Identifying defects in aircraft composite mouldings

This standard identifies the competences you need to identify and deal with defects in aircraft composite mouldings (such as moulds, panels, components, jigs), in accordance with approved procedures.  It covers both fixed wing and rotary winged aircraft mouldings. You will be required to use appropriate drawings, specifications and documentation to identify and deal with defects in composites mouldings.

You will be able to identify a range of defects in composite mouldings using various methods and techniques. Defects will be identified in a range of mouldings with a variety of resin and fibre materials.

Your responsibilities will require you to comply with organisational policy and procedures for the activities undertaken, and to report any problems with the activities that you cannot personally resolve, or 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 you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to identifying defects in composite mouldings, and to making decisions on what action needs to be taken.  You will understand composite materials, and their application, and will know about defects in adequate depth to provide a sound basis for dealing with the defects in line with organisation practice and procedures. 

You will understand the safety precautions required when working with the composite mouldings and when using 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.

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1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. identify defects with regard to the composite moulding
3. assess the defects and determine action required to return the composite moulding to specified condition
4. report recommendations for action to the appropriate people promptly and in accordance with organisational procedures
5. record details of defects in accordance with quality assurance and control systems and procedures
6. leave the work area in a safe and appropriate condition on completion of the activities

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1. 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
2. the requirements and importance of understanding and applying human factors as defined by the regulatory requirements and the potential impact if these are not adhered to
3. the hazards associated with carrying out inspections on composite mouldings, and with the composite materials, consumables, tools and equipment used, and how to minimise these and reduce any risks
4. the protective equipment (PPE) that is needed for personal protection and, where required, the protection of others
5. the application of COSHH regulations in relation to the storage, use and disposal of composite materials and consumables
6. the specific environmental conditions the must be observed when producing composite mouldings (such as temperature, humidity, fume/dust extraction systems and equipment)
7. 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
8. how to interpret drawings, lay up manuals imperial and metric systems of measurement, workpiece reference points and system of tolerancing
9. quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification) and the completion of such documents
10. conventions and terminology used when identifying and rectifying defects (such as dis-bonds, de-lamination, resin injection, resin voids, core potting, repair patches)
11. the different methods used to identify defects in composite mouldings including sensory checks, hand measuring tools, machine tools such as co-ordinate measuring machines, NDT machines (ultrasonic scanning, x-ray, thermography and sheraography) and testing equipment to check tensile strength, compression, sheer, impact and peel
12. the procedure used to select the method(s) used to identify defects in composite mouldings
13. the advantages and disadvantages of the different methods used to identify defects in composite mouldings 
14. failure modes for various composite mouldings, and what can contribute to these
15. different types of composite resin systems, fibres, reinforcements, and their applications
16. different methods of production for composite mouldings, and their applications
17. different methods of trimming composite mouldings and their applications
18. different methods of producing composite assemblies and their applications
19. different bonding agents, methods used, and their applications
20. correct methods of storage and handling of composite materials
21. tools and equipment used for various activities associated with composite mouldings
22. 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
23. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve

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1. Carry out all of the following during the inspection activities:

   1. obtain and use the appropriate documentation (such as job instructions, drawings, material data sheets, specifications, planning and quality control documentation)
   2. 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
   3. provide and maintain a safe working environment for the composite moulding inspection activities
   4. obtain and check that all tools and equipment to be used are in a safe, tested and usable condition and where appropriate, are within current calibration/certification dates
   5. follow safe practice/approved techniques and procedures at all times
   6. return all tools and equipment to the correct location on completion of the activities

2. Identify defects in composite mouldings using three of the following methods:

   1. touch
   2. sound
   3. visual   hand tools (such as measuring equipment)
   4. mechanical testing equipment

   5. other (to be specified)

                  Or one of the following

   6. non-destructive testing (such as ultrasonic scanning, x-ray, thermography and sheraography )
   7. co-ordinate measuring machines
   8. testing equipment to check features (such as  tensile strength, compression, sheer, impact and peel etc)
   9. other (to be specified)

3. Identify defects applicable to two of the following resin types:

   1. bio resin
   2. Thermoplastic
   3. polyester
   4. vinyl ester
   5. epoxy
   6. phenolic
   7. bismaleimide
   8. cyanate ester
   9. other (to be specified)

4. Identify defects applicable to two of the following fibre types:

   1. natural fibre
   2. thermo plastic
   3. glass
   4. aramid
   5. carbon
   6. hybrid
   7. other (to be specified)

5. Identify defects applicable to two of the following core materials:

   1. solid timber
   2. end grain balsa
   3. rigid foam
   4. expanding foam
   5. coremat
   6. honeycomb
   7. fibrous honeycomb
   8. aluminium honeycomb
   9. syntactic core
   10. expanding core
   11. thermoplastic core
   12. other (to be specified)

6. Identify fifteen of the following types of defect in composite mouldings:

   1. dimensional
   2. tolerances
   3. surface finish
   4. colour separation
   5. distortion
   6. blisters
   7. dents or 'dings'
   8. surface cracks
   9. incorrect material
   10. contamination
   11. bridging
   12. broken fibres
   13. stray fibres
   14. ply orientation
   15. wrong join type
   16. gaps at joins
   17. incorrect overlap
   18. wrinkles
   19. splintering
   20. voids
   21. resin rich areas
   22. fibre deviation
   23. damaged cores
   24. dis-bonds
   25. excessive adhesive
   26. wrong inserts
   27. insert positions
   28. porosity
   29. local exotherm
   30. fayed/burned area
   31. incomplete curing
   32. de-lamination
   33. impact damage
   34. puncture
   35. gouges
   36. holes
   37. abrasion/erosion
   38. fluid ingress
   39. fractures
   40. other (to be specified)

7. Ensure actions recommended to rectify the defect comply with one of the following standards:

   1. Civil Aviation Authority (CAA)/European Aviation Safety Agency (EASA)
   2. Ministry of Defence (MoD)
   3. Military Aviation Authority (MAA)
   4. Federal Aviation Authority (FAA)
   5. Aerospace Quality Management Standards (AS)
   6. BS, ISO or BSEN standards and procedures
   7. customer standards and requirements
   8. company standards and procedures
   9. manufacturers standards and procedures

8. Complete the relevant paperwork, to include one from the following and pass it to the appropriate people:

   1. build records                 
   2. job cards
   3. log cards       
   4. aircraft log
   5. other specific recording method

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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

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3

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2024

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Current

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Original

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Enginuity

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SEMAE3206

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Engineer, Engineering, Engineering and Manufacturing Technologies, Engineering Technicians

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5234

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Engineering; aeronautical; identify; inspect; composite; mouldings; components; laminating; resin; fibre; assemblies; defects; drawings

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