Hardware and Materials For Aviation Maintenance; EASA Module 06 [Paperback] [Jan 01, 2014] Aircraft Technical Book Company LLC

Materials and Hardware EASA Module 06
	Contents
		Welcome
		Revision Log
		Forward
	Sub-Module 01
		Ferrous
		Knowledge Requirements
		Aircraft Metals
		Properties Of Metals
			Hardness
			Strength
			Density
			Malleability
			Ductility
			Elasticity
			Toughness
			Brittleness
			Fusibility
			Conductivity
			Thermal Expansion
		Ferrous Aircraft Metals
			Iron
			Steel And Steel Alloys
			Types, Characteristics, And Uses Of Alloyed Steels
			Electrochemical Test
		Substitution of Aircraft Metals
		Metal working Processes
			Hot Working
			Heat Treating
			Internal Structure Of Metals
			Heat-Treating Equipment
			Furnaces and Salt Baths
				Temperature Measurement and Control
			Heating
			Soaking
			Cooling
			Quenching Equipment
			Heat Treatment of Ferrous Metals
			Behavior of Steel During Heating and Cooling
			Hardening
			Hardening Precautions
			Tempering
			Annealing
			Normalizing
			Case hardening
				Carburizing
				Nitriding
			Forging
			Casting
			Extruding
			Cold Working/Hardening
		Hardness Testing
			Brinell Tester
			Rockwell Tester
		Other Testing
			Tensile Strength Testing
			Fatigue Strength Testing
			Impact Testing
		Questions
		Answers
	Sub-Module 02
		Aircraft Materials — Non-Ferrous
		Knowledge Requirements
		Aircraft Metals
		Properties of Metals
			Hardness
			Strength
			Density
			Malleability
			Ductility
			Elasticity
			Toughness
			Brittleness
			Fusibility
			Thermal Expansion
		Non-Ferrous Aircraft Metals
			Aluminum And Aluminum Alloys
			Wrought Aluminum
			Effect of Alloying Element
			Hardness Identification
			Magnesium And Magnesium Alloys
			Titanium and Titanium Alloys
			Titanium Designations
			Corrosion Characteristics
			Copper and Copper Alloys
			Nickel and Nickel Alloys
			Monel
			Inconel
		Substitution of Aircraft Metals
		Heat Treatment of Non-ferrous Metals
			Aluminum Alloys
			Alclad Aluminum
			Solution Heat Treatment
				Temperature
				Time at Temperature
			Quenching
				Cold Water Quenching
				Hot Water Quenching
				Spray Quenching
				Lag Between Soaking and Quenching
			Reheat Treatment
			Straightening After Solution Heat Treatment
			Precipitation Heat Treating
				Precipitation Practices
			Annealing of Aluminum Alloys
			Heat Treatment of Aluminum Alloy Rivets
			Heat Treatment of Magnesium Alloys
				Solution Heat Treatment
				Precipitation Heat Treatment
			Heat Treatment of Titanium
				Stress Relieving
			Full Annealing
			Thermal Hardening
			Case hardening
		Hardness Testing
			Brinell Tester
			Rockwell Tester
			Barcol Tester
			Casting
			Extruding
			Cold Working/Hardening
		Questions
		Answers
	Sub-Module 03
		Aircraft Materials — Composite and Non-Metallic
		Knowledge Requirements
		Non-Metallic Aircraft Materials
			Wood
			Plastics
			Transparent Plastics
			Composite Materials
				Advantages/Disadvantages of Composites
				Composite Safety
				Laminated Structures
			Reinforced Plastic
			Rubber
				Natural Rubber
				Synthetic Rubber
