Standard Aircraft Handbook for Mechanics and Technicians

Cover
Title Page
Copyright Page
Contents
Preface
Acknowledgments
1 Introduction
	Fuselage Structure
	Location Numbering Systems
	Wing Structure
	Empennage or Tail Assembly
2 Tools and How to Use Them
	Safety Considerations
	General-Purpose Hand Tools
		Hammers
		Screwdrivers
		Pliers
		Punches
		Wrenches
	Metal-Cutting Tools
		Hand Snips
		Hacksaws
		Chisels
		Files
		Drilling and Countersinking
		Reamers
	Layout and Measuring Tools
		Rules
		Combination Sets
		Scriber
		Dividers and Calipers
		Slide Calipers
	Taps and Dies
	Shop Equipment
		Holding Devices
		Squaring Shears
		Throatless Shears
		Bar Folder
		Sheet-Metal Brake
		Slip Roll Former
		Grinders
		Rotary Punch
3 Materials and Fabricating
	Aircraft Woods
	Wood Substitutions
		Plywood
	Laminated Wood
	Bonding of Wood Structures
		Inspection of Wood Structures
		Dry Rot and Decay
		Adhesive Joints
		Cracks
	Compression Failure
		Surface Crushing
		Staining
		Corrosion
		Slope of a Grain
		Wood Repairs
	Repair of Damaged Plywood Structures
	Aircraft Fabrics
		Dopes and Finishing Materials
	Supplemental Type Certificates
	Minimum Fabric Requirements
		Fabric Seams
	Covering Methods
	Hand Sewing
		Rib Lacing
		Fabric Inspection
	Tears in Fabric
	Aluminum and Aluminum Alloys
		Alloy and Temper Designations
		Cast and Wrought Aluminum Alloy Designation System
		Aluminum
		Aluminum Alloys
		Temper Designation System
	Characteristics of Aluminum Alloys
		Nonheat-Treatable Alloys
		Heat-Treatable Alloys
		Clad Alloys
		Annealing Characteristics
		Typical Uses of Aluminum and Its Alloys
		Heat Treatment of Aluminum Alloys
		Identification of Aluminum
	Handling Aluminum
	Forming Aluminum Alloys
		Forming at the Factory
	Blanking
	Bending
	Press-Brake Forming
	Stretch Forming
	HydroPress Forming
	Roll Forming
	Flexible-Die Forming
	Machining
	Drilling
	Turret Lathes and Screw Machines
	Milling
	Routing
	Forging
	Casting
	Chemical Milling
	Making Straight-Line Bends
		Bend Allowance
		Brake or Sight Line
		J Chart for Calculating Bend Allowance
	Making Layouts
		Relief Holes
		Miscellaneous Shop Equipment and Procedures
	Magnesium and Magnesium Alloys
		Heat Treatment of Magnesium Alloys
	Titanium and Titanium Alloys
		Titanium Designations
		Corrosion Characteristics
		Treatment of Titanium
	Working with Titanium
		Machining of Titanium
	Milling
		Turning
		Drilling
	Tapping
		Grinding
		Sawing
		Cleaning After Machining
		Shop-Forming Titanium
		Stress Relief
	Ferrous Aircraft Metals
		Identification
		Types, Characteristics, and Uses of Alloyed Steels
		Heat Treatment of Ferrous Metals
4 Drilling and Countersinking
	Rivet Hole Preparation
		Rivet Hole Location
		Drills
		Drill Sharpening
		Drill Points
		Drilling Equipment
	Drilling Operations
		Chucking the Drill
		Drilling Holes
		Drill Stops and Drill Bushings
		Using an Extension Drill
		Drilling Aluminum and Aluminum Alloys
		Drilling Titanium and Titanium Alloys
		Drilling Stainless Steel
		Deburring
	Countersinking
		Types of Countersinking Cutters
		Countersinking Holes
		Minimum Countersinking Depth
		Form Countersinking (Dimpling)
		100 Degree Combination Predimple and Countersink Method
		Hole Preparation for Form Countersinking
	Shaving Flush Head Fasteners
	Reamers
5 Riveting
