Repairing defects in vehicle composite mouldings
Overview
This standard identifies the competences you need to repair defects in composite mouldings (cured panels, body mouldings, structural sections, cover panels, trim panels), in accordance with approved procedures. You will be required to use appropriate drawings, specifications and documentation to bond advanced composite 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 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 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, correcting faults and ensuring that the completed repairs are 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:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant specifications for the component to be repaired
- ensure that materials and equipment are available and in a usable condition
- prepare the component for repair
carry out the repairs within the agreed timescale using appropriate materials and components; methods and procedures
ensure that the repaired component meets the specified operating conditions
- ensure that work records are completed, stored securely and available to others as per organisational requirements
- leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
- the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you
- the hazards associated with the activities, and how to minimise them and reduce risks
- the personal protective equipment and clothing (PPE) to be worn during the activities
- the application of current regulations in relation to the storage, use and disposal of composite materials and consumables
- the specific workshop environmental conditions the must be observed when repairing defects in 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. current industry standards and codes of practice) in relation to work undertaken
- how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
- the quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification)
- conventions and terminology used when repairing composite mouldings (dis-bonds, de-lamination, resin injection, resin voids, core potting, repair patches)
- the failure modes for various composite mouldings, and what can contribute to these
- different types of composite resin systems, fibres, reinforcements, and their merits
- different methods of production for composite mouldings, and their merits
- different methods of trimming composite mouldings, and their merits
- different methods of producing composite assemblies, and their merits
- different bonding agents, methods used, and their merits
- correct methods of storage and handling of composite materials
- tools and equipment used for various activities associated with repairing composite mouldings
- the problems that can occur with the trimming operations and how these can be overcome
- the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
- how to access, use and maintain information to comply with organisational requirements and legislation
Scope/range
Scope Performance
Carry out all of the following during the repair 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, hazardous substances, 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 mould repair 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 repair techniques and procedures at all times
- return all tools and equipment to the correct location on completion of the mould repair activities
- dispose of waste materials in accordance with approved procedures
- leave the work area in a safe and appropriate condition on completion of the activities
Prepare for repair activities:
- check that mouldings are correct and complete
- select the correct equipment for the activity
- identify the method of repair to be used
- check that equipment is suitable for use
- check availability of ancillary materials required
- identify what needs to be repaired
- identify and protect the moulding and repair materials in the work area
Repair defects in six of the following types of composite mouldings:
- trims
- body panels
- sandwich panels
- moulds
- closing panels
- tubes
- structural
- jigs
- housings
- sections
- aerodynamic
Repair defects in composite mouldings using four of the following methods:
- localised curing
- relieving distortion
- resin injection
- core patching
- fettling
- separation of bonds
- wet-lay patching
- insert/core potting
- surface filling
- bonding
- pre-preg patching
- repair patches/kits
Repair defects using techniques/materials applicable to two of the following resins types:
- polyester
- epoxy
- bismaleimide
- cyanate ester
- phenolic
- vinyl ester
Repair defects using techniques/materials applicable to two of the following fibre types:
- polyethylene
- glass
- aramid
- carbon
Repair eight of the following types of defect in composite mouldings:
- incomplete curing
- blisters
- voids
- damaged cores
- dimensional
- bridging
- dis-bonds
- wrong inserts
- tolerances
- de-lamination
- dents or 'dings'
- insert positions
- surface finish
- broken fibres
- excessive adhesive
- impact damage
- distortion
Check that repaired mouldings comply with all of the following quality and accuracy standards:
- meet company standards and procedures
- dimensionally accurate within specification tolerances
- have an appropriate surface finish and are free from defects or surface blemishes