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

MEA405 Mapping and Delivery Guide
Repair/modify aircraft composite material structure/components

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency MEA405 - Repair/modify aircraft composite material structure/components
Description
Employability Skills
Learning Outcomes and Application This unit of competency requires application of hand skills and the use maintenance publications, applicable materials, tools and methods to repair aircraft composite material structure and components during the performance of scheduled or unscheduled maintenance. Maintenance may be performed individually or as part of a team.Applications include composite material structure and components from fixed and rotary wing aircraft either on-aircraft or in the workshop.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 and performance criteria of the unit of competency are being achieved under routine supervision using materials from each of:

pre-preg materials hot cure (performed on one of carbon graphite, kevlar, fibreglass or aluminium)

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: Prepare components for hot bonding
  • Components are prepared in accordance with applicable process specification while observing all relevant work health and safety (WHS) requirements, including the use of material safety data sheets (MSDS) and items of personal protective equipment (PPE)
  • Bagging is checked to ensure vacuum seal is correct
  • Temperature probes are placed appropriately to provide accurate measurement
  • Equipment is checked for serviceability to ensure safety in application
  • Heat blanket is laid on component or repair in a manner that ensures even temperature distribution
       
Element: Repair/modify components using hot bond
  • Hot bonding equipment is operated in accordance with equipment manufacturer's procedures
  • Vacuum and temperature recordings are monitored, including checking of hot and cold spots on trailing and leading temperature probes, to ensure specifications are met
  • Curing cycle and recording of operating cycle data are monitored as required by approved procedures to ensure specifications are met
  • Blemishes are sealed, potted or filled, where necessary, in accordance with applicable process specification
  • Component assemblies, including test pieces, requiring further or special treatment are made ready for the appropriate processes
  • Required maintenance documentation is accurately completed and correctly processed
  • Completed assemblies are tagged, sealed or packaged as required
       
Element: Repair/modify components using cold cure
  • Lay up of materials is checked to confirm that components meet required specifications while observing all relevant WHS requirements, including the use of MSDS and items of PPE
  • 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.

Prepare components for hot bonding

2.1

Components are prepared in accordance with applicable process specification while observing all relevant work health and safety (WHS) requirements, including the use of material safety data sheets (MSDS) and items of personal protective equipment (PPE)

2.2

Bagging is checked to ensure vacuum seal is correct

2.3

Temperature probes are placed appropriately to provide accurate measurement

2.4

Equipment is checked for serviceability to ensure safety in application

2.5

Heat blanket is laid on component or repair in a manner that ensures even temperature distribution

3.

Repair/modify components using hot bond

3.1

Hot bonding equipment is operated in accordance with equipment manufacturer's procedures

3.2

Vacuum and temperature recordings are monitored, including checking of hot and cold spots on trailing and leading temperature probes, to ensure specifications are met

3.3

Curing cycle and recording of operating cycle data are monitored as required by approved procedures to ensure specifications are met

3.4

Blemishes are sealed, potted or filled, where necessary, in accordance with applicable process specification

3.5

Component assemblies, including test pieces, requiring further or special treatment are made ready for the appropriate processes

3.6

Required maintenance documentation is accurately completed and correctly processed

3.7

Completed assemblies are tagged, sealed or packaged as required

4.

Repair/modify components using cold cure

4.1

Lay up of materials is checked to confirm that components meet required specifications while observing all relevant WHS requirements, including the use of MSDS and items of PPE

4.2

Curing cycle is regularly monitored to ensure required specifications are met

4.3

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

4.4

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

4.5

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

4.6

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 PPE and MSDS

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

performing composite component repairs using:

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 and curing requirements. 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 safety protective clothing is critical, particularly in the hot bonding process.

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:

how to obtain relevant MSDS

the use of applicable items of PPE

WHS procedures

aircraft construction principles

defining composite terminology

composite component construction methods, including structural assembly fastener identification.

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.

Prepare components for hot bonding

2.1

Components are prepared in accordance with applicable process specification while observing all relevant work health and safety (WHS) requirements, including the use of material safety data sheets (MSDS) and items of personal protective equipment (PPE)

2.2

Bagging is checked to ensure vacuum seal is correct

2.3

Temperature probes are placed appropriately to provide accurate measurement

2.4

Equipment is checked for serviceability to ensure safety in application

2.5

Heat blanket is laid on component or repair in a manner that ensures even temperature distribution

3.

Repair/modify components using hot bond

3.1

Hot bonding equipment is operated in accordance with equipment manufacturer's procedures

3.2

Vacuum and temperature recordings are monitored, including checking of hot and cold spots on trailing and leading temperature probes, to ensure specifications are met

3.3

Curing cycle and recording of operating cycle data are monitored as required by approved procedures to ensure specifications are met

3.4

Blemishes are sealed, potted or filled, where necessary, in accordance with applicable process specification

3.5

Component assemblies, including test pieces, requiring further or special treatment are made ready for the appropriate processes

3.6

Required maintenance documentation is accurately completed and correctly processed

3.7

Completed assemblies are tagged, sealed or packaged as required

4.

Repair/modify components using cold cure

4.1

Lay up of materials is checked to confirm that components meet required specifications while observing all relevant WHS requirements, including the use of MSDS and items of PPE

4.2

Curing cycle is regularly monitored to ensure required specifications are met

4.3

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

4.4

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

4.5

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

4.6

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:

Pre-preg materials hot cure (performed on one of carbon graphite, kevlar, fibreglass or aluminium)

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 
Components are prepared in accordance with applicable process specification while observing all relevant work health and safety (WHS) requirements, including the use of material safety data sheets (MSDS) and items of personal protective equipment (PPE) 
Bagging is checked to ensure vacuum seal is correct 
Temperature probes are placed appropriately to provide accurate measurement 
Equipment is checked for serviceability to ensure safety in application 
Heat blanket is laid on component or repair in a manner that ensures even temperature distribution 
Hot bonding equipment is operated in accordance with equipment manufacturer's procedures 
Vacuum and temperature recordings are monitored, including checking of hot and cold spots on trailing and leading temperature probes, to ensure specifications are met 
Curing cycle and recording of operating cycle data are monitored as required by approved procedures to ensure specifications are met 
Blemishes are sealed, potted or filled, where necessary, in accordance with applicable process specification 
Component assemblies, including test pieces, requiring further or special treatment are made ready for the appropriate processes 
Required maintenance documentation is accurately completed and correctly processed 
Completed assemblies are tagged, sealed or packaged as required 
Lay up of materials is checked to confirm that components meet required specifications while observing all relevant WHS requirements, including the use of MSDS and items of PPE 
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

MEA405 - Repair/modify aircraft composite material structure/components
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

MEA405 - Repair/modify aircraft composite material structure/components

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: