Aircraft Structural Repairs Syllabus Diploma in Aircraft Maintenance Engineering, Regulation 2010:
- To provide conception about the standard and specification of hardware materials and their type, material code, temper designation identification process.
- To provide knowledge about wood & wood structure of an aircraft.
- To make familiar with reinforced plastic & epoxy composite materials.
- To give guideline about rivet spacing/rivet formula as per the classification and location of damage.
- To make skill in installation/removal of rivets
- To make skill in forming countersink and dimpling
- To provide clear conception on the purpose/principle of repair and different classification of damage.
- To give knowledge on some terminology of minor repair, some repairing tools and their operation.
- To make familiar with the repair procedure of aircraft structure and structural components.
- To make skill in repair of wood and plastic structure.
SHORT DESCRIPTION
To provide knowledge about standard and specification of hardware materials, material code of rivets, their spacing, criteria about countering and dimpling process, their installation and removal procedure, principle of repair and classification of damage, repair procedure of metallic, wood and plastic structure and their different structural parts and components.
DETAIL DESCRIPTION
Theory
- Introduction
- Understand the purpose of Aircraft Structural Repairs
- Comprehension of the Wood Structure
3.1. List the types of wood & application
3.2. Mention the disease of wood & environmental controls
3.3. Define Ply wood
3.4. Distinguish between glues & paste
3.5. Describe paint & protective finishes.
3.6. Describe storage & condition control
- Outline the different types of Reinforced Plastic
4.1. Explain glass, fiber & reinforced plastic
4.2. Define thermosetting plastic
4.3. Define thermoplastic
- List the use of epoxy composite materials
- Explain about aircraft fabrics and their use
- Rewrite the specification of hardware materials
- Summaries the type of rivets, their material, code and identification procedure.
- Reproduce the temper designation of aluminum alloy rivets
- Understand the procedure of installation and removal of aircraft rivet
- Skill in forming of counter shank and dimpling
- Out line the rivet spacing or rivet layout formula
- Calculate shear, bearing and tensile strength of rivet
- Familiar with the application of tools for repair job
14.1 Describe hand brace and power operated twist drill
14.2 Describe Rivet gun, its use and care
14.3 Mention the use of bucking bar and extended bucking bar
- Understand the classification of Aircraft Damage
15.1 Define negligible damage
15.2 Explain the damage repairable by patching
15.3 Explain the damage repairable by insertion
15.4 Explain the damage necessitating replacement of parts.
- Define and explain the following Terminologies
16.1 Grinding
16.2 Burnishing
16.3 Burr
16.4 Corrosion
16.5 Crack
16.6 Cut
16.7 Dent
16.8 Erosion
16.9 Chattering
16.10 Galling
16.11 Gauge
16.12 Inclusion
16.13 Nick
16.14 Pitting
16.15 Scratch
16.16 Score
16.17 Stain
16.18 Upsetting
- Understand the following Aircraft Typical Repair
17.1 Small hole repair
17.2 Replacement of skin panels
17.3 Repair of sheet metal ribs
17.4 Splicing of sheets.
17.5 Stringer and flange splices
17.6 Repairing of cracked structure.
- Identify different types of Blind Rivets
18.1 Describe the cherry rivets.
18.1.1 Self plugging type
18.1.2 Pull-through hollow type.
18.2 State the Explosive rivets
18.3 Mention the use of rivnuts
18.4 Explain Hi-sheer rivets
- Define the following Metal Forming Terminologies
19.1 Bumping
19.2 Crimping
19.3 Stretching
19.4 Shrinking
19.5 Folding
- Describe how to Relief a Hole
- Describe how to Repair a Laminated Structure with the Following Materials
21.1 Honey comb sandwich material
21.2 Repair of metal faced laminates
21.3 Replacement of core repair
21.4 Repair of honey comb sandwich with riveted doublers.
21.5 Inspection of laminated and bonded seams.
21.6 Router and template honeycomb repair tools.
- Illustrate the Maintenance and Repair of Aircraft Plastic Materials
22.1 Mention the type of plastic
22.2 Explain the optical consideration
22.3 Describe the cleaning and handling plastics
22.4 Describe cutting and drilling plastics
22.5 Define cementing plastics
22.6 Describe installation of acrylic sheet
22.7 Explain the repair of cracks.
- Understand the Inspection for Abnormal Occurrences
23.1 Introduction
23.2 Describe the damage for jet blast
23.2.1 Flying control surfaces
23.2.2 Windscreen/ windows
23.2.3 Engine air intake
23.2.4 Structure (light a/c)
23.3 Explain the activities of Heavy or over Weight Landing
23.3.1 Landing gear
23.3.2 Weighs
23.3.3 Fuselage
23.3.4 Engine
23.3.5 Tail unit
23.3.6 Engine runs
23.4 Enlist Burst Tire Incidents & Explain the Following
23.4.1 The burst wheel
23.4.2 The other wheels
23.4.3 The affected leg
23.4.4 Secondary areas
23.5 Understand the Flight Through Severe Turbulence
23.6 Understand the Lightning Strikes
23.6.1 Mention the primary areas
23.6.2 Mention the secondary areas
Practical
- Show Skill in Identifying Aircraft Hardware
- Show Skill in Identifying Repairing & Riveting Equipment
- Show Skill in Aircraft Repair.
- Show Skill in Installation and Removal of the Following
- common rivet
- countersink rivet
- Show Skill in Minor Repair
- Small hole repair.
- Replacement of skin panels
- Repair of sheet metal ribs
- Show Skill in Major Repair
6.1 Explain the damage repairable by patching
6.2 Explain the damage repairable by insertion
Reference Books
- Haeco training manual
Australian training centre
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2. Airframe & Power Plant MechanicsAirframe Hand book – AC 65-15A
Federal Aviation Administration (FAA)
3. A & P Technician Airframe Textbook: EA –ITP – A 2
4. Aircraft Bonded Structure (Training Manual) by Dale Crane Aviation maintenance Publications INC.
5. Airframe & Power Plant Mechanics General Hand book – AC 65-9A Federal Aviation Administration (FAA)
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