			Sealing Compounds
				One-Part Sealants
				Two Part Sealants
		Advanced Composite Materials
		Laminated Structures
			Major Components of A Laminate
			Strength Characteristics
				Fiber Orientation
				Warp Clock
		Fiber Forms
			Roving
			Unidirectional (Tape)
			Bidirectional (Fabric)
			Nonwoven (Knitted or Stitched)
		Types Of Fiber
			Fiberglass
			Kevlar®
			Carbon/Graphite
			Boron
			Ceramic Fibers
			Lightning Protection Fibers
		Matrix Materials
			Thermosetting Resins
				Polyester Resins
				Vinyl Ester Resin
				Phenolic Resin
				Epoxy
				Polybenzimidazoles (PBI)
				Bismaleimides (BMI)
			Thermoplastic Resins
				Semicrystalline Thermoplastics
				Amorphous Thermoplastics
				Polyether Ether Ketone (PEEK)
		Curing Stages of Resins
		Pre-Impregnated Products (Prepregs)
		Dry Fiber Material
		Thixotropic Agents
		Adhesives
			Film Adhesives
			Paste Adhesives
			Foaming Adhesives
		Sandwich Structures
			Properties
			Facing Materials
			Core Materials
				Honeycomb
				Foam
				Balsa Wood
		Manufacturing Defects
			Fiber Breakage
			Matrix Imperfections
			Delamination and Debonds
			Combinations of Damages
			Flawed Fastener Holes
		In-Service Defects
		Corrosion
		Non-Destructive Inspection (NDI) of Composites
			Visual Inspection
			Audible Sonic Testing (Coin Tapping)
			Automated Tap Test
			Ultrasonic Inspection
				Through Transmission Ultrasonic Inspection
				Pulse Echo Ultrasonic Inspection
				Ultrasonic Bond Tester Inspection
				Phased Array Inspection
			Radiography
			Thermography
			Neutron Radiography
			Moisture Detector
		Composite Repairs
			Layup Materials and tools
				Air Tools
				Caul Plate
				Support Tooling and Molds
			Vacuum Bag Materials
				Release Agents
				Bleeder Ply
				Peel Ply
				Layup Tapes
				Perforated Release Film
				Solid Release Film
				Breather Material
				Vacuum Bag
			Vacuum Equipment
				Vacuum Compaction Table
		Heat Sources
			Oven
			Autoclave
				Heat Bonder and Heat Lamps
				Heat Bonder
				Heat Blanket
				Hot Air System
			Heat Press Forming
			Thermocouples
				Thermocouple Placement
			Thermal Survey of Repair Area
				Temperature Variations in Repair Zone
				Thermal Survey
				Solutions to Heat Sink Problems
		Types of Layups
			Wet Layups
			Prepregs
				Co-Curing
				Co-Bonding
		Wet Laminated Layup Techniques
			Bleedout Technique
			No Bleedout
			Ply Orientation Warp Clock
		Mixing Resins
		Saturation Techniques
			Fabric Impregnation With a Brush or Squeegee
			Fabric Impregnation Using a Vacuum Bag
		Vacuum Bagging Techniques
			Envelope Bagging
		Alternate Pressure Application
			Shrink Tape
			C-Clamps
			Shotbags and Weights
		Curing of Composite Materials
			Room Temperature Curing
			Elevated Temperature Curing
		Composite Honeycomb Sandwich Repairs
			Damage Classification
			Minor Core Damage (Filler and Potting Repairs)
			Damage Requiring Core Replacement and Repair to One or Both Face Plates
		Solid Laminates
			Bonded Flush Patch Repairs
			Trailing Edge and Transition Area Patch Repairs
			Resin Injection Repairs
			Composite Patch Bonded to Aluminum Structure