	Solid-Shank Rivets
		Material
		Rivet Types and Identification
	Riveting Practice
		Edge Distance
		Rivet Length
		Rivet Spacing
		Hole Preparation
		Use of Clecos
		Driving Solid-Shank Rivets
		Rivet Sets
		Bucking Bars
		Riveting Procedure
		Blind Bucking
		Tapping Code
	Hand Riveting
	Rivet Squeezers
		Inspection After Riveting
	Rivet Removal
	NACA Method of Double Flush Riveting
	Blind Rivets
		Mechanical Locked-Stem Self-Plugging Rivets
		Removal of Mechanically Locked Blind Rivets
	Sheet-Metal Repair
		Damage Removal
		Repair Material Thickness
		Rivet Selection
		Rivet Spacing and Edge Distance
		Repair Approval
		Typical Sheet-Metal Repairs
		Patches
	Flush Patch
6 Welding
	Welding Processes
	Types of Weld Joints
	Parts of a Weld
	Proportions of a Weld
	Correct Formation of a Weld
	Oxyacetylene Welding Equipment
		Acetylene
		Oxygen
	Acetylene and Oxygen Regulators
	Welding Torches
	Welding, or Filler, Rod
	Safety Equipment
		Welding Gloves
		Spark Lighter
	Setting the Pressure
	Lighting the Torch
	Oxyacetylene Flames
	Backfire and Flashback
	Shutting Down the Welding Apparatus
	Gas Welding Techniques
	Holding the Torch
	Forming the Puddle and Adding Filler Material
	Torch Motions
	Reducing Distortion and Residual Stress
	Weld Quality
	Gas Welding Aluminum, Magnesium, and Titanium
	Types of Inert-Gas Welding
	Metal Inert-Gas (MIG) Welding
	Advantages of Inert-Gas Welding
	Soldering and Brazing
7 Bolts and Threaded Fasteners
	Aircraft Bolts
		General-Purpose Bolts
	Close-Tolerance Bolts
	Classification of Threads
		Identification and Coding
	Aircraft Nuts
		Self-Locking Nuts to 250°F
		High-Temperature Self-Locking Nuts
		Miscellaneous Nut Types
	Aircraft Washers
		Plain Washers
		Lock Washers
	Installation of Nuts and Bolts
		Torque Tables
		Cotter Pin Hole Line-Up
		Safetying of Nuts, Bolts, and Screws
	Cotter Pin Safetying
	Installation: Bolts, Washers, Nuts, and Cotter Pins
	Miscellaneous Threaded Fasteners
		Screws
	Dzus Fasteners
	Camloc Fasteners
	Hi-Lok ®, Hi-Tigue ®, and Hi-Lite ® Fasteners
		Hi-Lok® Fastening System
		Hi-Tigue® Fastening System
		Hi-Lite® Fastening System
	Installation of Hi-Lok®, Hi-Tigue®, and Hi-Lite® Fasteners
		Hole Preparation
		Pin Grip Length
		Installation Tools
		Installation Steps for an Interference-Fit Hole
		Inspection After Installation
		Removal of the Installed Fastener
	Lockbolt Fastening Systems
		Installation Procedure
		Lockbolt Inspection
		Lockbolt Removal
	Blind Bolts
		Cherry Maxibolt® Blind Bolt System
		Drive-Nut-Type Blind Bolt
8 Aircraft Plumbing
	Fluid Lines
		Aluminum Alloy Tubing
		Steel
		Titanium 3AL-2.5V
		Tubing Identification
		Sizes
	Flexible Hose
		Synthetics
		Rubber Hose
		Teflon Hose
		Identification of Hose
		Size Designation
		Identification of Fluid Lines
	Plumbing Connections
		Flared-Tube Fittings
		Flareless-Tube Fittings
		Swaged Fittings
		Cryofit Fittings
		Tube Cutting
		Deburring
		Tube Bending
		Tube Flaring
		Assembling Sleeve-Type Fittings
		Proof-Testing After Assembly
		Installing Flexible Hose Assemblies
	Installing Rigid Tubing
		Support Clamps
		Rigid Tubing Inspection and Repair
9 Control Cables
	Cable Assembly
		Fabricating a Cable Assembly
		Swaging
		Nicopress Process
	Turnbuckles
		Safety Methods for Turnbuckles
		Double-Wrap Method
