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Repairing aircraft composite mouldings

URN: SEMAE3207
Business Sectors (Suites): Aeronautical Engineering Suite 3
Developed by: Enginuity
Approved on: 2021

Overview

This standard identifies the competences you need to repair aircraft composite mouldings (such as cured panels, moulds, components and 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 repair composites materials, using the correct techniques.

You will be expected to identify the method of repair to be used and select suitable repair materials.  You will repair a range of composite mouldings with various defects using a range of methods.  Mouldings repaired will include a range of resin and fibre materials.

Your responsibilities will require you to comply with organisational policy and procedures for the repair activities undertaken, and to report any problems with the repair activities, equipment or materials 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 that you produce.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying composite moulding repair procedures.  You will understand the repair techniques used, and their application, in adequate depth to provide a sound basis for carrying out the activities to the required specification. 

You will understand the safety precautions required when carrying out the repair activities 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:

  1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
  2. follow the relevant specifications for the moulding to be repaired
  3. prepare the moulding for repair
  4. carry out the repairs within agreed timescale using approved materials and components and methods and procedures
  5. ensure that the repaired moulding meets the specified operating conditions
  6. produce accurate and complete records of all repair work carried out
  7. leave the work area in a safe and appropriate condition on completion of the activities
  8. complete the relevant documentation, in accordance with organisational requirements

Knowledge and Understanding

You need to know and understand:

  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 composite repair activities, 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. safe working practices that are required when working in confined spaces (such as ventilation, use of flammable materials) and emergency procedures that may need to be followed
  8. 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
  9. how to interpret drawings, lay up manuals, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
  10. quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification) and the completion of such documents
  11. conventions and terminology used when repairing composite mouldings (such as dis-bonds, de-lamination, resin injection, resin voids, core potting, repair patches)
  12. the methods used to cure bonded repairs and their applications
  13. failure modes for various composite mouldings, and what can contribute to these
  14. different types of composite resin systems, fibres, reinforcements, and their applications
  15. different methods of production for composite mouldings, and their applications
  16. different methods of trimming composite mouldings, and their applications
  17. different methods of producing composite assemblies, and their applications
  18. different bonding agents, methods used, and their applications
  19. the importance of carrying out dimensional/tolerance checks on completion of the repair activity
  20. why repairs may affect the structural integrity of the composite moulding
  21. correct methods of storage and handling of composite materials
  22. tools and equipment used for various activities associated with repairing composite mouldings
  23. 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
  24. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve

Scope/range

Scope Performance

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  1. Carry out all of the following during the repair 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 repair activities
    4. obtain and check that all tools and equipment to be used are correct for the operation to be carried out and are in a safe, tested and usable condition
    5. follow safe practice/approved composite repair techniques and procedures at all times
    6. return all tools and equipment to the correct location on completion of the composite repair activities
    7. segregate and dispose of waste materials using the correct procedure

  2. Carry out all of the following activities when preparing for the repair activity:

    1. confirm what has to be prepared
    2. assess the extent of the damage to be repaired
    3. identify the method of repair to be used
    4. check availability of ancillary materials required
    5. select the correct equipment for the activity
    6. check that the equipment is suitable for use
    7. identify and protect the moulding and repair materials in the work area

  3. Carry out five of the following types of repair:

    1. temporary
    2. cosmetic
    3. non structural
    4. minor structural
    5. major structural
    6. temporary mould
    7. graft/pre-cured patch
    8. laminate only
    9. partial thickness laminate
    10. through laminate
    11. type A sandwich panel
    12. type B sandwich panel
    13. type C sandwich panel
    14. single sided access
    15. double sided access

  4. Repair defects in six of the following types of composite moulding:

    1. internal corners
    2. external corners
    3. horizontal surface
    4. vertical surface
    5. double curvature
    6. concave surface
    7. convex surfaces
    8. flat surfaces
    9. return surfaces
    10. joggle details
    11. nett edges
    12. webs/ribs
    13. inserts
    14. fixtures
    15. other (to be specified)

  5. Repair defects in composite mouldings using four of the following methods:

    1. localised curing
    2. fettling
    3. surface filling
    4. laminating
    5. relieving distortion
    6. bonding
    7. osmosis
    8. resin injection
    9. wet-lay patching
    10. pre-preg patching
    11. polishing
    12. core patching
    13. insert/core potting
    14. repair patches/kits
    15. colour matching

  6. Repair defects using techniques/materials 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)

  7. Repair defects using techniques/materials 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)

  8. Repair defects in two of the following core materials (where applicable to the Sector or process):

    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
    12. other (to be specified)

  9. Repair ten 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)

  10. Cure bonded repairs using two of the following methods:

    1. room temperature
    2. oven
    3. autoclave
    4. heated tools/moulds
    5. heat mats
    6. curing lamps
    7. infrared heating
    8. UV curing
    9. electro-magnetic inductance
    10. micro-wave
    11. hot bonder
    12. other (to be specified)

  11. Repair mouldings which 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

  12. 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

Scope Knowledge

Values

Behaviours

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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

Skills

Glossary

Links To Other NOS

External Links

Version Number

3

Indicative Review Date

2024

Validity

Current

Status

Original

Originating Organisation

Enginuity

Original URN

SEMAE3207

Relevant Occupations

Engineer, Engineering, Engineering and Manufacturing Technologies, Engineering Technicians

SOC Code

5234

Keywords

Engineering; aeronautical; repair; composite; mouldings; components; laminating; resin; fibre; assemblies; mark out; drawings