			Fiberglass Molded Mat Repairs
			Radome Repairs
			External Bonded Patch Repairs
			External Bonded Repair With Prepreg Plies
			External Repair Using Wet Layup And Double Vacuum Debulk Method (DVD)
				Double Vacuum Debulk Principle
				Patch Installation on the Aircraft
			External Repair Using Precured Laminate Patches
		Bonded versus Bolted Repairs
			Bolted Repairs
		Fasteners Used with Composite Laminates
			Corrosion Precautions
			Fastener Materials
			Fastener System For Sandwich Honeycomb Structures
				Adjustable Sustain Preload Fastening System (ASP)
			Hi-Lok® and Huck-Spin® Lockbolt Fasteners
			Eddie-Bolt® Fasteners
			Cherry's E-Z Buck® (CSR90433) Hollow Rivet
			Blind Fasteners
			Blind Bolts
			Fiberlite
			Screws and Nutplates in Composite Structures
		Machining Processes and Equipment
			Drilling
			Equipment
			Processes and Precautions
			Countersinking
			Cutting Processes and Precautions
			Cutting Equipment
		Repair Safety
			Eye Protection
			Respiratory Protection
			Downdraft Tables
			Skin Protection
			Fire Protection
		Transparent Plastics
			Optical Considerations
			Storage and Handling
			Forming Procedures and Techniques
				Heating
				Forms
			Forming Methods
				Simple Curve Forming
				Compound Curve Forming
				Stretch Forming
				Male and Female Die Forming
				Vacuum Forming Without Forms
				Vacuum Forming With a Female Form
			Sawing and Drilling
				Sawing
				Drilling
				Cementing
					Application of Cement
			Repairs
			Cleaning
			Polishing
			Windshield Installation
				Installation Procedures
		Aircraft Wood and Structural Repair
		Wood Aircraft Construction and Repairs
		Inspection of Wood Structures
			External and Internal Inspection
			Glued Joint Inspection
			Wood Condition
		Repair of Wood Aircraft Structures
			Suitable Wood
			Defects Permitted
			Defects Not Permitted
			Glues (Adhesives)
			Definition of Terms Used in the Glue Process
			Preparation of Wood for Gluing
			Preparing Glues for Use
			Applying the Glue/Adhesive
			Pressure on the Joint
			Testing Glued Joints
		Repair of Wood Aircraft Components
			Wing Rib Repairs
			Wing Spar Repairs
		Bolt and Bushing Holes
		Plywood Skin Repairs
			Fabric patch
			Splayed Patch
			Surface Patch
			Plug Patch
			Scarf Patch
			The Back Of The Skin Is Accessible For Repair
			The Back Of The Skin Is Not Accessible For Repair
		Finishing Wood Structures
			Acceptable Finishes
			Precautions
			Finishing Of Interior Surfaces
			Finishing Of Exterior Surfaces
			Finishing Of End Grain Surfaces
			Finishing With Fabric Or Tape
			Sealing Of Bolt Holes
		Aircraft Fabric Coverings
			Applicability Notice
			General History
		Legal Aspects of Fabric Covering
		Fabric Terms
		Approved Materials
			Fabric
			Other Fabric Covering Materials
				Anti-Chafe Tape
				Reinforcing Tape
				Rib Bracing
				Surface Tape
				Rib Lacing Cord
				Sewing Thread
				Special Fabric Fasteners
				Grommets
				Inspection Rings
				Primer
				Fabric Cement
				Fabric Sealer
				Fillers
				Topcoats
		Available Covering Processes
		Determining Fabric Condition—Repair Or Recover?
		Fabric Strength
			How Fabric Breaking Strength is Determined
			Fabric Testing Devices
		General Fabric Covering Process
			Blanket Method Versus Envelope Method
			Preparation for Fabric Covering Work
				Removal of Old Fabric Coverings
				Preparation of the Airframe Before Covering
			Attaching Polyester Fabric to the Airframe
				Seams
				Fabric Cement
			Fabric Heat Shrinking
			Attaching Fabric to the Wing Ribs
				Rib Lacing
			Rings, Grommets, and Gussets
			Finishing Tapes
			Coating the Fabric
		Polyester Fabric Repairs
			Applicable Instructions
			Repair Considerations
		Cotton-Covered Aircraft
		Fiberglass Coverings
		Questions
		Answers
	Sub-Module 04
		Corrosion
		Knowledge Requirements
		Introduction To Corrosion
		Corrosion
			Common Corrosion Agents
			Micro Organisms
		Corrosion Types
			General Surface Corrosion
			Pitting Corrosion
			Concentration Cell Corrosion
			Active-Passive Cells
			Filiform Corrosion
			Intergranular Corrosion
			Exfoliation Corrosion
			Galvanic Corrosion
			Stress Corrosion Cracking
			Fatigue Corrosion
			Fretting Corrosion
		Material Types And Corrosion
			Aluminum And Aluminum Alloys
			Magnesium And Magnesium Alloys
			Ferrous Metals
			Noble Metals
			Chromium And Nickel-Plated Parts
			Cadmium And Zinc-Plated Parts
		Water And Corrosion
		Corrosion Prone Areas
			Battery Compartments And Battery Vent Openings
			Lavatories, Buffets, And Galleys
			Bilge Areas
			External Skin Areas
			Water Entrapment Areas
			Engine Frontal Areas And Cooling Air Vents
			Electronic Package Compartments
			Miscellaneous Trouble Areas
		Factors In Corrosion Control
			Preventative Maintenance
		Questions
		Answers
	Sub-Module 05
		Fasteners
		Knowledge Requirements
		Fasteners
			Screw Threads
				Identification
				Threaded Fasteners
			Bolts, Studs And Screws
				Classification of Threads
				Aircraft Bolts
					Identification and Coding
					General Purpose Bolts
					Close Tolerance Bolts
					Internal Wrenching Bolts
				Special-Purpose Bolts
					Clevis Bolts
					Eyebolt
					Jo-Bolt
					Lockbolts
				Aircraft Nuts
					Identification and Coding
					Non-Self-Locking Nuts
					Self-Locking Nuts
					Boots Self-Locking Nut
					Stainless Steel Self-Locking Nuts
					Elastic Stop Nuts
					Anchor Nuts
					Pal Nuts
					Sheet Spring Nuts
					Internal and External Wrenching Nuts
				Screws
					Identification and Coding for Screws
					Structural Screws
					Machine Screws
					Self-Tapping Screws
					Drive Screws
				Studs
					Standard Studs
					Waisted Studs
					Stepped Studs
					Shouldered Studs
				Dowels
			Locking Devices
				Aircraft Washers
					Plain Washers
					Lockwashers
					Shakeproof Lockwashers
					Special Washers
				Nutplates
					Sealing Nutplates
					Riveted and Rivetless Nutplates
					Rivnuts
				Lock Plates
				Pins
					Cotter Pins
					Cotter Pin Safetying
					Roll Pins
					General Safety Wiring Rules
					Oil Caps, Drain Cocks, and Valves
					Electrical Connectors
					Turnbuckles
				Captive Fasteners
					Turnlock Fasteners
					Dzus Fasteners
					Airloc Fasteners
				Keys
				Snap rings
			Aircraft Rivets
				Identification
				Standards and Specifications
				Solid Shank Rivets
				Heat Treating Rivets
				Blind Rivets
					Mechanically Expanded Rivets
					Self-Plugging Rivets (friction lock)
					Pull-Thru Rivets
					Self-Plugging Rivets (Mechanical Lock)
					Wiredraw Cherrylock Rivets
					Huck Mechanical Locked Rivets
					Material
					Head Styles
					Diameters
					Grip Length
					Rivet Identification
				Special Shear And Bearing Load Fasteners
				Pin Rivets
				Taper-Lok
			Hi-Tigue
				Dill Lok-Skrus and Dill Lok-Rivets
				Deutsch Rivets
			Installation of Nuts, Washers, and Bolts
				Bolt and Hole Sizes
				Installation Practices
