Aircraft Structures Technician Course

Lesson 1 • Loads and Stress Fundamentals

Explains tension, compression, shear, bending, and torsion as they act on airframe members. Connects load types to visible damage patterns technicians encounter.

Lesson 2 • Regulatory and Safety Framework

Covers airworthiness standards, maintenance documentation requirements, and personal safety protocols. Establishes the compliance mindset required for all hands-on work.

Lesson 3 • Structural Components and Terminology

Identifies frames, stringers, spars, ribs, and skin panels by name and function. Provides the component-level vocabulary used throughout the course.

Lesson 1 • Composite Materials Fundamentals

Introduces fiber-reinforced polymer composites, core materials, and laminate construction. Prepares students for composite inspection and repair covered in later chapters.

Lesson 2 • Material Testing and Identification

Teaches field and laboratory methods for verifying material identity and condition. Ensures technicians can confirm correct material use before and after repairs.

Lesson 3 • Steel and Titanium Alloys

Examines high-strength steel and titanium use in fittings, landing gear, and fastener applications. Highlights handling precautions and dissimilar-metal corrosion risks.

Lesson 4 • Corrosion Types and Prevention

Classifies corrosion forms found on aircraft structures and explains their electrochemical causes. Connects prevention strategies to material selection and surface treatment.

Lesson 1 • Layout and Marking Techniques

Covers scribing, center-punching, and template use for accurate part layout before cutting or drilling. Proper layout reduces material waste and rework.

Lesson 2 • Precision Measurement Instruments

Introduces micrometers, calipers, dial indicators, and feeler gauges for structural measurements. Accurate measurement underpins all fit, clearance, and tolerance checks.

Lesson 3 • Tool Calibration and Maintenance

Establishes calibration intervals, storage practices, and inspection criteria for precision tools. Calibrated tools are a regulatory requirement for structural maintenance.

Lesson 4 • Cutting and Shaping Tools

Covers saws, files, snips, and deburring tools used to cut and shape sheet metal and structural members. Emphasizes safe technique and proper tool selection.

Lesson 1 • Solid and Blind Rivets

Covers rivet types, material codes, head styles, and installation using hand and pneumatic tools. Rivet selection and installation quality directly affect structural strength.

Lesson 2 • Structural Bolts and Nuts

Examines bolt grades, thread forms, nut types, and washer requirements for structural joints. Correct torque application and locking methods prevent in-service loosening.

Lesson 3 • Fastener Inspection and Removal

Teaches visual and dimensional inspection criteria for installed fasteners and safe removal methods. Damaged fasteners compromise structural integrity and must be identified promptly.

Lesson 4 • Hi-Lok and Lockbolt Fasteners

Introduces interference-fit and swaged fastener systems used in primary structure. These fasteners provide superior fatigue performance over standard rivets.

Lesson 1 • Bend Allowance and Flat Pattern Layout

Teaches bend allowance, setback, and K-factor calculations for accurate flat pattern development. Correct flat patterns ensure parts fit without trimming after forming.

Lesson 2 • Forming Equipment and Operations

Covers cornice brakes, slip rolls, English wheels, and stretch-forming equipment. Each machine type is matched to specific part geometries and production requirements.

Lesson 3 • Fitting and Trimming to Drawing

Develops skills in trimming, filing, and fitting formed parts to structural assemblies per engineering drawings. Proper fit ensures correct load transfer at joints.

Lesson 4 • Forming Defects and Correction

Identifies springback, cracking, wrinkling, and oil-canning defects and their corrective actions. Defect recognition prevents installation of substandard parts.

Lesson 1 • Visual and Tactile Inspection Methods

Covers direct visual, mirror-assisted, and borescope inspection techniques for structural areas. Systematic inspection patterns ensure no damage is overlooked.

Lesson 2 • Nondestructive Testing Fundamentals

Introduces dye penetrant, magnetic particle, ultrasonic, and eddy current methods for hidden defect detection. Each method's sensitivity and limitations are compared.

Lesson 3 • Measuring and Mapping Damage

Teaches dimensional measurement of dents, scratches, cracks, and corrosion for comparison against allowable limits. Accurate mapping supports engineering disposition requests.

Lesson 4 • Structural Repair Manual Navigation

Develops proficiency in locating allowable damage limits, repair schemes, and material callouts in structural repair manuals. Correct manual use is mandatory before any repair begins.

Lesson 1 • Repair Design Principles

Covers repair sizing rules, doubler design, and fastener pattern layout for metallic repairs. Repairs must restore original static strength and fatigue life.

Lesson 2 • Stringer and Frame Repairs

Covers splice repair and section replacement for damaged stringers, frames, and longerons. These repairs restore primary load paths in the fuselage structure.

Lesson 3 • Corrosion Removal and Treatment

Teaches mechanical and chemical corrosion removal methods and subsequent surface treatment. Incomplete corrosion removal leads to rapid re-attack and structural degradation.

Lesson 4 • Skin and Panel Repairs

Teaches flush patch, overlay patch, and insert repair methods for damaged skin panels. Method selection depends on damage size, location, and structural criticality.

Lesson 1 • Composite Repair Materials

Covers fabric types, resin systems, core materials, and film adhesives used in approved composite repairs. Material traceability and shelf-life compliance are mandatory.

Lesson 2 • Prepreg and Heated Tool Repair

Introduces prepreg ply repair using heat blankets and hot bonders for elevated-temperature cure. Temperature and pressure profiles must match the original material cure cycle.

Lesson 3 • Surface Preparation for Composite Repair

Teaches scarfing, sanding, and solvent cleaning procedures that ensure bond strength in composite repairs. Contamination is the leading cause of composite repair failure.

Lesson 4 • Composite Damage Inspection

Applies tap testing, ultrasonic C-scan, and thermography to locate delamination, disbond, and impact damage in composite panels. Accurate damage mapping defines the repair boundary.