This unit of competency requires application of procedures and techniques associated with the repair of non-pressurised small aircraft structure during scheduled or unscheduled maintenance. Work may be performed individually or as part of a team and involves the performance of a limited range of metal and composite repairs. Where extensive repair involving the replacement of major structural components, such as wing spars and fuselage frames, is required the applicable unit is MEA371 Perform major repairs and modifications to small aircraft metal structure.

The unit is part of the Aeroskills Mechatronics Certificates III and IV small aircraft maintenance training pathways.

Where a Civil Aviation Safety Authority (CASA) licensing outcome is sought this unit forms part of the CASA requirement for the granting of the chosen maintenance certification licence under Civil Aviation Safety Regulation (CASR) Part 66, in accordance with the licensing provisions in the Companion Volume Implementation Guide.

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:

applying all relevant WHS procedures, including the selection and use of MSDS and applicable items of PPE

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 – hillocks and 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, stepped and bolted repairs

metal to metal and metal to composite bonding

applying structural corrosion removal/treatment techniques

restoring aircraft structure sealing and surface finishes.

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 structures 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.

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 of:

applicable WHS procedures, including the use of PPE and MSDS

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

structural and non-structural component methods of attachment, faying surface treatment and fuel tank sealing

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

bolted repairs

repair of integral fuel tanks and sealing of faying surfaces, including specific WHS and PPE requirements

surface finishes and methods of restoration, including specific WHS and PPE requirements

how to obtain MSDS

relevant maintenance and structural repair manuals

relevant regulatory requirements and standard procedures.

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.

The following conditions of assessment represent the requirements of the Regulators (ADF and CASA) and maintenance stakeholders and must be rigorously observed.

A person cannot be assessed as competent until it can be demonstrated to the satisfaction of the workplace assessor that the relevant elements and performance criteria of the unit of competency are being achieved under routine supervision across the variables in the Range of Conditions as follows:

recognition of each type of damage:

impact damage

fatigue cracking

corrosion

delamination of composites and bonded structures

one (1) repair task from each of the following groups:

remove corrosion by chemical and mechanical methods

restore protective coatings

apply sealants and jointing compounds

freehand precision hole generation

remove and install structural hardware and fastening devices

remove and replace bushes, bearings and bearing surfaces

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

composite external patch, scarf and stepped repairs.

This shall be established via the records in the Log of Industrial Experience and Achievement or, where appropriate, an equivalent Industry Evidence Guide (for details refer to the Companion Volume Assessment Guidelines).

Assessors must satisfy the requirements of the National Vocational Education and Training Regulator (Australian Skills Quality Authority, or its successors).

Where the unit is to be used for CASA licensing purposes the Assessor must also meet the criteria specified in the CASR Part 147 Manual of Standards.

The competency elements and performance criteria also cover a significant portion of those required for unit MEA339 Inspect, repair and maintain aircraft structures. Refer to that unit for details of credits that may be granted during assessment.

Foundation skills essential to performance are explicit in the performance criteria of this unit of competency.

Aviation maintenance