				Safetying of Bolts and Nuts
				Repair of Damaged Internal Threads
					Helicoils
			Fastener Torque
				Torque and Torque Wrenches
				Cotter Pin Hole Line Up
			Hole Repair and Hole Repair Hardware
				Acres Fastener Sleeves
					Advantages and Limitations
					Identification
					Installation
					Sleeve Removal
		Questions
		Answers
	Sub-Module 06
		Pipes and Unions
		Knowledge Requirements
		Pipes And Unions
		Rigid Fluid Lines
			Tubing Materials
				Copper Tubing
				Aluminum Alloy Tubing
				Steel Tubing
				Titanium Tubing 3AL-2.5V
			Material Identification
			Fluid Line End Fittings
				Universal Bulkhead Fittings
				AN Flared Fittings
				Flareless Fittings
				Swaged Fittings
				Cryofit™ Fittings
		Flexible Hose Fluid Lines
			Hose Materials And Construction
				Teflon™
				Low, Medium, And High Pressure Hoses
			Hose Identification
			Hose Fittings
		Fluid Line Identification
		Questions
		Answers
	Sub-Module 07
		Springs
		Knowledge Requirements
		Types Of Springs And Applications
			Flat Springs
			Leaf Springs
			Spiral Springs
			Helical Compression And Tension Springs
			Helical Torsion Springs
			Belleville (Cone Disc) Springs
			Torsion Bar Springs
			Spring Dimensions
			Spring Characteristics
		Questions
		Answers
	Sub-Module 08
		Bearings
		Knowledge Requirements
		Bearings
			Plain Bearings
			Ball Bearings
			Roller Bearings
		Questions
		Answers
	Sub-Module 09
		Transmissions
		Knowledge Requirements
		Transmissions
			The Gear
				Propeller Reduction Gearing
				Gear Terms
					Backlash (or lash)
					Idler Gear
					Intermediate Gear
					Compound Gear
					Pinion
					Lay-shaft
					Rack and Pinion
					Step-Up Drive
					Step-Down Drive
				Gear Lash and Pattern
			Chains and Sprockets
			Belts and Pulleys
		Questions
		Answers
	Sub-Module 10
		Control Cables
		Knowledge Requirements
		Control Cables and Terminals
			Cable Construction
			Cable Fittings
		Cable System Installation
			Cable Guides
			Travel Adjustment
			Cable Tension
			Tension Regulators
			Turnbuckles
			Cable Connectors
			Spring-Back
		Push Rods (Control Rods)
			Torque Tubes
			Cable Drums
			Bowden Cable
		Questions
		Answers
	Sub-Module 11
		Electrical Cables and Connectors
		Knowledge Requirements
		Wire Types
			Conductors
		Insulation
		Wire Shielding
		Wire Substitutions
			Severe Wind and Moisture
			Problem (SWAMP)
			Wire Size Selection
			Current Carrying Capacity
			Maximum Operating Temperature
			Computing Current Carrying Capacity
		Allowable Voltage Drop
			Electric Wire Chart Instructions
		Wire Identification
			Placement of Identification Markings
			Types of Wire Markings
		Wire Installation and Routing
			Open Wiring
			Wire Groups and Bundles and Routing
			Slack in Wire Bundles
			Twisting Wires
			Spliced Connections
			In Wire Bundles
			Bend Radii
			Protection Against Chafing
			Protection Against High Temperature
			Protection Against Solvents and Fluids
			Protection of Wires in Wheel Well Areas
			Clamp Installation
				Wire and Cable Clamp Inspection
				Movable Controls Wiring Precautions
		Conduit
			Rigid Conduit
			Flexible Conduit
			Wire Shielding
			Bonding and Grounding
			Grounding
			Bonding
			Testing of Bonds and Grounds
			Bonding Jumper Installation
			Lacing and Tying Wire Bundles
			Tying
		Wire Termination
			Stripping Wire
		Terminal Strips
			Terminal Lugs
			Copper Wire Terminals
			Aluminum Wire Terminals
			Pre-Insulated Splices
			Crimping Tools
			Emergency Splicing Repairs
		Junction Boxes
		AN/MS Connectors
			Types of Connector
			Voltage and Current Rating
			Spare Contacts for Future Wiring
			Wire Installation Into the Connector
			Adjacent Locations
			Sealing
			Drainage
			Wire Support
			Coaxial Cable
		Wire Inspection
		Questions
		Answers
	Acronym Index
	Index