Inspect and assess fuselage corrosion and plan the repair

You are a structures technician.

Simulated workplaceIntermediate missionCAQA AeroTech Maintenance

What is going on

During the annual inspection of VH-DDA, an agricultural aircraft, corrosion about 120 millimetres long was found on the lower fuselage skin below the cabin floor and logged as DEF-26-0408 with work order WO-26-1188. Kirsten Holm wants a thorough inspection of the area and surrounding structure, removal of the light corrosion, measurement of the remaining material against the structural repair manual limits and a recommended repair scheme before any cutting starts. The task involves working under the aircraft, chemical treatment and a chance of finding more damage, so a task risk assessment is required.

Kirsten Holm, Base Maintenance Manager
Subject: Corrosion assessment and repair planning on VH-DDA

The corrosion on the lower fuselage skin of VH-DDA needs a proper inspection and assessment before we commit to the repair. Please inspect the area and the surrounding structure, measure the extent and depth after removing the light corrosion, and compare the findings with the structural repair manual limits. Prepare a task risk assessment for the work and update work order WO-26-1188 and the defect log with your findings and the repair scheme you recommend. I will review it before any cutting starts.

Your brief

Inspect the corroded area and adjacent structure, remove light corrosion to the approved method, measure and compare the findings with the structural repair manual, prepare a task risk assessment, and update the work order and defect log with a recommended repair scheme.

Work through it

You do not need to do it all. Doing a few of these will show you what the work is like. Your ticks and notes stay on this device.

Read the structural repair manual section for the lower fuselage skin and the Quality and Airworthiness Policy to confirm the data revision and the inspection and repair limits.
Complete the Maintenance Task Risk Assessment Template for working under the aircraft with chemical corrosion treatment, and have it approved by Kirsten Holm.
Gain access to the area following the task card, inspect the skin, stringers and adjacent fasteners with a torch and mirror and record the extent of the corrosion with sketches and photographs.
Remove the light corrosion using the approved method and materials from the store, then clean and inspect the area again for pitting and cracks.
Measure the remaining skin thickness with calibrated equipment from the Tool Control and Calibration Register, record the readings and compare them with the manual limits.
Decide whether the finding is within limits for blend out, requires a doubler repair, or exceeds the manual and needs engineering support, and write your recommended repair scheme with data references.
Update WO-26-1188 and DEF-26-0408 with the findings and the recommendation, and present them to Kirsten Holm for review before repair work starts.

My notes: what did I enjoy, and what surprised me?

What someone in this role would produce

Approved task risk assessment
Inspection record with sketches, photographs and measurements
Repair scheme recommendation with data references
Updated work order and defect log entries

Printing this is a record of what you explored. It is not a certificate or a qualification.