SEMAE3207

Repairing aircraft composite mouldings

Overview This standard identifies the competences you need to repair aircraft composite
mouldings (such as cured panels, moulds, components and jigs), in
accordance with approved procedures. It covers both fixed wing and rotary
winged aircraft mouldings. 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.

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Repairing aircraft composite mouldings

Performance
criteria

You must be able to: P1 work safely at all times, complying with health and safety and other
relevant regulations, directives and guidelines
P2 follow the relevant specifications for the moulding to be repaired
P3 prepare the moulding for repair
P4 carry out the repairs within agreed timescale using approved materials
and components and methods and procedures
P5 ensure that the repaired moulding meets the specified operating
conditions
P6 produce accurate and complete records of all repair work carried out

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Knowledge and
understanding

You need to know and K1 health and safety precautions to be taken and procedures used when
understand: working with aircraft composite materials, consumables, tools and
equipment in the specific work area
K2 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
K3 protective equipment (PPE) that is needed for personal protection and,
where required, the protection of others
K4 the application of COSHH regulations in relation to the storage, use and
disposal of composite materials and consumables
K5 the specific environmental conditions the must be observed when
producing composite mouldings (such as temperature, humidity,
fume/dust extraction systems and equipment)
K6 safe working practices that are required when working in confined
spaces (such as ventilation, use of flammable materials) and emergency
procedures that may need to be followed
K7 how to extract and use information from engineering drawings and
related specifications, to include symbols and conventions to appropriate
BS, ISO or BSEN standards in relation to work undertaken
K8 how to interpret drawings, lay up manuals, imperial and metric systems
of measurement, workpiece reference points and system of tolerancing
K9 quality procedures used in the workplace to ensure production control (in
relation to currency, issue, meeting specification) and the completion of
such documents
K10 conventions and terminology used when repairing composite mouldings
(such as dis-bonds, de-lamination, resin injection, resin voids, core
potting, repair patches)
K11 the methods used to cure bonded repairs and their applications
K12 failure modes for various composite mouldings, and what can contribute
to these
K13 different types of composite resin systems, fibres, reinforcements, and
their applications
K14 different methods of production for composite mouldings, and their
applications
K15 different methods of trimming composite mouldings, and their
applications
K16 different methods of producing composite assemblies, and their
applications
K17 different bonding agents, methods used, and their applications
K18 the importance of carrying out dimensional/tolerance checks on
completion of the repair activity

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K19 why repairs may affect the structural integrity of the composite moulding
K20 the procedure used to determine if additional testing such as joint
integrity, strength testing, is required following a repair
K21 correct methods of storage and handling of composite materials
K22 tools and equipment used for various activities associated with repairing
composite mouldings
K23 the extent of your own responsibility and to whom you should report if
you have problems that you cannot resolve

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Additional Information

Scope/range
related to
performance
criteria
You must be able to: 1 Carry out all of the following during the repair activities:
1.1 obtain and use the appropriate documentation (such as job
instructions, drawings, material data sheets, specifications,
planning and quality control documentation)
1.2 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
1.3 provide and maintain a safe working environment for the
composite repair activities
1.4 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,
tested and usable condition
1.5 follow safe practice/approved composite repair techniques and
procedures at all times
1.6 return all tools and equipment to the correct location on
completion of the composite repair activities
1.7 segregate and dispose of waste materials using the correct
procedure
1.8 leave the work area in a safe and appropriate condition on
completion of the activities

2 Carry out all of the following activities when preparing for the repair
activity:
2.1 confirm what has to be prepared
2.2 assess the extent of the damage to be repaired
2.3 identify the method of repair to be used
2.4 check availability of ancillary materials required
2.5 select the correct equipment for the activity
2.6 check that the equipment is suitable for use
2.7 identify and protect the moulding and repair materials in the
work area

3 Carry out five of the following types of repair:

3.1 temporary
3.2 cosmetic
3.3 non structural
3.4 minor structural

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3.5 major structural

3.6 temporary mould
3.7 graft/pre-cured patch
3.8 laminate only
3.9 partial thickness laminate
3.10 through laminate
3.11 type A sandwich panel
3.12 type B sandwich panel
3.13 type C sandwich panel
3.14 single sided access
3.15 double sided access

4 Repair defects in six of the following types of composite moulding:

4.1 internal corners
4.2 external corners
4.3 horizontal surface
4.4 vertical surface
4.5 double curvature
4.6 concave surface
4.7 convex surfaces
4.8 flat surfaces
4.9 return surfaces
4.10 joggle details
4.11 nett edges
4.12 webs/ribs
4.13 inserts
4.14 fixtures
4.15 other (to be specified)

5 Repair defects in composite mouldings using four of the following

methods:
5.1 localised curing
5.2 fettling
5.3 surface filling
5.4 laminating
5.5 relieving distortion
5.6 bonding
5.7 osmosis
5.8 resin injection
5.9 wet-lay patching
5.10 pre-preg patching
5.11 polishing
5.12 core patching
5.13 insert/core potting
5.14 repair patches/kits

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5.15 colour matching

6 Repair defects using techniques/materials applicable to two of the

following resin types:
6.1 bio resin
6.2 thermoplastic
6.3 polyester
6.4 vinyl ester
6.5 epoxy
6.6 phenolic
6.7 bismaleimide
6.8 cyanate ester
6.9 other (to be specified)

7 Repair defects using techniques/materials applicable to two of the

following fibre types:
7.1 natural fibre
7.2 thermo plastic
7.3 glass
7.4 aramid
7.5 carbon
7.6 hybrid
7.7 other (to be specified)

8 Repair defects in two of the following core materials (where applicable

to the Sector or process):
8.1 solid timber
8.2 end grain balsa
8.3 rigid foam
8.4 expanding foam
8.5 coremat
8.6 honeycomb
8.7 fibrous honeycomb
8.8 aluminium honeycomb
8.9 syntactic core
8.10 expanding core
8.11 thermoplastic
8.12 other (to be specified)

9 Repair ten of the following types of defect in composite mouldings:

9.1 dimensional
9.2 tolerances
9.3 surface finish
9.4 colour separation
9.5 Distortion

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9.6 blisters
9.7 dents or ‘dings’
9.8 surface cracks
9.9 incorrect material
9.10 contamination
9.11 bridging
9.12 broken fibres
9.13 stray fibres
9.14 ply orientation
9.15 wrong join type
9.16 gaps at joins
9.17 incorrect overlap
9.18 wrinkles
9.19 splintering
9.20 voids
9.21 resin rich areas
9.22 fibre deviation
9.23 damaged cores
9.24 dis-bonds
9.25 excessive adhesive
9.26 wrong inserts
9.27 insert positions
9.28 porosity
9.29 local exotherm
9.30 fayed/burned area
9.31 incomplete curing
9.32 de-lamination
9.33 impact damage
9.34 puncture
9.35 gouges
9.36 holes
9.37 abrasion/erosion
9.38 fluid ingress
9.39 fractures
9.40 other (to be specified)

10 Cure bonded repairs using two of the following methods:

10.1 room temperature
10.2 oven
10.3 autoclave
10.4 heated tools/moulds
10.5 heat mats
10.6 curing lamps
10.7 infrared heating
10.8 UV curing

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10.9 electro-magnetic inductance

10.10 micro-wave
10.11 hot bonder
10.12 other (to be specified)

11. Repair mouldings which comply with one of the following standards:
11.1 Civil Aviation Authority (CAA)/European Aviation Safety Agency
(EASA)
11.2 Ministry of Defence (MoD)
11.3 Military Aviation Authority (MAA)
11.4 Federal Aviation Authority (FAA)
11.5 Aerospace Quality Management Standards (AS)
11.6 BS, ISO or BSEN standards and procedures
11.7 customer standards and requirements
11.8 company standards and procedures
11.9 manufacturers standards and procedures

12. Complete the relevant paperwork, to include one from the following and
pass it to the appropriate people:
12.1 build records
12.2 job cards
12.3 log cards
12.4 aircraft log
12.5 other specific recording method

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Developed by SEMTA

Version number 2

Date approved March 2014

Indicative review April 2017

date

Validity Current

Status Original

Originating SEMTA
organisation

Original URN O45NAER3207

Relevant Engineering Professionals; Engineering and manufacturing technologies;

occupations Engineering; Science and Engineering Technicians

Suite Aeronautical engineering suite 3

Key words Engineering; aeronautical; repair; composite; mouldings; components;

laminating; resin; fibre; assemblies; mark out; drawings

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