• E-9/M-9

    Cure Management & Process Control for Composites: In and Out of Autoclave

    This course is designed as an overview of the fundamentals of composite processing from a Material State Management (MSM™) perspective and how this can be used to reduce costs while improving quality and performance. Data from two new instruments will be demonstrated including sensors within the laminate without the need for a thermocouple lead penetrating the vacuum bag and near measurement of the viscoelastic state of the prepreg for acceptance and shelf-life determination.  The change in viscoelastic state as it is cured will also be demonstrated and a new approach to shelf-life management will be discussed.    This course has been designed to provide a fundamental understanding of the properties critical to procurement, storage, and cure of composites with the goal of teaching how and why procurement specifications, storage requirements and cure cycles were developed in the past and to demonstrate new tools that can lower cost while improving quality of the product.

  • ER-1

    Aerospace Repair Analysis & Substantiation

    This course is designed for degree-qualified aerospace and mechanical engineers or persons having practical experience in strength of materials calculations who are responsible for the design analysis and substantiation of repairs to secondary structure and lightly loaded primary structures. This course is an entry level course and provides classroom lecture on composite materials, processes, and manufacturing with a focus on repair techniques and repair analysis. The hands-on shop work involves manufacturing test panels, damaging the panels, performing repairs, and mechanically testing coupons from both the original and repaired panels. The mechanical characteristics of the original and repaired panels are validated with analysis using an Excel spreadsheet, which has become one of the most recognized analysis training tool in the industry. Many students come from aircraft operators involved with commercial, business, general aviation, and military aviation, but the course is also applicable for engineers involved in original design who need to consider the design for maintainability and supportability of composite structures. The ER-1 course is also a mandatory prerequisite for the ER-2 Advanced Aerospace Repair Analysis and Substantiation course.

  • ER-2

    Advanced Aerospace Repair Analysis and Substantiation

    This course is an advanced level course designed for degree-qualified aerospace and mechanical engineers who are responsible for the design analysis and substantiation of repairs to both primary and secondary composite structures.  All students are required to have completed the ER-1 Aerospace Repair Analysis and Substantiation course to be prepared to explore a more in depth analysis of repairs to global structures.

  • ES-1

    Composite Essentials for Engineers and Managers

    This course has been developed to provide engineers and technical managers with a broad, but comprehensive understanding of composite materials and manufacturing techniques used in component development, design, and “in-service” operation. The course covers the major considerations for the application of composite materials with an emphasis on the structural requirements, material usage, manufacturing techniques, vacuum bagging, and cure cycles. The E-1 course also covers the fundamentals of composite analysis. The course incorporates classroom lecture, and hands-on fabrication of wet layup, prepreg, solid laminate, foam core, and honeycomb core panels. These panels are then both bonded and bolted together then mechanically tested to evaluate their performance and failure to the classroom analysis. E-1 is a recommended prerequisite for all of the Engineering Structures courses to ensure that the students have a sufficient understanding of composite materials and processes before they begin the learning process on more in-depth composite analysis techniques. Only engineers with extensive composite materials and process experience from OJT, or other formal training, such as Abaris' Advanced Composite Structures: Fabrication & Damage Repair - Phase 1 (M-1/R-1) course should consider omitting this course as a prerequisite.

  • ES-2

    Composite Laminate Analysis

    This course provides the backbone designing and analyzing composites with a thorough understand on classical laminate plate theory and failure criteria. The ES-2 course is perfect for engineers who did not take composite course during their university education, or who recognize that their university courses were too theoretical and did not provide enough practical understanding. ES-2 goes well beyond university level composite courses by using mechanical property data for modern composite materials that are currently available and evaluating these materials on existing composite configurations. The course is 80% analysis and 20% hands-on. The shop work involves manufacturing unidirectional and woven fabric panels at the lamina and laminate level as well as loading test coupons to failure. The course performs the analysis with a highly evolved Excel spreadsheet. Additionally, it introduces the students to composite analysis using FEA. ES-2 is a prerequisite for ES-3 and ES-4, unless the students have an extensive background with laminate analysis through their past work experience or university education. ES-2 is also recommended as an intermediate prerequisite between ER-1 and ER-2 for engineers performing repairs and modification who have access to load data.

  • ES-3

    Design of Composite Structures

    This course has been developed specifically for engineers to provide a thorough understanding of the configuration of composite details and components to meet the design requirements for structural applications. ES-3 discusses the requirements for designing both assembled and co-cured/co-bonded structure using solid laminates, sandwich panels, stiffened structure, panel edge bands, ply drop-offs, and panel field areas. The course also addresses the requirements for assembling composite structures using both bonded and mechanically fastened joints, and utilizes the most robust bonded and bolted joint analysis available. Analysis is performed to evaluate panel buckling and vibration. Additionally, ES-3 provides an understanding of allowables, knockdown, and design values to meet the Damage Tolerance requirements for both primary and secondary structure. This courses performs analysis with both traditional hand calculations and FEA.

  • ES-4

    Advanced Stress Analysis Methods for Composites

    This course the most advanced course in the Abaris Engineering Structures (ES) curriculum, and is intended for engineers who need to understand composite structural analysis at the highest level. ES-4 evaluates how the laminate in-plane and flexural stiffness and compliance properties are applied to both FEA and traditional analysis, as well as modulus weighted cross sections using composite laminates in moment of inertia calculations. The course progresses from strength of materials analysis, through equilibrium, to Work and Energy calculations using strain energy and strain energy density. ES-4 addresses the fifteen field equations and field variables for static analysis from a strain-displacement aspect. The course looks at load distribution throughout the entire structure with both traditional analysis and FEA, to allow engineers to analyze a composite structure as a whole without having to rely solely on FEA software, but provides a means to validate FEA models.

  • HBR

    Hawker-Beechcraft Composite Repair (A FlightSafety International Course)

    This course is designed as a manufacturer specific course.It is a FlightSafety approved course designed to provide the repair station with the knowledge and skills needed to repair Hawker –Beechcraft composite structures on aircraft such as the Hawker 850, 1000, 4000, and the Premier 1and 1A. The course is extremely beneficial to individuals, such as technicians, mechanics,inspectors and supervisors that come in contact with these aircraft. This course will cover the posites, and using the manufacturer’s Structural Repair Manuals, the students will get plenty of time in the shop performing repairs on various parts developing their hands-on skills.

  • M-1/R-1

    Advanced Composite Structures: Fabrication & Damage Repair-Phase 1

    Our most popular class, Advanced Composite Structures: Fabrication & Damage Repair-Phase 1 is designed to meet the needs of a wide range of personnel; from the novice to the seasoned professional. This course is a prerequisite for both our repair and manufacturing programs and is highly recommended to anyone seeking a better understanding of advanced composite materials, processes, layup/lamination, vacuum bagging, adhesive bonding, tooling, repair, and inspection methods and techniques.

  • M-10/R-12

    Certified Composite Instructor: Level I

    The certificate program is offered to those persons who are currently teaching, or those that wish to teach subjects related to advanced composite materials, manufacturing, or repair. This course is designed as part of Abaris’ train-the-trainer (TTT) program that allows a dedicated student to become an Abaris “Certified Composite Instructor: Level I.” It is an opportunity to learn and grow with the best trainers in the world.

  • M-2

    Advanced Composite Manufacturing 2

    This course is designed as follow-on to the M-1/R-1 Composite Structures: Fabrication & Damage Repair-Phase 1 course and is intended for those wanting to further their knowledge of composite manufacturing, whether in preparation for employment in the advanced composite manufacturing industry, or as engineers or technicians desiring a further understanding of the practical skills involved in producing quality composite structures.  

  • M-4/R-7

    Adhesive Bonding of Composites & Metals

    This course is designed for engineers, technicians, and anyone else looking to advance their knowledge in adhesive bonding technology, while gaining a deeper understanding of surface preparation and the fundamental adhesion principles necessary to achieve a good bond to both (polymeric) composite and metallic surfaces.

