Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

MEA367 Mapping and Delivery Guide
Repair/modify aircraft composite structure using cold bonding

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency MEA367 - Repair/modify aircraft composite structure using cold bonding
Description
Employability Skills
Learning Outcomes and Application This unit of competency requires application of hand skills and the use of maintenance publications, applicable materials, tools and methods to repair aircraft composite material structure and components using cold cure repair techniques either on-aircraft or in the workshop during scheduled or unscheduled maintenance.The unit is part of the Aeroskills Structures Maintenance Certificate IV training pathway, and of the Mechanical Certificate IV (Aircraft Maintenance Stream) training pathways. The unit is used in workplaces that operate under the airworthiness regulatory systems of the Australian Defence Force (ADF) and the Civil Aviation Safety Authority (CASA).
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.

Competency should be assessed in the workplace or simulated workplace. It is also expected that general purpose tools and test equipment found in most routine situations would be used where appropriate.

The following conditions of assessment represent the requirements of the Regulators (ADF and CASA) and maintenance stakeholders and must be rigorously observed.

A person cannot be assessed as competent until it can be demonstrated to the satisfaction of the workplace assessor that the relevant elements of the unit of competency and the performance criteria are being achieved under routine supervision using materials from each of:

cold cure or wet lay-up (using either fibreglass or carbon graphite)

core materials (using one of aluminium, nomex or foam)

This shall be established via the records in the Log of Industrial Experience and Achievement or, where appropriate, an equivalent Industry Evidence Guide (for details refer to the Companion Volume Assessment Guidelines).

Assessors must satisfy the requirements of the National Vocational Education and Training Regulator (Australian Skills Quality Authority, or its successors).

Where the unit is to be used for CASA licensing purposes the Assessor must also meet the criteria specified in the CASR Part 147 Manual of Standards.
Prerequisites/co-requisites
Competency Field Aviation maintenance
Development and validation strategy and guide for assessors and learners Student Learning Resources Handouts
Activities 		Slides
PPT 		Assessment 1 Assessment 2 Assessment 3 Assessment 4
Elements of Competency Performance Criteria              
Element: Plan repair/modification
  • Extent of damage is correctly assessed to assist in determining repair procedure
  • Structure is supported and prepared in accordance with the applicable maintenance manual to ensure personnel safety and freedom from damage
  • Appropriate modification or repair scheme is identified in accordance with structural repair manual and/or approved data
  • Specialist advice is obtained in establishing an approved repair scheme where a standard repair scheme cannot be identified or damage criteria are out of limits
  • All materials and equipment required are organised
       
Element: Repair/modify components using cold cure
  • Lay-up of materials is checked to confirm that components meet required specifications and bagging equipment is correctly installed and operated
  • Curing cycle is regularly monitored to ensure required specifications are met
  • Components are checked for blemishes or delamination in accordance with quality procedures
  • Component assemblies requiring further or special treatment are made ready for the appropriate processes
  • Required maintenance documentation is completed and processed in accordance with standard enterprise procedures
  • Completed assemblies are tagged, sealed or packaged as required
       


Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1.

Plan repair/modification

1.1

Extent of damage is correctly assessed to assist in determining repair procedure

1.2

Structure is supported and prepared in accordance with the applicable maintenance manual to ensure personnel safety and freedom from damage

1.3

Appropriate modification or repair scheme is identified in accordance with structural repair manual and/or approved data

1.4

Specialist advice is obtained in establishing an approved repair scheme where a standard repair scheme cannot be identified or damage criteria are out of limits

1.5

All materials and equipment required are organised

2.

Repair/modify components using cold cure

2.1

Lay-up of materials is checked to confirm that components meet required specifications and bagging equipment is correctly installed and operated

2.2

Curing cycle is regularly monitored to ensure required specifications are met

2.3

Components are checked for blemishes or delamination in accordance with quality procedures

2.4

Component assemblies requiring further or special treatment are made ready for the appropriate processes

2.5

Required maintenance documentation is completed and processed in accordance with standard enterprise procedures

