Safety isn’t just a priority in aviation. Rather, it is the fundamental operating principle throughout design, manufacturing, implementation, and daily operations. Therefore, quality control is a must at all FAA-approved composite repair stations.
When an aircraft suffers damage to its advanced composite structures, uncompromising precision must be part of the repair process. This is where FAA-approved repair stations play a critical role. At their core is a rigorous and detailed quality control (QC) system.
QC’s implied imperative is the basis for the FAA mandating such stringent standards for aviation. One example is the FAR Part 145 (Repair Stations) standard that dictates how personnel should view repairs. Under the standard, every repair to a composite part must return the component to its original and airworthy condition.
Why is this standard so important? Because unlike more traditional materials, composite materials can hide internal damage. This is damage that cannot be seen on the surface. If it is left undetected and unrepaired, catastrophic failure eventually becomes imminent. When such a failure occurs in-flight, the consequences can be devastating.
The imperative that is QC is baked into how FAA-approved composite repair stations complete their missions. Without safety-conscious personnel and federal standards guiding the work, safety could not be guaranteed.
Supporting the QC imperative are four quality control pillars. A comprehensive QC system implemented at an FAA-approved composite repair station demonstrates all four as interconnected elements.
Quality control begins with the very technicians who complete repairs. However, composite repair is highly specialized. It is not something that can be done properly or safely without proper training. QC ensures:
Without trained and certified personnel, QC is little more than a rubber stamp. Improper training and certification are simply unacceptable in composite repair.
Proper composite repair relies on a traceable chain. The chain includes all the materials used to repair the targeted composite. Think resins, adhesives, fabrics, prepregs, etc. Chain tracing ensures that materials are handled, stored, and cured correctly. This guarantees that the final repair will not be compromised.
Completed repairs must be tested before an aircraft can return to service. As such, non-destructive testing is arguably the most critical step in composite repair QC. Moreover, specialized tools must be utilized to look for damage that cannot be seen with the naked eye.
Repair technicians use ultrasonic equipment to test composites. They compare changes in the echo pattern to find potential problems. They also use tap testing and thermography to identify potential anomalies and subsurface defects.
The final pillar of QC in composite repair is process control and documentation. All composite repair procedures must adhere strictly to OEM Structural Repair Manuals or FAA-approved engineering data.
Tooling and equipment must be calibrated and tested. Curing cycles must be exactly as specified in repair procedures. All instructions must be detailed and approved for every step. Through it all, documentation must be maintained.
An FAA-approved composite repair station bears a tremendous responsibility in maintaining aviation safety. Neither the station nor its personnel can afford to cut corners. Likewise, composite manufacturers like Aerodine must always adhere to the highest standards of quality and safety when manufacturing aerospace composites.
