This unit requires application of procedures and techniques associated with the inspection and maintenance of aircraft structure, and with the performance of a limited range of metal and composite repairs.

Applications include the performance of structural maintenance activities on fixed or rotary wing aircraft on the flight line or in the hangar.

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 is 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.

1.5. Maintenance documentation is completed and processed in accordance with standard enterprise procedures.

2. Prepare to undertake repair

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

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

2.3. Specialist advice is obtained in establishing an approved repair scheme where a standard repair scheme cannot be identified or damage is out of limits.

2.4. All materials and equipment required are organised.

3. Repair and maintain aircraft structure

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

3.2. Preventative maintenance techniques are employed to preserve the integrity of aircraft structure.

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

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

Required skills

Look for evidence that confirms skills in:

Applying all relevant occupational health and safety (OHS) procedures including the use of Material Safety Data Sheets (MSDS) and selection and use of applicable items of personal protective equipment (PPE)

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 or the various types of corrosion.

Inspecting damage and assessing composite components/structures.

Identifying various aircraft metals and their basic properties.

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

Correctly interpreting repair scheme drawings (including third angle projection, isometric, sectional formats and hand sketches).

Using appropriate hand tools and machines 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

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:

Applicable occupational health and safety (OHS) procedures, including the use of MSDS and PPE

Construction methods and materials 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

Definition of structural terms, i.e. failsafe, stress, strain, shear, cycles

Potential causes of structural failure.

Non-destructive inspection methods and application of the various techniques.

Construction methods of, and assessing common defects in, aircraft plastic transparencies.

Basic constructional features of, and assessing common defects in, glass windscreens.

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

The terms associated with composite materials.

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

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

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

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

Surface finishes and methods of restoration including specific OHS and PPE requirements

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 inspect and maintain aircraft structure and perform a range of metal and composite structural repair tasks that are representative of the scope of the listed variables in accordance with relevant maintenance documentation while applying all relevant OH&S procedures and standard processes.

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 across the variables in the Range Statement as follows:

Inspection and/or testing of at least one item from each of groups 1 to 6

Recognition of each type of damage 7 to 10

One repair task from each of groups 11 to 18

This shall be established via the records in the Log of Industrial Experience and Achievement.

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.

Inspection and repair of aircraft structure

Inspection of aircraft structure includes:

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.

Damage or defects may include:

7. Impact damage

8. Fatigue cracking

9. Corrosion

10. Delamination of composites and bonded structures

Structural repairs may include the following:

11. Remove corrosion by chemical and mechanical methods

12. Restore protective coatings

13. Apply sealants and jointing compounds

14. Freehand precision hole generation

15. Remove and install structural hardware and fastening devices

16. Remove and replace bushes, bearings and bearing surfaces

17. Metal scab patch, flush, splice, lap and formed section repair

18. Composite external patch, scarf and stepped repairs.

Specialist advice

Specialist advice is obtained from:

Supervisors

Specialist structures personnel

Documentation

Relevant maintenance documentation includes:

Servicing Schedules

Maintenance manuals

Applicable Defence regulations and instructions

Application of this unit may relate to:

Scheduled or unscheduled maintenance including 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.