Carrying out bonding activities on composite mouldings

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This standard identifies the competences you need to bond composite mouldings (such as cured panels, moulds, components and jigs), in accordance with approved procedures.  You will be required to use appropriate drawings, specifications and documentation to bond composites materials, using the approved techniques.

You will produce a range of bonded composite mouldings, incorporating a variety of features and using a range of techniques and processes.  Bonded mouldings produced will include a range of resin, fibre and adhesive materials.

Your responsibilities will require you to comply with organisational policy and procedures for the bonding activities undertaken and to report any problems with the bonding 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 to instructions under 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 composite bonding techniques and procedures.  You will understand the bonding techniques used and their application, in adequate depth to provide a sound basis for carrying out the activities and ensuring the work produced is to the required specification. 

You will understand the safety precautions required when carrying out the composite bonding 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.

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1. work safely at all times, complying with health and safety, environmental and other relevant regulations, directives and guidelines

2. follow the relevant bonding procedure specification and job instructions

3. confirm that the materials to be bonded and bonding agents comply with the specification

4. carry out preparation activities on the parent material and bonding agents in line with the bonding specification
5. carry out the bonding operations using the specified processes and techniques to position and bond the materials in their correct locations
6. confirm that any equipment used to maintain surface contact during the bonding activities is set up correctly
7. achieve bonds of the required quality and within the specified dimensional accuracy
8. deal promptly and effectively with problems within your control and report those that cannot be solved
9. complete relevant documentation
10. leave the work area in a safe and appropriate condition on completion of the activities

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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 composite bonding activities and with the composite materials, consumables, tools and equipment used and how to minimise these and reduce any risks
3. the protective equipment (PPE) that is needed for personal protection 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 environmental conditions that must be observed when bonding composite mouldings (such as temperature, humidity, fume/dust extraction systems and equipment)
6. how to extract and use information from engineering drawings and related documentation (to include symbols and conventions to appropriate BS, ISO or BSEN standards) in relation to work undertaken
7. how to interpret drawings, lay up manuals, systems of measurement, workpiece reference/datum points and system of tolerancing
8. the quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification) and the completion of such documents
9. the basic conventions and terminology used for bonding (such as gel points, cure times, bond thickness, bond strength, peel strength)
10. the function resins, reinforcement, catalysts, accelerators and additives play in the production of mouldings
11. the function fibre materials, weave patterns, orientations play in the production of mouldings
12. the bonding agents used, and their applications
13. the correct methods of storage and handling of bonding agents
14. the methods used to prepare materials for bonding
15. the importance of following the correct mixing procedures and having the correct ratios for two-part pastes and their associated working times
16. the methods used to determine if the bonded component has cured correctly
17. the methods of applying different bonding agents
18. the methods of retaining the bond during curing and their applications
19. the tools and equipment used in bonding activities and their care, preparation and safe handling
20. the identification of bonding defects
21. the common problems that can occur during the bonding process (including defects such as contamination and distortion)
22. how defects can be prevented during the bonding activity
23. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
24. the documentation to be completed during and/or on completion of the bonding activity

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

   1. 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. maintain a safe working environment for the composite bonding activities
   4. check that all tools and equipment to be used are in a safe and usable condition
   5. follow safe practice/approved composite bonding techniques and procedures at all times
   6. return all tools and equipment to the correct location on completion of the bonding activities
   7. segregate and dispose of waste materials using the correct procedure 

2. Carry out four of the following activities when preparing for the bonding activity:

   1. check that mouldings are correct and complete
   2. check for any defects in the mouldings
   3. confirm that bonding materials are within life
   4. check availability of ancillary materials required
   5. select the correct equipment for the activity
   6. confirm that the equipment is suitable for use
   7. identify and protect the moulding and bonding materials in the work area
   8. check that bonding materials are correct and complete

3. Bond composite mouldings using techniques for one of the following:

   1. one-part pastes
   2. two-part pastes
   3. film adhesives
   4. syntactic films

4. Prepare bonding surfaces using two of the following methods:

   1. peel plies
   2. templates
   3. abrading
   4. abrasive blasting
   5. water cleaning
   6. solvent cleaning
   7. dry fitting
   8. acid etching
   9. priming
   10. surface masks
   11. other (to be specified)

5. Bond composite mouldings, use two of the following methods:

   1. bonding sequences
   2. shimming materials
   3. laying film adhesives
   4. mixing adhesives
   5. wetting-out by brush
   6. applicator gun
   7. bead sizing
   8. fillet sizing

6. During curing, retain the bond using one of the following:

   1. weighting down
   2. bonding jigs
   3. pinning joins
   4. clamping
   5. press
   6. vacuum bagging
   7. other (to be specified)

7. Cure bonded joins using one of the following methods:

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

8. Bond composite mouldings for one of the following:

   1. sandwich panels
   2. butt joins
   3. overlap joins
   4. joggle joins
   5. return joins
   6. tongue and groove
   7. strap join
   8. other (to be specified)

9. Bond composite mouldings to include three of the following features:

   1. internal corners
   2. external corners
   3. horizontal surface
   4. vertical surface
   5. double curvature
   6. concave surface
   7. convex surfaces
   8. joggle details
   9. return surfaces
   10. inserts
   11. fixtures
   12. other specific feature

10. Use techniques for bonding one of the following materials to the composite moulding:

    1. other composites
    2. metals
    3. ceramics
    4. polymers
    5. natural materials
    6. other (to be specified)

11. Bond composite mouldings using adhesives suitable for one 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)

12. Bond composite mouldings using adhesives suitable for one of the following fibre types:

    1. natural fibre
    2. thermo plastic
    3. glass
    4. aramid
    5. carbon
    6. hybrid
    7. other specific types

13. Bond a range of mouldings in compliance with one of the following standards:

    1. BS, ISO or BSEN standards and procedures
    2. customer standards and requirements
    3. company standards and procedures
    4. recognised compliance agency/body standards

14. Complete the relevant documentation, to include one of the following:

    1. production documentation
    2. quality control documentation
    3. job cards

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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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2

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01 Feb 2021

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Current

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Original

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Semta

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SEMCOMP216

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Composite Fitter, Composite Technician, Laminator, Moulding Technician

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8114

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Engineering; produce; composite; mouldings; components; laminating; resin; fibre; bond; adhesive; mark out; drawings

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