Standard Aircraft Handbook for Mechanics and Technicians, Eighth Edition
By Ronald Sterkenburg and Peng Hao Wang
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
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
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