Bonding composite mouldings
URN: SEMCOMP316
Business Sectors (Suites): Composite Engineering Suite 3
Developed by: Enginuity
Approved on:
30 Mar 2022
Overview
| 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 advanced composites materials, using the correct 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 with a minimum of 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, correcting faults, 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. |
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 bonding procedure specification and job instructions 3. check that the materials to be bonded and bonding agents comply with the specification 4. correctly prepare the parent materials and bonding agents in line with the bonding specification 5. carry out the bonding operations using the specified processes and techniques to position, bond and retain the materials in their correct locations 6. ensure that any equipment used to maintain surface contact during the bonding activities is set up and used correctly 7. achieve bonds of the required quality and within the specified dimensional accuracy 8. complete and store all relevant documentation in accordance with organisational procedures 9. deal promptly and effectively with problems within your control and report those that cannot be solved 10. leave the work area in a safe and appropriate condition on completion of the activities |
Knowledge and Understanding
You need to know and understand:
| 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 specific environmental conditions that must be observed when producing composite mouldings (such as temperature, humidity, fume/dust extraction systems and equipment) 5. how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate standards) in relation to work undertaken 6. how to interpret first and third angle drawings, lay-up manuals, imperial and metric systems of measurement, workpiece reference/datum points and system of tolerancing 7. the quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification) and the completion of such documents 8. the conventions and terminology used for bonding (such as gel points, cure times, bond thickness, bond strength, peel strength) 9. the different types of composite resin systems, fibres, reinforcements, and their applications 10. the different bonding agents, and their applications 11. correct methods of storage and handling of bonding agents 12. the methods of preparation for bonding different materials 13. mixing procedures and ratios for two-part pastes, and the associated working times 14. methods of application for different bonding agents 15. methods of retaining the bond during curing, and their applications 16. the tools and equipment used in bonding activities, and their care, preparation and control procedures 17. the identification and rectification of bond defects 18. the problems that can occur during the bonding process (including defects such as contamination and distortion) 19. how defects can be overcome during the bonding activity 20. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve |
Scope/range
Scope Performance
| 1. Carry out all of the following during the bonding activities: 1. obtain and use the appropriate documentation (such as job instructions, drawings, material/adhesive data sheets, specifications, planning and quality control documentation) 2. adhere to procedures or systems in place for risk assessment, 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 bonding activities 4. obtain and 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. dispose of waste materials in accordance with approved procedures 2. Carry out all 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. check that bonding materials are within life 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 bonding materials in the work area 8. check that bonding materials are correct and complete 3. Bond composite mouldings using techniques for two of the following: 1. one-part pastes 2. two-part pastes 3. film adhesives 4. syntactic films 4. Prepare bonding surfaces using four of the following methods: 1. peel plies 2. templates 3. abrading 4. water cleaning 5. solvent cleaning 6. bead blasting 7. dry fitting 8. acid etching 9. priming 10. surface masks 11. laser ablation 12. other specific method 5. Bond composite mouldings, using three of the following methods: 1. dry fitting 2. oven curing 3. heated press 4. bonding sequences 5. shimming materials 6. laying film adhesives 7. mixing adhesives 8. wetting-out by brush 9. applicator gun 10. other specific method 6. During curing, retain the bond using two of the following: 1. weighting down 2. bonding jigs 3. pinning joins 4. clamping 5. press 6. vacuum bagging 7. other specific method 7. Bond composite mouldings for two of the following: 1. sandwich panels 2. butt joins 3. overlap joins 4. joggle joins 5. return joins 6. other specific method 8. Bond composite mouldings using techniques for two of the following: 1. flat surfaces 2. shaped surfaces 3. internal surfaces 4. external surfaces 9. Use techniques for bonding three of the following materials to the composite moulding: 1. metals 2. ceramics 3. plastics 4. wood-based materials 5. other specific composite 10. Bond composite mouldings using adhesives suitable for two of the following resin types: 1. polyester 2. vinyl ester 3. epoxy 4. phenolic 5. bismaleimide 6. cyanate ester 7. other specific type 11. Bond composite mouldings using adhesives suitable for two of the following fibre types: 1. polyethylene 2. glass 3. aramid 4. carbon 5. other specific type 12. Bond a range of mouldings which comply with all of the following quality and accuracy standards: 1. company standards and procedures 2. dimensionally accurate within specification tolerances 3. bonded components are mechanically secure and are free from damage or defects |
Scope Knowledge
Values
Behaviours
Skills
Glossary
Links To Other NOS
External Links
Version Number
3
Indicative Review Date
31 Mar 2025
Validity
Current
Status
Original
Originating Organisation
Enginuity
Original URN
SEMCOMP316
Relevant Occupations
Engineering, Engineering and Manufacturing Technologies, Engineering Professionals, Science and Engineering Technicians
SOC Code
8114
Keywords
Engineering; produce; composite; mouldings; components; laminating; resin; fibre; bond; adhesive; mark out; drawings