING LEVELS The following definitions of minimum teaching levels are derived from Title 14 Code of Federal Regulations, Part 147 and may be exceeded. Level 1 Level 1 requires knowledge of general principles and includes instruction by lecture, demonstration, and discussion, but does not include practical application or development of manipulative skill. This teaching level generally refers to classroom discussion and does not require practical application. Teaching aids or instructional equipment may include charts, books, diagrams, or other visual teaching aids. If a training organization chooses to teach Level 1 courses incorporating actual components, the components do not have to be operational.

Level 2 Level 2 requires knowledge of general principles and includes instruction by lecture, demonstration, discussion, and limited practical application, but does not include development of sufficient manipulative skill to perform basic operations. This teaching level requires some hands-on manipulative skills and their accompanying actual or simulated components/equipment, but still may be taught primarily in the classroom environment.

Level 3 Level 3 requires knowledge of general principles and includes instruction by lecture, demonstration, discussion, and a high degree of practical application to develop sufficient manipulative skill to accomplish return to service (normal operation). This teaching level requires hands-on skill, as well as sufficient and appropriate instructional aides to train the students to develop manipulative skills sufficient to simulate return to service mechanical skill. At this level, the teaching aids must be similar to or be the actual items of equipment on which the student is expected to develop required skill levels. A Level 3 subject cannot be taught solely by lecture in the classroom; the appropriate training aids and hands-on experience must be used.


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Module 1- Sheetmetal: Fabrication Scope After completion of this module the technician is able to understand the techniques and principles sheetmetal fabrication and manufacturing. Outline for Sheetmetal Fabrication

Topic Teaching Level

Hours Theoretical

Hours Practical

1 Mould making 3 8 2 Forming flanged angles with the use of forming blocks

(moulds) 3 3

3 Spot facing 3 1 Total Hours 12 * Included in Practical exercises as well

Topics and Objectives

Sheetmetal Fabrication Objective: Given discussion, lecture, practice, and feedback, this module is specially designed to allow technicians and engineers to fabricate sheetmetal parts. The course will give the participants the basic understanding of sheetmetal materials and build up the skills of how to use and read technical drawings.

Topic: Level Mould making 3 Forming flanged angles with the use of forming blocks (moulds) 3 Spot facing 3


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Module 2 – Sheetmetal: Inspection Scope After completion of this module the technician is able to understand the inspection techniques, how to perform a proper damage assessment and how to report a damage. Outline for Sheetmetal Inspection


Hours Theoretical

Hours Practical

1 Performing inspection 3 9 2 Damage determination 3 1 3 Corrosion inspection 3 1 4 Damage assessment 3 1 5 Damage reporting 3 2 Total Hours 14

Inspection Techniques Objective: Given discussion, lecture, practice, and feedback, the student will list the various types of Non-Destructive Inspection (NDI) techniques and their limitations during manufacture and repair of metal structures.

Topic: Level Performing inspection 3 Damage determination 3 Corrosion inspection 3 Damage assessment 3 Damage reporting 3


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Module 3 – Sheetmetal: Repair Scope After completion of this repair Module the technician is able to understand the Structural Repair Manual and perform repairs on the structure and components of the aircraft according the technical documentation. Outline for Sheetmetal Repair


Hours Theoretical

Hours Practical

3 Special fasteners 1 1 4 Shot/Flap-peening 1 1 5 Coldworking 1 1 6 Metal bonding 1 1 7 Repairs i.a.w. SRM

- Leading edge repair - Bulkhead repair

3 50

Total Hours 4 50

Topics and Objectives

Composites Repair Objective: Given discussion, lecture, practice, and feedback, the student will develop the basic skills necessary to perform a patch repair on a metal structure. Participant will learn about the various repair methods (typical and general) given in structural repair manuals.

Topic: Level Special fasteners 1 Shot/Flap-peening 1 Coldworking 1 Metal bonding 1 Repairs i.a.w. SRM 3

Examination

Examination Written 1 hour The written examination shall contain multiple choice questions for 2-week courses. The examination shall contain questions from each of the Topics listed in the outline for each Part. The examination will be closed book.

Examination Practical During Practical Hours

The student must demonstrate to the approved training provider that they can perform the basic tasks required to perform the applicable repairs.

sheetmetal; fabrication, inspection and repair. level 3

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