2.6

Completed assemblies are tagged, sealed or packaged as required

Evidence required to demonstrate competency in this unit must be relevant to and satisfy all of the requirements of the elements and performance criteria under the specified conditions of assessment, and must include:

applying relevant WHS procedures, including the use of MSDS and applicable items of PPE

using approved maintenance documentation and aircraft publications relating to aircraft structure

identifying composite component applications in aircraft structures

identifying various aircraft composite materials/resins and their basic properties by interpretation of markings and visual means

handling and storing of composite materials to industry standards

assessing composite component damage using visual and tap test methods

relative advantages and disadvantages of hot and cold cure

performing composite component repairs using cold cure adhesives:

external patch repair

scarf repair

stepped repair

wet lay-up repair

composite fastener hole repair

metal to metal and metal to composite bonding

correctly interpreting and/or producing repair scheme/modification drawings/sketches

using appropriate hand tools and machines to disassemble and assemble aircraft composite components, parts, sections and skin, including extraction/installation equipment, drilling/cutting equipment, and material fasteners.

The underlying skills inherent in this unit should be transferable across the range of different material applications applicable to cold curing. It is essential that specific aspects of the laying up and curing process for aircraft composite materials are checked to ensure quality and safety standards are achieved in this area. Correct checking and wearing of PPE is critical.

Evidence of knowledge about repair techniques and the use of the standard repair manual in a range of different repair situations will be necessary to supplement evidence of ability to plan and undertake component repair. Ability to apply different materials and curing cycles, including composite to composite and composite to metal components, will be necessary to indicate competency in preparing and curing composite materials.

Evidence required to demonstrate competency in this unit must be relevant to and satisfy all of the requirements of the elements and performance criteria and include knowledge of:

aircraft construction principles and the causes of structural damage, including metal fatigue and corrosion

structural fatigue preventative measures

composite terminology and materials used in both hot and cold bonding

composite component construction and repair methods, including structural assembly fastener types, specifications and identification

procedures for the design and approval of repair schemes and modifications

composite material storage requirements

sealants used in aircraft structure and their application and handling

paints and finishes for composite structure

WHS precautions associated with repair of aircraft structure

MSDS

PPE.

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)

Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1.

Plan repair/modification

1.1

Extent of damage is correctly assessed to assist in determining repair procedure

1.2

Structure is supported and prepared in accordance with the applicable maintenance manual to ensure personnel safety and freedom from damage

1.3

Appropriate modification or repair scheme is identified in accordance with structural repair manual and/or approved data

1.4

Specialist advice is obtained in establishing an approved repair scheme where a standard repair scheme cannot be identified or damage criteria are out of limits

1.5

All materials and equipment required are organised

2.

Repair/modify components using cold cure

2.1

Lay-up of materials is checked to confirm that components meet required specifications and bagging equipment is correctly installed and operated

2.2

Curing cycle is regularly monitored to ensure required specifications are met

2.3

Components are checked for blemishes or delamination in accordance with quality procedures

2.4

Component assemblies requiring further or special treatment are made ready for the appropriate processes

2.5

Required maintenance documentation is completed and processed in accordance with standard enterprise procedures

2.6

Completed assemblies are tagged, sealed or packaged as required

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.

Applicable materials and methods include:

Cold cure or wet lay-up (using either fibreglass or carbon graphite)

Core materials (using one of aluminium, nomex or foam)

Procedures and requirements include:

Industry standard procedures specified by manufacturers, regulatory authorities or the enterprise

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Extent of damage is correctly assessed to assist in determining repair procedure 
Structure is supported and prepared in accordance with the applicable maintenance manual to ensure personnel safety and freedom from damage 
Appropriate modification or repair scheme is identified in accordance with structural repair manual and/or approved data 
Specialist advice is obtained in establishing an approved repair scheme where a standard repair scheme cannot be identified or damage criteria are out of limits 
All materials and equipment required are organised 
Lay-up of materials is checked to confirm that components meet required specifications and bagging equipment is correctly installed and operated 
Curing cycle is regularly monitored to ensure required specifications are met 
Components are checked for blemishes or delamination in accordance with quality procedures 
Component assemblies requiring further or special treatment are made ready for the appropriate processes 
Required maintenance documentation is completed and processed in accordance with standard enterprise procedures 
Completed assemblies are tagged, sealed or packaged as required 

Forms

Assessment Cover Sheet

MEA367 - Repair/modify aircraft composite structure using cold bonding
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:

Assessment Record Sheet

MEA367 - Repair/modify aircraft composite structure using cold bonding

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: