Course # 603 –

Aircraft Structures and Repair Analysis III – Advanced

When a student completes this course she/he should be able to:

    • understand fatigue concepts and fundamentals
    • check the repair for inter-rivet buckling
    • be familiar with the steps to solve advanced buckling problems
    • possess an excellent knowledge of cold expansion of holes and how they improve fatigue crack growth life
    • estimate joint load distributions
    • grasp the fundamentals of the damage tolerance philosophy and damage tolerant repairs
    • appreciate which fastener holes are fatigue-critical
    • know how to construct residual strength diagram
    • understand stiffened structures, the effects of fastener pitch, stiffener spacing and other variables on residual strength of a stiffened panel
    • explain the idea behind “zero-timing” of fastener holes and the pitfalls
    • how/when to communicate with OEM for repairs beyond SRM (Structural Repair Manual) limits
    • have a solid familiarity with NDI techniques used, their applications and limitations


  • preferably taken FATIGUE CONCEPTS 602 or Boeing/Airbus Intermediate Structural Repair training and,
  • some experience in OEM-approved aircraft structural repairs
  • a Bachelor’s Degree in Engineering or equivalent experience

Who should take this training:

Managers / Engineers / Materials Scientists / Inspectors / DERs in:

  • Aircraft Maintenance
  • Aircraft Production
  • Airline Liaison with OEM
  • Continuing Airworthiness
  • Aircraft Production
  • Helicopter Maintenance
  • Repair & Overhaul of Airframes
  • Accident Investigation
  • Engine Overhaul
  • Materials Selection
  • Materials and Processing (M&P)
  • Automobile
  • Structural Analysis
  • Structural Design
  • Fatigue Crack Growth Analysis
  • Safety Officers
  • Wiring / Ageing Avionics
  • Regulatory Authority, NAAs
  • Corrosion Prevention & Control Programs (CPCP)

From Industries including but not limited to:

  • Airlines
  • Defense Directorates
  • MROs, Repair Stations
  • Army
  • Aircraft and Component Manufacturers
  • Airforce
  • Technical College
  • Navy
  • Civil Aviation Authorities
  • Aircraft Manufacturers
  • Material Suppliers
  • Universities
  • Accident Investigation Agencies, NTSB


  1. Review of Fundamentals of Fatigue Concepts
    • Effects of Stress Concentration, Size, Thickness…
    • Mean Stress and Alternating Stress Effects
    • Environmental Effects, Corrosive Atmosphere
    • Fatigue Fundamentals
    • Designing for Durability
  2. Miner’s Rule
    • Cumulative Damage Hypothesis
    • Applicability
  3. Joint Analysis
    • Springs
    • Fasteners
  4. Fatigue Life Estimation
    • Fuselage Fatigue Life Estimates
    • Loads Data or Lack thereof
  5. Damage Tolerance
    • Safe Life vs Fail Safe
    • Multiple Load Paths and Crack Arrest Concepts
    • Damage Tolerant Design
    • Inspection Techniques
    • Probability of Detection
    • Human Factors
    • Proximity of Repairs
  6. Aging Airplane RAP – Repair Assessment Program
This syllabus is for guidance only; the syllabus may change retaining the current flavor.