aircraft structural repairer Interview Questions and Answers

1. What is your experience with composite materials repair?

   • Answer: I have [Number] years of experience repairing composite structures, including [List specific types of composites, e.g., carbon fiber, fiberglass]. My experience encompasses [List specific repair techniques, e.g., lamination, scarf repairs, honeycomb repair]. I'm proficient in using various resin systems and understand the importance of proper curing processes and non-destructive testing (NDT) methods to ensure structural integrity.

2. Describe your experience with metal aircraft structure repair.

   • Answer: My experience includes repairing various metal alloys commonly used in aircraft construction, such as aluminum, steel, and titanium. I'm familiar with techniques like riveting, welding (specify types if applicable, e.g., MIG, TIG), and the use of specialized tools and equipment for repairs. I understand the importance of proper surface preparation, heat treatment (if applicable), and stress relieving to maintain structural integrity.

3. Explain the process of conducting a damage assessment on an aircraft structure.

   • Answer: A damage assessment starts with a visual inspection to identify the extent and type of damage. This includes documenting the location, size, and nature of the damage using photos and sketches. Next, I would use appropriate NDT methods such as dye penetrant inspection, ultrasonic testing, or radiographic inspection to determine the depth and extent of any hidden damage. Finally, I'd consult relevant maintenance manuals and repair manuals to determine the appropriate repair procedure and ensure compliance with regulatory requirements.

4. What are the common types of aircraft structural damage?

   • Answer: Common types of aircraft structural damage include dents, cracks, corrosion, delamination (in composites), punctures, fatigue damage, and impact damage. The severity can range from minor cosmetic damage to significant structural compromise requiring major repairs.

5. How do you ensure compliance with FAA regulations during repairs?

   • Answer: Compliance with FAA regulations is paramount. I meticulously follow the approved repair manuals and airworthiness directives for the specific aircraft type and damage. I maintain accurate records of all repairs performed, including parts used, inspection results, and the completion of required documentation. I also ensure that all repairs are inspected and signed off by authorized personnel.

6. What are the different types of Non-Destructive Testing (NDT) methods you are familiar with?

   • Answer: I am familiar with several NDT methods including visual inspection (VI), dye penetrant inspection (DPI), magnetic particle inspection (MPI), ultrasonic testing (UT), radiographic inspection (RT), and eddy current testing (ECT). I understand the limitations and applications of each method and select the appropriate technique based on the type of material and suspected damage.

7. Describe your experience with corrosion control and prevention.

   • Answer: I have experience in identifying and mitigating corrosion in aircraft structures. This includes cleaning and preparing surfaces, applying corrosion inhibitors and primers, and performing repairs to damaged areas to prevent further corrosion. I understand the importance of regular inspections and preventative maintenance to extend the lifespan of the aircraft structure.

8. How do you handle discrepancies found during an inspection?

   • Answer: Any discrepancies found during an inspection are documented thoroughly, including photographs and detailed descriptions. I would then consult the relevant maintenance manuals and airworthiness directives to determine the appropriate course of action, which may range from minor repairs to major structural overhaul. The discrepancy and the repair plan would be communicated to the supervisor for review and approval before proceeding with the repairs.

9. What safety precautions do you take when working on aircraft structures?

   • Answer: Safety is my top priority. I always follow all safety regulations and company procedures. This includes wearing appropriate personal protective equipment (PPE) such as safety glasses, gloves, hearing protection, and respiratory protection as needed. I also follow lockout/tagout procedures when working with machinery and ensure the work area is properly secured and organized. I am trained in the safe handling of hazardous materials and understand the risks associated with working at heights or in confined spaces.

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