Repairing composite mouldings
URN: SEMCOMP320
Business Sectors (Suites): Composite Engineering Suite 3
Developed by: Enginuity
Approved on:
2022
Overview
| This standard identifies the competences you need to repair 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 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. complete and store all relevant documentation in accordance with organisational procedures 7. 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 repair 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 the must be observed when producing composite mouldings (such as temperature, humidity, styrene levels to threshold limits, 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 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 when repairing composite mouldings (such as dis-bonds, de-lamination, resin injection, resin voids, core potting, repair patches) 9. failure modes for various composite mouldings, and what can contribute to these 10. different types of composite resin systems, fibres, reinforcements, and their applications 11. different methods of production for composite mouldings, and their applications 12. different methods of trimming composite mouldings, and their applications 13. different methods of producing composite assemblies, and their applications 14. different bonding agents, methods used, and their applications 15. why repairs may affect the structural integrity of the composite moulding 16. correct methods of storage and handling of composite materials 17. the tools and equipment used for various activities associated with repairing composite mouldings 18. 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 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, 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 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 in accordance with approved procedures 2. Carry out all of the following activities when preparing for the repair activity: 1. check that the mouldings are correct and complete 2. identify what needs 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 specific moulding 5. Repair defects in composite mouldings using four of the following methods: 1. localised curing 2. fettling 3. separation of bonds 4. surface filling 5. relieving distortion 6. bonding 7. resin injection 8. wet-lay patching 9. pre-preg patching 10. core patching 11. insert/core potting 12. repair patches/kits 13. other specific method 6. Repair defects using techniques/materials applicable to two of the following resin types: 1. polyester 2. vinyl ester 3. epoxy 4. phenolic 5. bismaleimide 6. cyanate ester 7. other specific type 7. Repair defects using techniques/materials applicable to two of the following fibre types: 1. polyethylene 2. glass 3. aramid 4. carbon 5. other specific type 8. Repair defects in two of the following core materials: 1. wood 2. foam 3. syntactic core 4. expanding core 5. nomex honeycomb 6. aluminium honeycomb 7. other specific material 9. Repair eight of the following types of defect in composite mouldings: 1. dimensional 2. tolerances 3. surface finish 4. distortion 5. blisters 6. dents or 'dings' 7. bridging 8. broken fibres 9. voids 10. damaged cores 11. dis-bonds 12. excessive adhesive 13. wrong inserts 14. incomplete curing 15. de-lamination 16. impact damage 17. other specific defect 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 specific method 11. Repair a range of mouldings in compliance with all of the following quality and accuracy standards: 1. company standards and procedures 2. dimensionally accurate within specification tolerances 3. have an appropriate surface finish and are free from defects or surface blemishes |
Scope Knowledge
Values
Behaviours
Skills
Glossary
Links To Other NOS
External Links
Version Number
3
Indicative Review Date
2025
Validity
Current
Status
Original
Originating Organisation
Enginuity
Original URN
SEMCOMP320
Relevant Occupations
Engineering, Engineering and Manufacturing Technologies, Engineering Professionals, Science and Engineering Technicians
SOC Code
8114
Keywords
Engineering; repair; composite; mouldings; components; laminating; resin; fibre; assemblies; mark out; drawings