This unit requires application of hand skills, applicable tools, maintenance publications and repair drawings to inspect and repair/modify aircraft structure, including the replacement of primary structure components.

Applications include both fixed and rotary wing aircraft.

MEA304C

Remove and install non-pressurised aircraft structural and non-structural components

OR

MEA317C

Remove and install pressurised aircraft structural and non-structural components

ELEMENT

PERFORMANCE CRITERIA

1. Inspect aircraft structure.

1.1. Relevant maintenance documentation and modification status, including defect reports, where relevant, are used to identify specific inspection requirements.

1.2. Appropriate preparation and access to the aircraft structure is undertaken to allow for proper inspection in accordance with maintenance documentation.

1.3. Aircraft structure is visually or physically checked for signs of deformation defects or damage in accordance with maintenance documentation and approved procedures.

1.4. Damage or defects are assessed against damage or wear limits specified by structural repair manual or other approved data to determine if repair or replacement is required.

2. Prepare to undertake repair.

2.1. Extent of damage is correctly assessed to assist in determining repair procedure.

2.2. Structure is supported and prepared in accordance with the applicable maintenance manual to ensure personnel safety and freedom from damage. Jigs, fixtures or bracing is used as required to maintain shape and/or alignment.

2.3. Appropriate modification or repair scheme is identified in accordance with structural repair manual and/or approved data.

2.4. Specialist advice is obtained in establishing an approved repair scheme where a standard repair scheme cannot be identified or where damage is beyond specified limits.

2.5. All materials and equipment required are organised

3. Repair/modify aircraft structure

3.1. Required maintenance/repair documentation is accurately completed and correctly processed.

3.2. Structural repairs/modifications are performed, in accordance with approved repair scheme, ensuring that aircraft standard practices are used and process requirements are carried out.

3.3. Work area is cleaned of all waste material or contaminants.

3.4. Required mensuration/alignment checks are completed and components are adjusted, where necessary, to operate within prescribed specifications.

3.5. Repaired components or assemblies are tagged, sealed and packaged or cradled in accordance with specified procedures, where required.

3.6. Required maintenance documentation is completed and processed in accordance with standard enterprise procedures.

Required skills

Look for evidence that confirms skills in:

Application of applicable occupational health and safety (OHS) regulations and practices including the use of Material Safety Data Sheets (MSDS) and personal protective equipment (PPE)

The use of approved maintenance documentation and aircraft publications relating to aircraft structure

Demonstrating appropriate cleaning procedures to enable structure inspection.

Demonstrating correct inspection procedures, in particular pressurised aircraft, in accordance with aircraft and procedures manuals.

Identifying damage to aircraft metallic (ferrous and non-ferrous) structures and/or components by way of:

impact

fatigue

corrosion

Identifying the various forms of structural corrosion, stating the causes and structural effects of corrosion on aircraft.

Identifying composite materials used in aircraft construction, associated safety precautions and hazards.

Inspecting damage and assessing composite components/structures.

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 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

Correctly supporting the aircraft structure by jacking, trestling and/or jigging methods

Performing a range of metal structure and composite material repair techniques including:

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

composite external patch, scarf and stepped repairs

metal to metal and metal to composite bonding

Applying structural corrosion removal/treatment techniques

Restoring aircraft structure sealing and surface finishes

Required knowledge

Look for evidence that confirms knowledge of:

Aircraft construction principles and structural component attachment methods:

types of aircraft structure

structural loads

loads under various conditions of flight

causes of structural failure

attachment methods:

bolts and screws

solid and blind rivets

close tolerance fasteners

bonding

The construction methods used in:

fuselage sections

wing sections

engine nacelles and mounts

windows and window frames

doors, locks and access panels in pressurised and non-pressurised aircraft

Describing various aircraft metals and their basic properties:

ferrous

non-ferrous

Aircraft plastic transparency construction methods and common defects

Glass windscreen basic constructional features and common defects

Composite materials:

terminology

materials used for minor repairs

OHS requirements

Aircraft structure inspection requirements:

metallic structure

non-metallic/composite structure (other than wood and fabric)

Non-destructive inspection methods and application of the various techniques

Assessment of structural damage:

types and classes of mechanical damage

types of corrosion and determining the extent of damage

relevant documentation and manuals

damage limits and repair schemes for metallic and non-metallic structure

Procedures for the fabrication and fitment of metal repairs:

scab patch

flush patch

splice

lap

formed section

Corrosion removal and passivation

Procedures for performing composite repairs:

external patch

scarf patch

stepped repairs

Procedures for replacement of primary structure components such as:

fuselage frames and longerons

wing spars or spar caps

wing-to-fuselage attachment fittings

tailplane attachment fittings

Aircraft mensuration checks - when required and methodology

Repair of integral fuel tanks and sealing of faying surfaces including specific OHS and PPE requirements

Surface finishes and methods of restoration

How to obtain MSDS

Relevant maintenance and structural repair manuals

Relevant regulatory requirements and standard procedures

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 use maintenance manuals, repair scheme drawings and applicable tools to inspect and repair/modify aircraft structure while observing 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 across a range of inspection, testing and repair applications associated with aircraft maintenance. It is essential that the procedures take into account all aircraft and personal safety precautions relating to aircraft structure.

Evidence of transferability of skills and knowledge related to inspection, testing and repair of aircraft structure is essential. This may be demonstrated through application across a number of aircraft systems or aircraft types. Ability to interpret inspection and repair procedures and specifications and apply them in practice is critical. The application of the procedures should also clearly indicate knowledge of structural flight loads and aerodynamic requirements.

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 inspection task from each of Groups 1 to 6 and at least one repair task from each of Groups 7 to 15, as 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 .

Context of and specific resources for assessment

Competency should be assessed in the work environment or simulated work environment using tools and equipment specified in maintenance documentation. It is also expected that general purpose tools and test equipment found in most routine situations would be used where appropriate.

Method of assessment

Guidance information for assessment

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

Range statements listed below are numbered to facilitate specification of the assessment requirements included in the Evidence Guide.

Specific inspection requirements and repair tasks

Specific inspection requirements may cover:

1. Non-ferrous and ferrous alloys and composite (FRP) materials used in aircraft construction

2. Structural fastening and attachment hardware and/or devices

3. Seals, sealants

4. Glass, moulded plastics

5. Application of NDI techniques

6. Doors, hinges and locking mechanisms for damage/misalignment

Repair tasks may include:

7. Removing corrosion by chemical and mechanical methods

8. Restoring protective coatings

9. Applying sealants and jointing compounds

10. Freehand precision hole generation

11. Removing and installing structural hardware and fastening devices

12. Removing and replacing bushes, bearings and bearing surfaces

13. Removing and repairing damaged sections and reinstalling

14. Repairing by replacement major load-carrying structural members, ie skins, longerons, spars, frames, bulkheads

15. Minor repairs to non-metallic materials.

Inspection techniques

Inspection techniques may include:

Visual inspection

Physical checks

Mensuration and alignment.

Assembly stress defects

Assembly stress defects can refer to:

Oil canning

Buckling

Contour misalignment.

Application of this unit may relate to:

Scheduled or unscheduled maintenance activities, and includes special inspections required after events such as heavy landings, overstress or flight through heavy turbulence

Individual or team related activities

Procedures and requirements

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

Unit sector

Aviation maintenance

This unit contains employability skills.