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Evidence Guide: MEA405 - Repair/modify aircraft composite material structure/components

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

MEA405 - Repair/modify aircraft composite material structure/components

What evidence can you provide to prove your understanding of each of the following citeria?

Plan repair/modification

  1. Extent of damage is correctly assessed to assist in determining repair procedure
  2. Structure is supported and prepared in accordance with the applicable maintenance manual to ensure personnel safety and freedom from damage
  3. Appropriate modification or repair scheme is identified in accordance with structural repair manual and/or approved data
  4. Specialist advice is obtained in establishing an approved repair scheme where a standard repair scheme cannot be identified or damage criteria are out of limits
  5. All materials and equipment required are organised
Extent of damage is correctly assessed to assist in determining repair procedure

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Structure is supported and prepared in accordance with the applicable maintenance manual to ensure personnel safety and freedom from damage

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

All materials and equipment required are organised

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare components for hot bonding

  1. Components are prepared in accordance with applicable process specification 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. Bagging is checked to ensure vacuum seal is correct
  3. Temperature probes are placed appropriately to provide accurate measurement
  4. Equipment is checked for serviceability to ensure safety in application
  5. Heat blanket is laid on component or repair in a manner that ensures even temperature distribution
Components are prepared in accordance with applicable process specification 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)

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Bagging is checked to ensure vacuum seal is correct

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Temperature probes are placed appropriately to provide accurate measurement

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Equipment is checked for serviceability to ensure safety in application

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Heat blanket is laid on component or repair in a manner that ensures even temperature distribution

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Repair/modify components using hot bond

  1. Hot bonding equipment is operated in accordance with equipment manufacturer's procedures
  2. Vacuum and temperature recordings are monitored, including checking of hot and cold spots on trailing and leading temperature probes, to ensure specifications are met
  3. Curing cycle and recording of operating cycle data are monitored as required by approved procedures to ensure specifications are met
  4. Blemishes are sealed, potted or filled, where necessary, in accordance with applicable process specification
  5. Component assemblies, including test pieces, requiring further or special treatment are made ready for the appropriate processes
  6. Required maintenance documentation is accurately completed and correctly processed
  7. Completed assemblies are tagged, sealed or packaged as required
Hot bonding equipment is operated in accordance with equipment manufacturer's procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Vacuum and temperature recordings are monitored, including checking of hot and cold spots on trailing and leading temperature probes, to ensure specifications are met

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Curing cycle and recording of operating cycle data are monitored as required by approved procedures to ensure specifications are met

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Blemishes are sealed, potted or filled, where necessary, in accordance with applicable process specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Component assemblies, including test pieces, requiring further or special treatment are made ready for the appropriate processes

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Required maintenance documentation is accurately completed and correctly processed

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Completed assemblies are tagged, sealed or packaged as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Repair/modify components using cold cure

  1. Lay up of materials is checked to confirm that components meet required specifications while observing all relevant WHS requirements, including the use of MSDS and items of PPE
  2. Curing cycle is regularly monitored to ensure required specifications are met
  3. Components are checked for blemishes or delamination in accordance with quality procedures
  4. Component assemblies requiring further or special treatment are made ready for the appropriate processes
  5. Required maintenance documentation is completed and processed in accordance with standard enterprise procedures
  6. Completed assemblies are tagged, sealed or packaged as required
Lay up of materials is checked to confirm that components meet required specifications while observing all relevant WHS requirements, including the use of MSDS and items of PPE

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Curing cycle is regularly monitored to ensure required specifications are met

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Components are checked for blemishes or delamination in accordance with quality procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Component assemblies requiring further or special treatment are made ready for the appropriate processes

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Completed assemblies are tagged, sealed or packaged as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1.

Plan repair/modification

1.1

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

1.2

Structure is supported and prepared in accordance with the applicable maintenance manual to ensure personnel safety and freedom from damage

1.3

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

1.4

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

1.5

All materials and equipment required are organised

2.

Prepare components for hot bonding

2.1

Components are prepared in accordance with applicable process specification 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)

2.2

Bagging is checked to ensure vacuum seal is correct

2.3

Temperature probes are placed appropriately to provide accurate measurement

2.4

Equipment is checked for serviceability to ensure safety in application

2.5

Heat blanket is laid on component or repair in a manner that ensures even temperature distribution

3.

Repair/modify components using hot bond

3.1

Hot bonding equipment is operated in accordance with equipment manufacturer's procedures

3.2

Vacuum and temperature recordings are monitored, including checking of hot and cold spots on trailing and leading temperature probes, to ensure specifications are met

3.3

Curing cycle and recording of operating cycle data are monitored as required by approved procedures to ensure specifications are met

3.4

Blemishes are sealed, potted or filled, where necessary, in accordance with applicable process specification

3.5

Component assemblies, including test pieces, requiring further or special treatment are made ready for the appropriate processes

3.6

Required maintenance documentation is accurately completed and correctly processed

3.7

Completed assemblies are tagged, sealed or packaged as required

4.

Repair/modify components using cold cure

4.1

Lay up of materials is checked to confirm that components meet required specifications while observing all relevant WHS requirements, including the use of MSDS and items of PPE

4.2

Curing cycle is regularly monitored to ensure required specifications are met

4.3

Components are checked for blemishes or delamination in accordance with quality procedures

4.4

Component assemblies requiring further or special treatment are made ready for the appropriate processes

4.5

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

4.6

Completed assemblies are tagged, sealed or packaged as required

Required Skills and Knowledge

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1.

Plan repair/modification

1.1

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

1.2

Structure is supported and prepared in accordance with the applicable maintenance manual to ensure personnel safety and freedom from damage

1.3

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

1.4

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

1.5

All materials and equipment required are organised

2.

Prepare components for hot bonding

2.1

Components are prepared in accordance with applicable process specification 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)

2.2

Bagging is checked to ensure vacuum seal is correct

2.3

Temperature probes are placed appropriately to provide accurate measurement

2.4

Equipment is checked for serviceability to ensure safety in application

2.5

Heat blanket is laid on component or repair in a manner that ensures even temperature distribution

3.

Repair/modify components using hot bond

3.1

Hot bonding equipment is operated in accordance with equipment manufacturer's procedures

3.2

Vacuum and temperature recordings are monitored, including checking of hot and cold spots on trailing and leading temperature probes, to ensure specifications are met

3.3

Curing cycle and recording of operating cycle data are monitored as required by approved procedures to ensure specifications are met

3.4

Blemishes are sealed, potted or filled, where necessary, in accordance with applicable process specification

3.5

Component assemblies, including test pieces, requiring further or special treatment are made ready for the appropriate processes

3.6

Required maintenance documentation is accurately completed and correctly processed

3.7

Completed assemblies are tagged, sealed or packaged as required

4.

Repair/modify components using cold cure

4.1

Lay up of materials is checked to confirm that components meet required specifications while observing all relevant WHS requirements, including the use of MSDS and items of PPE

4.2

Curing cycle is regularly monitored to ensure required specifications are met

4.3

Components are checked for blemishes or delamination in accordance with quality procedures

4.4

Component assemblies requiring further or special treatment are made ready for the appropriate processes

4.5

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

4.6

Completed assemblies are tagged, sealed or packaged as required

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 relevant WHS procedures, including the use of PPE and MSDS

using approved maintenance documentation and aircraft publications relating to aircraft structure

identifying composite component applications in aircraft structures

identifying various aircraft composite materials/resins and their basic properties by interpretation of markings and visual means

handling and storing of composite materials to industry standards

assessing composite component damage using visual and tap test methods

performing composite component repairs using:

external patch repair

scarf repair

stepped repair

wet lay-up repair

composite fastener hole repair

metal to metal and metal to composite bonding

correctly interpreting and /or producing repair scheme/modification drawings/sketches

using appropriate hand tools and machines to disassemble and assemble aircraft composite components, parts, sections and skin, including extraction/installation equipment, drilling/cutting equipment, and material fasteners.

The underlying skills inherent in this unit should be transferable across the range of different material applications and curing requirements. It is essential that specific aspects of the laying up and curing process for aircraft composite materials are checked to ensure quality and safety standards are achieved in this area. Correct checking and wearing of safety protective clothing is critical, particularly in the hot bonding process.

Evidence of knowledge about repair techniques and the use of the standard repair manual in a range of different repair situations will be necessary to supplement evidence of ability to plan and undertake component repair. Ability to apply different materials and curing cycles, including composite to composite and composite to metal components, will be necessary to indicate competency in preparing and curing composite materials.

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:

how to obtain relevant MSDS

the use of applicable items of PPE

WHS procedures

aircraft construction principles

defining composite terminology

composite component construction methods, including structural assembly fastener identification.

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.

Applicable materials and methods include:

Pre-preg materials hot cure (performed on one of carbon graphite, kevlar, fibreglass or aluminium)

Cold cure or wet lay-up (using either fibreglass or carbon graphite)

Core materials (using one of aluminium, nomex or foam)

Procedures and requirements include:

Industry standard procedures specified by manufacturers, regulatory authorities or the enterprise