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This standard identifies the competences you need to carry out repairs to aircraft composite mouldings (including items such as cured panels, moulds, components and jigs), in accordance with approved procedures. You will be required to use appropriate specifications and documentation for the repair of the composite materials, and to use the correct techniques.

You will be required to obtain all relevant and current documentation relating to the repair, to obtain the tools and equipment required for the repair operations, and to check that they are in a safe and usable condition. In carrying out the repair, you will be required to follow company procedures and specified repair techniques. 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 composite 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 need to ensure that all tools, equipment and materials used in the repair are correctly accounted for on completion of the activities, and you must complete all necessary job/task documentation accurately and legibly.

You will be expected to work either with a high level of supervision or as a member of a team, and you will take responsibility for your own actions and for the quality and accuracy of the work that you carry out. Where team working is involved, you must demonstrate a significant personal contribution during the team activities in order to satisfy the requirements of this standard, and you must demonstrate competence in all the areas required by the standard.

Your underpinning knowledge will be sufficient to provide a sound basis for your work, and will provide an informed approach to applying the appropriate composite repair techniques and procedures. You will understand the repair procedures and techniques used, and will know about the tools and techniques, 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 composite repair activities, and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout.  You will also understand your responsibilities for safety, and the importance of taking the necessary safeguards to protect yourself and others in the workplace.

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1. work safely at all times, complying with health and safety legislation, regulations, directives and other relevant guidelines
2. follow the relevant specifications for the component to be repaired
3. prepare the component for repair
4. carry out the repairs within agreed timescale using approved materials and components and methods and procedures
5. ensure that the repaired component meets the specified operating conditions
6. produce accurate and complete records of all repair work carried out

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1. the health and safety precautions to be taken and procedures used when working with composite materials, consumables, tools and equipment in the specific work area
2. the hazards associated with carrying out repairs to composite materials, consumables, tools and equipment, and how to minimise these hazards in the work area
3. protective equipment that is needed for personal protection (PPE) and, where required, the protection of others
4. the application of COSHH regulations in relation to the storage, use and disposal of composite materials and consumables
5. the specific workshop environmental conditions that must be observed when bonding aircraft composite materials (including tems such as temperature, humidity, styrene levels to threshold limits, fume/dust extraction systems and equipment)
6. how to use and extract information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS or ISO standards), in relation to work undertaken
7. how to carry out currency/issue checks of the specifications you are working with
8. the quality procedures used in the workplace to ensure that repairs are carried out satisfactorily
9. conventions and terminology used when repairing composite mouldings (including terminology such as dis-bonds, de-lamination, resin injection, resin voids, core potting, repair patches)
10. the different types of composite resin systems, fibres and reinforcements, and the repair techniques that can be used
11. methods of preparing the mouldings for the repair to be carried out (including methods such as cleaning, abrading, priming)
12. the various bonding agents and methods used
13. the correct methods for storage and handling of composite materials
14. the tools and equipment used for the various activities associated with repairing composite mouldings
15. the procedure for the safe disposal and correct separation of waste materials
16. the recording documentation to be completed for the repair activities undertaken and, where appropriate, the importance of marking and identifying specific pieces of work in relation to the documentation
17. the extent of your own authority, and whom you should report to if you have problems that you cannot resolve

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1. Carry out all of the following during the composite repair activities:

   1. ensure that you have the correct documentation for the repair operations (including items such as drawings, job instructions, aircraft standards)
   2. adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations
   3. obtain the correct tools and equipment for the activity, and check that they are in a safe and usable condition
   4. identify what needs to be repaired, and the method of repair to be used
   5. correctly prepare the materials for the repair activities
   6. apply appropriate and safe repair techniques at all times
   7. dispose of waste items and materials in a safe and environmentally acceptable manner, in line with company procedures
   8. return all tools and equipment to the correct location on completion of the activities
   9. leave the work area in a safe condition and free from foreign object debris

2. Repair defects in three of the following types of aircraft composite mouldings:

   1. trim                    
   2. casings and covers            
   3. sandwich panels          
   4. moulds
   5. closing panels     
   6. aerodynamic components  
   7. structural                    
   8. jigs
   9. housings          
   10. tubes                                
   11. galley units                  
   12. airframe components
   13. consoles             
   14. sections                             
   15. tanks                          
   16. other specific components

3. Repair defects in aircraft composite mouldings, using three of the following methods:

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

4. Repair defects in aircraft composite mouldings, using techniques and materials applicable to both of the following:

   1. resins (including items such as polyester, vinyl ester, epoxy, phenolic, bismaleimide, cyanate ester, acrylic)
   2. fibres (including items such as polyethylene, glass, aramid, carbon, hybrid materials)

5. Repair five of the following types of defect in aircraft composite mouldings:

   1. incomplete curing            
   2. blisters                     
   3. voids                           
   4. damaged cores
   5. dimensional                    
   6. bridging                    
   7. dis-bonds                    
   8. wrong inserts
   9. surface finish                
   10. de-lamination            
   11. dents or `dings'           
   12. incorrect insert positions
   13. distortion                        
   14. broken fibres            
   15. excessive adhesive      
   16. impact damage
   17. cosmetic can be filled    
   18. fractures                  
   19. gouges                       
   20. abrasion/erosion
   21. hole damage (access from both sides)                     
   22. hole damage (external access only)

6. Carry out repairs to composite mouldings, which comply with one or more of the following standards:

   1. Civil Aviation Authority (CAA )                                 
   2. Ministry of Defence (MoD)                                      
   3. customer standards and requirements
   4. Federal Aviation Authority (FAA)                             
   5. company standards and procedures

7. Produce accurate and complete records, to include one from the following, and pass it to the appropriate people:

   1. repair documentation                                               
   2. build records
   3. quality control documentation                                  
   4. other specific records

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​​Additional Information

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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2

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31 Mar 2020

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Current

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Original

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Semta

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SEMAER2-28

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Engineering, Engineering and Manufacturing Technologies, Engineering Professionals

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5234

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Aeronautical; Engineering; repair composite materials; tools and equipment; resins; fibres;

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