	Cable Tension Adjustment
		Cable Guides
10 Electrical Wiring and Installation
	Material Selection
		Wire Size
		Stripping Insulation
	Terminals
		Aluminum Wire Terminals
		Connecting Terminal Lugs to Terminal Blocks
		Wiring Identification
		Placement of Identification Markings
	Wire Groups and Bundles
		Spliced Connections in Wire Bundles
		Bend Radii
		Routing and Installations
		Protection Against Chafing
	Bonding and Grounding
	AN/MS Connectors
		Wire Inspection
	Electrical Components
		Switches
		Relays and Solenoids
		Fuses
		Circuit Breakers
11 Aircraft Drawings
	Orthographic Projection
	Working Drawings
		Detail Drawing
		Assembly Drawing
		Installation Drawing
	Title Block
	Bill of Material
	Other Data
	Sectional Views
	The Lines on a Drawing
	Rivet Symbols Used on Drawings (Blueprints)
12 Nondestructive Testing (NDT) or Nondestructive Inspection (NDI)
	Visual Inspection
	NDT Beyond Visual Inspection
		Liquid Penetrant Inspection
		Eddy-Current Inspection
		Ultrasonic Inspection
		Phased Array Inspection
		Magnetic Particle Inspection
		Radiography
		Tap or Coin Test
		Thermography
		Shearography
13 Corrosion Detection and Control
	Types of Corrosion
	Direct Chemical Attack
	Electrochemical Attack
	Forms of Corrosion
		Surface Corrosion
		Filiform Corrosion
		Pitting Corrosion
		Intergranular Corrosion
		Exfoliation Corrosion
		Stress Corrosion
		Fretting Corrosion
	Effects of Corrosion
	Corrosion Control
	Inspection Requirements
	Corrosion Prevention
	Corrosion-Prone Areas
	Corrosion-Removal Techniques
	Surface Damage by Corrosion
14 Composites
	Introduction
	Definition of Composite Materials
	Major Components of a Laminate
	Types of Fiber
		Fiberglass
		Carbon
		Kevlar®
	Fiber Forms
		Roving
		Unidirectional (Tape)
		Bidirectional (Fabric)
	Resin Systems
		Mixing Two-Part Resin Systems
		Curing Stages of Thermosetting Resins
	Dry Fiber and Prepreg
	Adhesives
		Film Adhesives
		Paste Adhesives
		Foaming Adhesives
	Honeycomb Sandwich Structures
	Laminate Structures
	Damage and Defects
		Delamination and Debonds
		Resin Rich or Starved
		Fiber Breakage
		Matrix Imperfections
		Moisture Ingress
	Vacuum Bagging Techniques
		Release Agents
		Bleeder Ply
		Peel Ply
		Layup Tapes
		Perforated Release Film
		Solid Release Film
		Breather Material
		Vacuum Bag
	Curing and Curing Equipment
		Oven
		Autoclave
		Heat Bonder
	Types of Layups for Repair
		Wet Layup
		Prepreg Layup
	Repairs of Honeycomb and Laminate Structures
		Honeycomb Sandwich Repair
		Repair of Laminate Structure
	Specialty Fasteners Used for Composite Structures
	Fastener Materials
	Drilling
	Countersinking
15 Standard Parts
	Standard Parts Identification
	Standard Parts Illustrations
	Additional Standard Parts (Patented)
16 Weight and Balance
	Introduction
		FAA Requirements
		Weight and Balance Terminology
		Aircraft Weighing
17 Regulations, Publications, Maintenance Forms, and Records
	Definitions
	Maintenance-Related Regulations
	Advisory Circulars (AC)
	Airworthiness Directives (AD)
	Aircraft Specifications
	Type Certificate Data Sheets (TCDS)
	Supplemental Type Certificates
	Manufacturers’ Published Data
	Service Bulletins (SB)
	Forms
		Airworthiness Certificates
		FAA Form 337—Major Repair and Alteration
	Records
		Temporary Records
		Permanent Records
Appendix
Glossary
Index