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Elements and Performance Criteria

1. Assess structural repair or modification requirements
   • Structural repair requirements are determined from maintenance manuals or approved repair schemes
   • Damage beyond repair scheme limits is referred to relevant personnel/authorities
   • Modification requirements are determined from approved drawings and specifications/ instructions or requirements are referred to relevant personnel/authorities
   • Completed work is evaluated for compliance with airworthiness requirements
2. Perform colour contrast dye penetrant NDT
   • Inspection requirements are identified from relevant maintenance data or to confirm a visually identified defect
   • Surfaces to be inspected are prepared for the dye penetrant process
   • Dye penetrant materials are selected in accordance with standard operating procedures
   • Penetrant test is performed in accordance with standard operating procedures and while observing all relevant work health and safety (WHS) precautions
   • Defect indications are checked and identified in accordance with standard operating procedures
   • Penetrant testing equipment is correctly maintained and stored while observing all relevant WHS requirements, including the use of material safety data sheets (MSDS) and items of personal protective equipment (PPE)
   • Results are recorded in accordance with standard enterprise and regulatory requirements

Range Statement

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.
Range of tasks and practices includes:	Standard practices for structural repair and modification, including damage measurement and assessment against approved repair schemes The process for referral of damage details and modification requirements to relevant personnel/authorities Supervision of repair scheme and modification incorporation, including evaluation of work against drawings and specifications Scheduled or unscheduled maintenance Individual activities or supervision of other personnel performing maintenance tasks classified in CASR part 145 as specialist maintenance, including: non-destructive inspection welding surface plating surface finishing preparing structural repair components machining
Surface preparation for dye penetrant NDT includes:	Removal of surface finishes where applicable Thorough cleaning of the surface Drying of the surface Processes included in standard procedures
Dye penetrant materials include:	Appropriate surface cleaning materials Emulsifiers Developers Materials for surface cleaning after testing
Procedures and requirements include:	Industry standard procedures specified by manufacturers, regulatory authorities or the enterprise

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Performance Evidence

Evidence required to demonstrate competency in this unit must be relevant to and satisfy all of the requirements of the elements and performance criteria under the specified conditions of assessment, and must include:

interpreting damage limits and identifying applicable repair schemes

interpreting all requirements of modification drawings and assessing work against them

evaluating completed repairs and modifications for compliance with the applicable data and with airworthiness requirements

recognising weld defects

performing colour contrast dye penetrant NDT to confirm defects in applicable aircraft components

application of relevant WHS practices, including the use of MSDS and PPE.

The underlying skills inherent in this unit should be transferable across a range of repair and modification applications related to the structure of aircraft. It is essential that the repair and modification procedures take into account all applicable safety precautions. The ability to interpret repair scheme and modification requirements, including applicable specifications (allowable limits) and ensure that they are applied in practice is critical.

This must be demonstrated through the correct determination of repair requirements and the determination of compliance with repair schemes and modification drawings.

The ability to assess sound weld repairs must also be demonstrated.

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Knowledge Evidence

Evidence required to demonstrate competency in this unit must be relevant to and satisfy all of the requirements of the elements and performance criteria and include knowledge at a post-trade level of:

application of regulatory requirements and of manufacturer’s requirements in the determination of structural maintenance needs

assessment of the extent of damage and an understanding of the need for a professional engineer to develop or extend a repair scheme where damage is beyond the limits of maintenance manual repair schemes, including the identification of relevant personnel and authorities

assessment of new equipment or component mounting requirements and an understanding of the need to have drawings and specifications developed by a professional engineer, including the identification of relevant personnel and authorities

the need for shoring and support to maintain aerodynamic shape and for safe performance of structural maintenance

the need for mensuration checks and the techniques used to perform them

how to determine welding requirements and the recognition of sound welds

the correct application of colour contrast dye penetrant NDT and the limitations of the testing method

dye penetrant test procedures:

relevant WHS precautions and how to obtain PPE and MSDS

cleaning and preparation processes and materials

consequences of incorrect preparation

basic concepts and principles of NDT and appropriate use of the colour contrast dye penetrant technique

general properties of penetrants (penetrability, removability and visibility)

types of emulsifiers and developers

established procedures and techniques

defect types and their consequences

post-test cleaning methods

aircraft welding regulations

aircraft welding processes and relevant parent metal groups

defects applicable to each welding process and parent metal group.

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