Identifying defects in composite mouldings
Overview
This standard identifies the competences you need to identify and deal with defects in composite mouldings (such as moulds, panels, components, jigs), in accordance with approved procedures. You will be required to follow appropriate drawings, specifications and documentation to identify and deal with defects in composites mouldings.
You will be able to identify a range of defects in composite mouldings, using various methods and techniques. Defects will be identified in a range of mouldings with a variety of resin and fibre materials.
Your responsibilities will require you to comply with organisational policy and procedures for the activities undertaken, and to report any problems with the activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to instructions, with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work you carry out.
Your underpinning knowledge will be sufficient to provide a good understanding of your work, and will provide an informed approach to identifying defects in composite mouldings. You will have an understanding of composite materials, and their application, and will know about the associated defects, in adequate depth to provide a sound basis for identifying the defects in line with organisation practice and procedures.
You will understand the safety precautions required when working with the composite mouldings and when using 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:
P1 work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
P2 inspect and identify defects with regard to the composite moulding specification
P3 assess the defects and determine action required to return the moulding to specified condition
P4 deal with problems within your control and report those that cannot be solved
P5 complete and store all relevant documentation in accordance with organisational requirements
Knowledge and Understanding
You need to know and understand:
K1 how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
K2 the importance of wearing the appropriate personal protective equipment (PPE), and of keeping the work area clean and tidy
K3 the application of COSHH regulations in relation to the storage, use and disposal of composite materials and consumables
K4 the specific environmental conditions that must be observed when handling composite mouldings
K5 how to extract and use information from engineering drawings and related specifications in relation to work undertaken
K6 how to use imperial and metric systems of measurement, work piece reference points and system of tolerance
K7 quality procedures used in the workplace to ensure production control and the completion of appropriate documents
K8 conventions and terminology used when identifying and rectifying defects
K9 how to recognise the different types of defect that can occur in composite mouldings
K10 the different methods used to identify defects in composite mouldings including sensory checks, hand measuring tools and machine tools
K11 the factors to be taken into consideration when selecting the method to check composite moulding for defects
K12 the importance of identifying defects in composite mouldings and the implications if defects are not identified during production
K13 the correct methods of storage and handling of composite materials
K14 the tools and equipment used for checking the various composite mouldings
K15 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 inspection activities:
1.1 obtain and use the appropriate documentation (such as job instructions, drawings, quality control documentation, material data sheets)
1.2 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
1.3 maintain a safe working environment for the composite moulding inspection activities
1.4 check that all tools and equipment to be used are in a safe and usable condition and, where appropriate, are within current calibration/certification dates
1.5 follow safe practice/approved techniques and procedures at all times
1.6 return all tools and equipment to the correct location on completion of the activities
1.7 leave the work area in a safe and appropriate condition on completion of the activities
2. Identify defects in composite mouldings using two of the following methods:
2.1 touch
2.2 sound
2.3 visual
2.4 mechanical equipment
2.5 other method to be specified
or one of the following:
2.6 non-destructive testing (NDT)
2.7 co-ordinate measuring machines
2.8 testing equipment to check features (such as tensile strength, compression, sheer, impact and peel)
2.9 other method to be specified
3 Identify defects applicable to one of the following resin types:
3.1 bio resin
3.2 thermoplastic
3.3 polyester
3.4 vinyl ester
3.5 epoxy
3.6 phenolic
3.7 bismaleimide
3.8 cyanate ester
3.9 other (to be specified)
4 Identify defects applicable to one of the following fibre types:
4.1 natural fibre
4.2 thermo plastic
4.3 glass
4.4 aramid
4.5 carbon
4.6 hybrid
4.7 other (to be specified)
5 Where core materials are required identify defects applicable to one of the following:
5.1 solid timber
5.2 end grain balsa
5.3 rigid foam
5.4 expanding foam
5.5 coremat
5.6 honeycomb
5.7 fibrous honeycomb
5.8 aluminium honeycomb
5.9 syntactic core
5.10 expanding core
5.11 thermoplastic core
5.12 other (to be specified)
6 Identify seven of the following types of defect in composite mouldings:
6.1 dimensional
6.2 tolerances
6.3 surface finish
6.4 colour separation
6.5 distortion
6.6 blisters
6.7 dents or ‘dings’
6.8 surface cracks
6.9 incorrect material
6.10 contamination
6.11 bridging
6.12 broken fibres
6.13 stray fibres
6.14 ply orientation
6.15 wrong join type
6.16 gaps at joins
6.17 incorrect overlap
6.18 wrinkles
6.19 splintering
6.20 voids
6.21 resin rich areas
6.22 fibre deviation
6.23 damaged cores
6.24 dis-bonds
6.25 excessive adhesive
6.26 wrong inserts
6.27 insert positions
6.28 porosity
6.29 local exotherm
6.30 fayed/burned area
6.31 incomplete curing
6.32 de-lamination
6.33 impact damage
6.34 puncture
6.35 gouges
6.36 holes
6.37 abrasion/erosion
6.38 fluid ingress
6.39 fractures
6.40 other (to be specified)
7 Ensure actions recommended to rectify the defect comply with one of the following standards:
7.1 BS, ISO or BSEN standards and procedures
7.2 customer standards and requirements
7.3 organisational standards and procedures
7.4 recognised compliance agency/body standards