Applying finishes to aircraft composite mouldings
Overview
This standard identifies the competences you need to apply finishes to aircraft composite mouldings, in accordance with approved procedures. It covers both fixed wing and rotary winged aircraft. You will be required to use appropriate drawings, specifications and documentation to apply finishes, using the correct techniques.
You will apply finishes to aircraft composite mouldings using a range of techniques and processes. A variety of finishes will be applied to a range of resin and fibre materials.
Your responsibilities will require you to comply with organisational policy and procedures for the finishing activities undertaken and to report any problems with the activities, equipment or materials that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying finishing techniques and procedures to aircraft composite mouldings. You will understand the finishing techniques used and their application, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring that the work output is to the required specification.
You will understand the safety precautions required when carrying out the finishing operations and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- ensure that material surfaces to be treated are suitably prepared for the finishing operations to be carried out
- check that the finishing equipment and treatment solutions are set up and maintained at satisfactory operating conditions and levels
- apply finishes in accordance with operating procedures and the component specification requirements
- ensure that the treated workpiece achieves the required characteristics and meets the finishing specification
- deal promptly and effectively with problems within your control and report those that cannot be solved
- dispose of waste and excess materials in line with agreed organisational procedures
- shut down the finishing equipment to a safe condition on completion of the processing activities
- complete the relevant documentation, in accordance with organisational requirements
- leave the work area in a safe and appropriate condition on completion of the activities
Knowledge and Understanding
You need to know and understand:
- health and safety precautions to be taken and procedures used when working with aircraft composite materials, consumables, tools and equipment in the specific work area
- the hazards associated with applying finishes to aircraft composite materials and with the consumables, tools and equipment used and how to minimise them and reduce any risks in the work area
- protective equipment that is needed for personal protection (PPE) and where required, the protection of others
- the application of COSHH regulations in relation to the storage, use and disposal of aircraft composite materials and consumables
- the specific workshop environmental conditions the must be observed when applying finishes to aircraft composite mouldings (such as temperature, humidity, styrene levels to threshold limits, fume/dust extraction systems and equipment)
- how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS, ISO or BSEN standards) in relation to work undertaken
- quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification) and the completion of such documents
- conventions and terminology used for applying finishes (such as surface keying, finish thickness, matt finish, gloss finish, treatment reactions)
- different types of composite resin systems, fibres, reinforcements and their merits
- different finishes applied to aircraft composites and their applications
- correct methods of storage, handling and disposal of finishing materials
- methods of preparation for applying different finishes
- mixing ratios for two-part finishes and the associated working times
- methods of application for different finishes
- problems that can occur during the finishing process (including defects such as contamination)
- how defects can be overcome during the finishing activity
- tools and equipment used in finishing activities and their care, preparation and control procedures
- why tool/equipment control is critical and what to do if a tool or piece of equipment is unaccounted for on completion of the activities
- the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
Scope/range
Scope Performance
Carry out all of the following during the finishing activities:
- obtain and use the appropriate documentation (such as job instructions, drawings, planning and quality control documentation, material data sheets, specifications)
- adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- provide and maintain a safe working environment for the composite finishing activities
- obtain the correct tools and equipment for the activity and check that they are in a safe, tested and usable condition
- follow safe practice/approved mould finishing techniques and procedures at all times
- return all tools and equipment to the correct location on completion of the mould finishing activities
- dispose of waste materials in accordance with approved procedures
Carry out all of the following activities when preparing for the finishing activity:
- check that mouldings are correct and complete
- select the correct equipment for the activity
- check for any defects in the mouldings
- check that the equipment is suitable for use
- check availability of ancillary materials required
- identify and protect the moulding in the work area
Apply finishes to composite mouldings, using two of the following techniques:
- cloth application
- brush
- spray
- laying films
- roller
- other specific technique
Prepare surfaces of composite mouldings, using two of the following methods:
- abrading
- surface masks
- peel ply
- etching
- bead blasting
- water cleaning
- solvent cleaning
- priming
- other specific method
Apply two types of finish to composite mouldings from:
- surface sealers
- top coats
- UV coatings
- speciality coatings
- primers
- adhesive films
- heatproof coatings
- flexible coatings
- other specific type of finish
Apply finishes to composite mouldings, using three of the following:
- one-part finishes
- multiple coatings
- solvent based
- water based
- single coatings
- two-part finishes
- combination coats
- adhesive based
- other specific finish
Apply finishes to composite mouldings, using four of the following consumable materials:
- abrasives
- masking films
- thinners
- stoppers
- sealers
- cutting compounds
- masking tapes
- polishes
- solvents
- fillers
- primers
- cleaning agents
- other specific consumable
Apply finishes suitable for two of the following resin types:
- bio resin
- thermoplastic
- polyester
- vinyl ester
- epoxy
- phenolic
- bismaleimide
- cyanate ester
- other specific resin type
Apply finishes suitable for two of the following fibre types:
- natural fibre
- thermoplastic
- glass
- aramid
- carbon
- hybrid
- other specific fibre
Apply finishes to a range of mouldings in compliance with one of the following:
- Civil Aviation Authority (CAA)/European Aviation Safety Agency (EASA)
- Ministry of Defence (MoD)
- Military Aviation Authority (MAA)
- Aerospace Quality Management Standards (AS)
- Federal Aviation Authority (FAA)
- BS, ISO or BSEN standards and procedures
- customer standards and requirements
- company standards and procedures
- manufacturers standards and procedures
Complete the relevant paperwork, to include one from the following and pass it to the appropriate people:
- build records
- log cards
- job cards
- aircraft flight log
- other specific recording system
Scope Knowledge
Values
Behaviours
You will be able to apply the appropriate behaviours required in the workplace to meet the job profile and overall company objectives, such as:
- strong work ethic
- positive attitude
- team player
- dependability
- responsibility
- honesty
- integrity
- motivation
- commitment