Assessor Resource

MEA422A
Repair_modify aircraft metal structure

Assessment tool

Version 1.0
Issue Date: May 2024


This unit requires application of hand skills, the use of special tools and structural repair manuals and approved repair schemes to repair aircraft structure. Where fabrication of replacement components is required the applicable units are MEA420A Fabricate basic structural components for aircraft and MEA421A Fabricate advanced structural components for aircraft. Where major structural disassembly is required the applicable unit is MEA423A Aircraft structure major disassembly and reassembly.

Applications include the metal structure of fixed and rotary wing aircraft.

This unit of competency is part of the Aeroskills Structures Maintenance Certificate IV training pathway. It covers the competencies required for the repair and modification of fixed and rotary wing aircraft metal structure. The unit is used in workplaces that operate under the airworthiness regulatory systems of the ADF and the CASA.

You may want to include more information here about the target group and the purpose of the assessments (eg formative, summative, recognition)

Prerequisites

MEA401C

Inspect aircraft structures

Employability Skills

This unit contains employability skills.



Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

A person who demonstrates competency in this unit must be able to apply hand skills, use special tools and structural repair manuals and schemes and modification data to repair/modify aircraft structure while applying all relevant safety precautions.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

The underlying skills inherent in this unit should be transferable into other areas that require similar techniques. It is essential that procedures take into account all safety precautions and quality requirements, standards and practices and processes associated with assembly.

Evidence of knowledge about repair techniques and the use of the standard repair manual in a range of different repair situations will be necessary to supplement evidence of ability to plan and undertake structure and component repair.

A person cannot be assessed as competent until it can be demonstrated to the satisfaction of the workplace assessor that the relevant elements of the unit of competency are being achieved under routine supervision on at least one item from each of Groups 1 to 6 listed in the Range Statement. This shall be established via the records in the Log of Industrial Experience and Achievement or, where appropriate, an equivalent Industry Evidence Guide.

Context of and specific resources for assessment

Competency should be assessed in the work environment, using tools and equipment specified by aircraft maintenance manuals. It is also expected that general purpose tools, test and ground support equipment found in most routine situations would be used where appropriate.

Method of assessment

Guidance information for assessment

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assingnment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)

Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

Look for evidence that confirms knowledge of:

aircraft construction principles and the causes of structural damage, including metal fatigue and corrosion

structural fatigue preventative measures

structural corrosion removal and preventative measures

aircraft repair schemes and modification data/drawings

procedures for the design and approval of repair schemes and modifications

material specifications for aluminium alloys and steel alloys used in aircraft structure

structural material identification by markings and numbering systems

material identification by chemical, electrical and mechanical methods

material storage requirements

hardware types and specifications

identification of hardware

sealants used in aircraft structure and their application and handling

chemical surface treatments

electroplating

paints and finishes

OHS precautions associated with repair of aircraft structure

MSDS

PPE

Look for evidence that confirms skills in:

applying relevant OHS procedures, including the use of MSDS and applicable items of PPE

using approved maintenance documentation and aircraft publications relating to aircraft structure

identifying various aircraft metals and their basic metallurgy properties by interpretation of markings, numbering systems or visual, chemical or mechanical means

identifying various aircraft composite materials and their basic properties by interpretation of markings and visual means

handling and storing aircraft metals and composite materials, including sealing agents, to industry standards

identifying aircraft structural assembly fasteners (metal and composite) by interpretation of markings, numbering systems, size, shape and colour

correctly assessing and describing the extent of damage

correctly interpreting and/or producing repair scheme/modification drawings (including third angle projection, isometric, sectional formats and hand sketches)

using appropriate hand tools and machines to remove and assemble aircraft structural components, parts, sections and skin, including riveting equipment, drilling equipment, aligning tools and material fasteners (grip pins)

applying correct removal, installation and repair techniques for:

a range of rivets (blind and solid) using hand, squeeze and pneumatic situations

a range of close tolerance fasteners (standard and oversize – hilocks, taper locks), including hole preparation

threaded devices, including internal and external thread cutting, helicoil inserts and damaged stud replacement

hardware assembled by close tolerance fits using heat, cooling and force methods, including bearings, bushes and inserts

correct support of the aircraft structure by jacking, trestling and/or jigging methods

performing a range of metal structure repair techniques, including:

metal scab patch, flush, splice, lap and formed section repair

metal to metal and metal to composite bonding

applying structural corrosion removal/treatment techniques

restoring aircraft structure sealing and surface finishes

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Note

The Range Statements below are numbered to facilitate specification of the assessment requirements included in the Evidence Guide

Repair procedures

Repair procedures may include:

1. Remove corrosion by chemical and mechanical methods

2. Restore protective coatings

3. Apply sealants and jointing compounds

4. Freehand precision hole generation

5. Remove and install structural hardware, fastening devices, bushes, bearings and bearing surfaces

6. Remove and repair damaged sections and reinstall

Procedures and requirements

Refer to industry standard specified by manufacturers, regulatory authorities or the enterprise

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
The extent of damage is correctly assessed to assist in determining repair procedure 
Structure is prepared and supported in accordance with the applicable maintenance manual to ensure personnel safety and freedom from damage 
The appropriate modification or repair scheme is identified in accordance with structural repair manual and/or approved data 
Specialist advice in establishing an approved repair scheme is obtained where a standard repair scheme cannot be identified or damage is out of limits 
All required materials and equipment are organised 
Structural repairs are performed in accordance with approved repair scheme, ensuring that aircraft standard practices are used and process requirements are carried out 
Work area is cleaned of all waste material or contaminants 
Components are adjusted, where necessary, to operate within prescribed specifications 
Repaired components or assemblies are tagged, sealed and packaged, or cradled in accordance with specified procedures, where required 
Required documentation is completed and processed in accordance with standard enterprise procedures 

Forms

Assessment Cover Sheet

MEA422A - Repair_modify aircraft metal structure
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:

Assessment Record Sheet

MEA422A - Repair_modify aircraft metal structure

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: