Metal to Metal Bonding

Metal to Metal Bonding (ACM01)

Course Code: ACM01
Duration: 5 Days
Course Fee: £2165+VAT
Course structure: 20% theory, 80% practical

This course is intended for those members of staff who will be carrying out bonded repairs on metallic aircraft structures. It will give them sufficient knowledge to be able to complete the repair to approved aerospace standards. No previous knowledge required.

The emphasis of the course is on developing the practical skills necessary to carry out metal-tometal bonded repairs on metallic structures in accordance with published manufacturers’ structural repair manuals. The theoretical content allows the delegate to produce quality repairs using the correct materials and procedures and to work safely.

The techniques used are those currently recommended in manufacturers’ structural repair manuals and emphasis will be placed on strict adherence to these procedures. The importance of quality assurance is stressed through-out with particular attention paid to quality control by adopting good practices throughout the repair procedure.

The course content has been devised to convey the latest accepted techniques for metal-to-metal bonding and SAE AIR4938 standards. 

The course aims to:

  • To familiarise the delegate with the materials and techniques used to repair metallic structures using bonding techniques
  • To provide the delegate with the knowledge to satisfy the appropriate health and safety requirements.
  • To equip the delegate with the knowledge and practical skills required to carry out sound and effective repairs on metallic aircraft components, according to the methods recommended and accepted by the aircraft manufacturers.
  • To provide the delegate with the skills necessary to carry out surface anodising using the phosphoric acid non-tank method (PANTA).
  • To introduce the delegate to the phosphoric acid containment system (PACS) for aluminium anodising as specified by Boeing.
  • To provide the delegate with the skills necessary to carry out the sol-gel (Boegel) process for aluminium conversion as specified by Boeing.
  • To provide the knowledge required to interpret standard structural repair manuals and to relate them to a given repair situation.
  • To satisfy all the relevant quality assurance requirements.

19th – 23rd February 2024
21st – 25th October 2024

Metal to Metal Bonding 2 (ACM02)

Course Code: ACM02
Duration: 5 Days
Course Fee: £2165+VAT
Course structure: 20% theory, 80% practical
Prior learning (Pre requisite): ACM01 Metal to Metal Bonding 1

This progression course is intended for those members of staff who will be
carrying out bonded repairs on metallic aircraft structures. It will give them sufficient knowledge to be able to complete the repair to approved aerospace standards together with completing repairs which are outside the SRM, enabling the repair of damage which has occurred to an existing repair.

Delegates will have completed ACM01 Metal to Metal Bonding 1 prior to commencing the course.

This course is designed to address metal to metal and metal to composite bonded repairs. The repairs addressed will be within the boundaries of the structural repair manuals (SRM)s and will address the procedures to take and how to complete repairs which are outside the SRM requirements. Familiarization and compliance to such procedures is the central focus to equip the technician with the skills to perform repairs utilising good practice bonding methodologies.

Various damage scenarios will be presented including, but not limited to, damage to: edge/s, corner, bolted locations with the application of repair triple septons. Delegates will also be introduced to the practices and methods to use when dealing with repairs to areas which have an existing repair and addressing and/or restoring unsuccessful damage repairs.

The emphasis of the course is on developing the practical skills necessary to carry out metal-to-metal and metal-to-composite bonded repairs on metallic structures in accordance with published manufacturers’ structural repair manuals. The theoretical content allows the delegate to produce quality repairs using the correct materials and procedures and to work safely.

The techniques used are those currently recommended in manufacturers’ structural repair manuals and emphasis will be placed on strict adherence to these procedures. The importance of quality assurance is stressed through-out with particular attention paid to quality control by adopting good practices throughout the repair procedure. The course content has been devised to convey the latest accepted techniques for metal-to-metal and metal-to-composite bonding and SAE AIR4938 standards.

This course aims to:

  • To provide delegates with the knowledge and confidence to undertake challenging repairs they will encounter.
  • To provide the delegate with the knowledge to satisfy the appropriate health and safety requirements for processes and material used in repair.
  • To enable delegates to identify the correct materials, techniques, tooling and equipment to utilise for a given situation.
  • To equip the delegate with the knowledge and practical skills required to carry out sound and effective repairs on metallic aircraft components, according to the methods recommended and accepted by the aircraft manufacturers.
  • To provide the delegate with the skills necessary to carry out effective surface anodising using a combination of anodising techniques.
  • To provide the knowledge required to interpret standard structural repair manuals and to relate them to a given repair situation and when required implement successfully repairs which have been defined outside repair allowable.
  • To satisfy all the relevant quality assurance and NDT requirements.

Dates on Application

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