  • M-5

    Resin Infusion Technologies

    This course is designed for the engineer, technician, laminator, fabricator, or anyone else wanting to learn about the fundamental principles and more complex concepts involved in resin infusion technology.

  • M-6/R-8

    Mold Fabrication for Production and Repairs

    This course is designed for the tooling engineer, tool designer, tool fabricator, or anyone else that has a desire to learn about designing and building molds and fixtures using advanced composite materials.

  • M-7/R-6

    Non Destructive Inspection Techniques for Technicians and Inspectors

    This five-day course is designed for the repair technician, fabricator, or inspector tasked with identifying and quantifying defects in new or damaged composite panels using the latest equipment, methods, and techniques. The course is very “hands-on” in nature, and quite busy. The instruction is performed by an ASNT certified Level III engineer and is flexible to adapting to the students needs.

  • MQA-1

    Fundamentals of Advanced Composites for Auditors

    This course is designed for the supplier quality auditor, internal auditor, quality engineer, inspector, or any other individuals wanting to gain knowledge in advanced composite manufacturing practices and procedures. The course is designed to provide an in-depth look at how composite products are fabricated and the quality controls that go along with each step in the process.  

  • R-1/R-2

    Advanced Composite Structures: Damage Repair 1-2-Combined

    Designed for onsite delivery at select composite repair stations requiring devoted training in hot bond repair, this "combined" repair course is for repair technicians, mechanics, supervisors, and quality assurance personnel directly involved in providing high performance repairs to advanced composite structures. 

  • R-10

    Helicopter Rotor Blade Repair

    Regardless of the make and model of the helicopter, accomplishing durable, high-quality rotor blade repairs requires a certain knowledge and skill set. This course is designed for helicopter mechanics, maintenance personnel, and inspectors looking to achieve sound repairs to composite rotor blades. This five-day course will provide the knowledge and teach the skills necessary to effect quality helicopter rotor blade repairs in-house with a high degree of confidence, and a shorter turn-around time.

  • R-13

    General Aviation Composite Repair

    The General Aviation Composite Repair Course was originally conceived as a manufacturer-specific Cessna repair course devoted specifically to the Columbia, Cessna Corvalis and TTx airframes. It is approved by Cessna, and was initially designed as an airframe specific course for Cessna Service Center repair technicians, mechanics, supervisors, and quality assurance personnel directly involved in providing high performance repairs on these advanced composite structures. However, many General Aviation aircraft from other manufacturers use similar resin and fiber systems and structural repair techniques, such as various models of the Cirrus, Diamond, most high-performance sailplanes, and many LSA composite aircraft. Technicians repairing these types of GA airframes will also benefit from this training. The principles of properly performing a good composite structural repair broadly apply to these airframes as well.

  • R-15

    Advanced Windblade Repair

    This 5-day advanced level repair course is a follow-on to our R-5 Composite Wind Blade Repair course. This is for the repair designers, technicians, mechanics, supervisors, and quality assurance personnel directly involved in providing high performance repairs to advanced composite structures. This course will cover more detailed repairs, such as repairs to spars, along with tooling and different repair processes.

  • R-2

    Advanced Composite Structures: Damage Repair: Phase 2

    The R-2 repair course is designed as a direct follow-on to our M-1/R-1 course for repair designers, technicians, mechanics, supervisors, and quality assurance personnel directly involved in providing high performance repairs to advanced composite structures.

  • R-3

    Advanced Composite Structures: Damage Repair: Phase 3

    This course is designed for repair designers, technicians, mechanics, leads or supervisors who want to further their education in repairs of advanced composite structures. This class presents more challenging damage assessment and repair challenges than those presented in our Phase 2 course.

  • R-4

    Repair of Bonded Aluminum Structures

    This course is designed for repair designers, technicians, mechanics, leads, supervisors, or inspectors who want to further their education in repairs of bonded aluminum structures.

  • R-5

    Composite Windblade Repair

    This 5-day course is prerequisite for the R-15 Advanced Windblade Repair course and is designed for both factory and field technicians, inspectors, and supervisors responsible for performing structural repairs to composite wind blades.