Application
This unit of competency requires application of hand skills and the use of drawings, specifications and maintenance publications to fabricate advanced structural components involving complex and multiple curves and section shapes from aluminium alloys and steel alloys at various temper during scheduled or unscheduled maintenance. Work may be performed individually or as part of a team.
Applications include components for fixed and rotary wing aircraft.
The unit is part of the Aeroskills Structures Maintenance Certificate IV training pathway.
The unit is used in workplaces that operate under the airworthiness regulatory systems of the Australian Defence Force (ADF) and the Civil Aviation Safety Authority (CASA).
Elements and Performance Criteria
Elements describe the essential outcomes. | Performance criteria describe the performance needed to demonstrate achievement of the element. | ||
1. | Interpret specifications and organise materials | 1.1 | Specifications and drawings are used to determine material requirements |
1.2 | Equipment use is planned by determining the procedure for fabricating component | ||
1.3 | Material is correctly identified in accordance with specifications | ||
1.4 | All materials and equipment are organised | ||
2. | Prepare material and tooling | 2.1 | Dimensions to material is translated in accordance with specifications |
2.2 | Cutting and forming equipment are prepared and adjusted to ensure accuracy of fabrication | ||
2.3 | Material is cut according to specifications ensuring minimisation of wastage and maintenance of surplus material identification while observing all relevant work health and safety (WHS) requirements, including the use of material safety data sheets (MSDS) and items of personal protective equipment (PPE) | ||
2.4 | Material requiring special treatment is prepared for the appropriate processes | ||
2.5 | Solution treatment of materials is carried out in accordance with approved procedures and specifications | ||
3. | Form material | 3.1 | Appropriate forming procedure is determined ensuring that specifications are met and the most suitable forming method is selected |
3.2 | Templates are manufactured, where required, by forming method | ||
3.3 | Press tools are designed and manufactured, where required, by forming method | ||
3.4 | Forming equipment is operated correctly and safely to form material in accordance with drawings and specifications | ||
3.5 | Hand forming is performed accurately, where necessary | ||
4. | Hand correct fabricated components | 4.1 | Components are checked for irregularities and correction requirements determined |
4.2 | Irregularities are removed to meet required dimensions and specifications | ||
5. | Inspect components | 5.1 | Fabricated components are inspected to confirm dimensional accuracy and specifications are met |
5.2 | Checking fixtures are used, where appropriate, to ensure requirements are met | ||
5.3 | Components requiring special or further treatment are prepared for the appropriate processes | ||
5.4 | Completed components are tagged or identified, as required | ||
Evidence of Performance
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 include:
applying relevant WHS 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
handling and storing aircraft metals to industry standards
identifying aircraft structural assembly fasteners by interpretation of markings, numbering systems, size, shape and colour
fabrication of aircraft structural components and parts by:
correctly interpreting drawings, including third angle projection, isometric, sectional formats and hand sketches
developing component flat pattern using basic drawing tools, geometric drawing processes, calculating and applying bend allowance/deduction/setback Undertake component flat pattern development utilising:
parallel line
radial line
triangulation
using appropriate hand tools, machines (stretching, shrinking, bending, cutting, drilling, rolling, wheeling and folding), forming blocks, templates and presses to form/produce dished, domed, curved components, bent/angled (L, Z, U, hat) sections and lightening holes, flanges and joggles
assembling component parts using appropriate hand and machine tools and standard aircraft fasteners to industry standards
applying appropriate metal heat treatment processes
applying appropriate metal surface treatments.
The underlying skills inherent in this unit should be transferable across a range of aircraft applications. Evidence of knowledge and skills associated with the broad range of structural fabrication techniques and their application to different materials used in aircraft manufacture will be required to supplement evidence of ability to fabricate components.
Evidence of Knowledge
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:
aircraft construction principles
causes of structural fatigue and preventative measures
structural corrosion and preventative measures
aircraft structural drawings and repair scheme drawings
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
chemical surface treatments
electroplating
paints and finishes
flat pattern development and terminology
design and manufacture of templates
design and manufacture of press tools
methods for folding complex and nested sections
machinery used for stretching, shrinking, bending, cutting, drilling and rolling, use of forming blocks, templates and press tools to form components
use of forming blocks, templates and press tools to form components
WHS precautions associated with fabrication of aircraft structural components
MSDS
PPE.
Assessment Conditions
Competency should be assessed in the work environment, or simulated work environment, using tools and equipment specified by aircraft maintenance manuals. It is 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 on a representative range of structural fabrication tasks.
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).
Foundation Skills
Foundation skills essential to performance are explicit in the performance criteria of this unit of competency.
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. | ||
Components are to be fabricated: | Using materials comprising various types of sheet metal used in aircraft manufacture, including aluminium alloys and structural steel alloys across a range of temper | |
Machinery processes include: | Bending, cutting, rolling, shrinking and stretching | |
Procedures and requirements include: | Industry standard procedures specified by manufacturers, regulatory authorities or the enterprise | |
Sectors
Competency Field
Aviation maintenance