EASA Module 06 Materials and Hardware

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MODULE 06 
FOR B1 & B2 CERTIFICATION 
MATERIALS AND HARDWARE 
Aviation Maintenance Technician _ _; 
Certification Series 
COMPLIANT WITH 
EASA PART 66/147 
~ 
AIRCRAFT 
TECHNICAL 
BOOK COMPANY 
72413 U.S. Hwy 40 
Tabernash, CO 80478-0270 USA 
www.actechbooks.com 
+1 970 726-5111 
AVIATION MAINTENANCE TECHNICIAN CERTIFICATION SERIES 
Contributor Tom Forenz 
LayouVDesign Michael Amrine 
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ISBN 976-09697 547 50 
EASA Part-66 
Aviation Maintenance Technician 
Certification Series 
NO COST REVISION/UPDATE SUBSCRIPTION PROGRAM 
Complete EASA Part-66 Aviation Maintenance Technician Certification Series 
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.-, 
WELCOME 
The publishers of this Aviation Maintenance Technician Certification Series welcome you to the world of 
aviation maintenance. As you move towards EASA certification, you are required to gain suitable knowledge and 
experience in your chosen area. C2!ialification on basic subjects for each aircraft maintenance license category or 
subcategory is accomplished in accordance with the following matrix. Where applicable, subjects are indicated by 
an "X" in the column below the license heading. 
For other educational tools created to prepare candidates for licensure, contact Aircraft Technical Book Company. 
We wish you good luck and success in your studies and in your aviation career. 
REVISION LOG 
VERSION I EFFECTIVE DATE DESCRIPTION OF CHANGE 
--------------
001 2014 03 Original Issue 
--- - -- ----------
~ - 2016 10 i Format Update 
--------
---------------------- -------
----- ---------
iii 
FORWARD 
PART-66 and the Acceptable Means of Compliance (AMC) and Guidance Material (GM) of the European Aviation 
Safety Agency (EASA) Regulation (EC) No. 1321/2014, Appendix 1 to the Implementing Rules establishes the 
Basic Knowledge Requirements for those seeking an aircraft maintenance license. The information in this Module 
of the Aviation Maintenance Technical Certification Series published by the Aircraft Technical Book Company 
meets or exceeds the breadth and depth of knowledge suqject matter referenced in Appendix 1 of the Implementing 
Rules. However, the order of the material presented is at the discretion of the editor in an effort to convey the 
required knowledge in the most sequential and comprehensible manner. Knowledge levels required for Category Al, 
Bl, B2, and B3 aircraft maintenance licenses remain unchanged from those listed in Appendix 1 Basic Knowledge 
Requirements. Tables from Appendix 1 Basic Knowledge Requirements are reproduced at the beginning of each 
module in the series and again at the beginning of each Sub-Module. 
How numbers are written in this book: 
This book uses the International Civil Aviation Organization (ICAO) standard of writing numbers. This method 
displays large numbers by adding a space between each group of 3 digits. This is opposed to the American method which 
uses commas and the European method which uses periods. For example, the number one million is expressed as so: 
ICAO Standard 
European Standard 
American Standard 
SI Units: 
1000000 
1.000.000 
1,000,000 
The International System of Units (SI) developed and maintained by the General Conference of Weights and · 
Measures (CGPM) shall be used as the standard system of units of measurement for all aspects of international civil 
aviation air and ground operations. 
Prefixes: 
The prefixes and symbols listed in the table below shall be used to form names and symbols of the decimal multiples 
and submultiples oflnternational System of Units (SI) units. 
MULTIPLICATION FACTOR PREFIX • SYMBOL I 
1 000 000 000 000 000 000 = 101s exa E 
1 000 000 000 000 000 = 101s peta p 
1 000 000 000 000 = 1012 tera T 
1000 000 000 = 109 giga G 
1000 000 = 106 mega M 
1 000 = 103 kilo k 
100 = 102 hecro h 
10 = 101 deca da 
0.1 =10-1 deci d 
0.01 = 10-2 centi C 
0 .001 = 10-3 milli m 
0.000 001 = 10-6 micro µ 
0.000 000 001 = 10-9 nano 11 
0 .000 000 000 001 = 10-12 pico p 
0.000 000 000 000 001 = 10-15 femto f 
0.000 000 000 000 000 001 = 10-18 atto a 
International System of Units (SI) Prefixes 
EASA LICENSE CATEGORY CHART 
I r ' A1 81.1 81.2 81.3 l 
Module number and title Airplane Airplane Airplane Helicopter 1 
I Turbine Turbine Piston Turbine I 
1 Mathematics X X X X 
2 Physics X X X X 
3 Electrical Fundamentals X X X X 
4 Electronic Fundamentals X X X 
5 Digital Techniques/ Electronic Instrument Systems X X X X 
6 Materials and Hardware X X X X 
7A Maintenance Practices X X X X 
8 Basic Aerodynamics X X X X 
9A Human Factors X X X X 
10 Aviation Legislation X X X X 
11A Turbine Aeroplane Aerodynamics, Structures and Systems X X 
118 Piston Aeroplane Aerodynamics, Structures and Systems X 
12 Helicopter Aerodynamics, Structures and Systems X 
13 Aircraft Aerodynamics, Structures and Systems 
14 Propulsion 
15 Gas Turbine Engine X X X 
16 Piston Engine X 
17A Propeller X X X 
MODULE 06 SYLLABUS AS OUTLINED IN PART-66, APPENDIX 1. 
CERTIFICATION CATEGORY -+ 
Sub-Module 01 -Aircraft Materials - Ferrous 
(a) Characteristics, properties and identification of common alloy steels used in aircraft; 
Heat treatment and application of alloy steels. 
(b) Testing of ferrous materials for hardness, tensile strength, fatigue strength and 
impact resistance. 
Sub-Module 02 -Aircraft Materials - Non-Ferrous 
(a) Characteristics, properties and identification of common non-ferrous materials used in 
aircraft; Heat treatment and application of non-ferrous materials; 
(b) Testing of non-ferrous material for hardness, tensile strength, fatigue strength and 
impact resistance. 
Sub-Module 03 -Aircraft Materials - Composite and Non-Metallic 
6.3.1 - Composite and non-metallic other than wood and fabric 
(a) Characteristics, properties andidentification of common composite and non-metallic 
materials, other than wood, used .in aircraft; Sealant and bonding agents; 
Module 06 - Materials and Hardware 
82 
Avionics 
X 
X 
X 
X 
X 
X 
X 
X 
X 
X 
X 
X 
LEVELS 
B1 B2 
1 
1 
2 1 
1 
2 
V 
CERTIFICATION CATEGO RY -+ 
(b) The detection of defects/deterioration in composite and non-metallic material; 
Repair of composite and non-metallic material. 
6.3.2 - Wooden Structure 
Construction methods of wooden airframe structures; 
Characteristics, properties and types of wood and glue used in aeroplanes; 
Preservation and maintenance of wooden structure; 
Types of defects in wood material and wooden structures; 
The detection of defects in wooden structure; 
Repair of wooden structure. 
6.3.3 - Fabric Covering 
Characteristics, properties and types of fabrics used in aeroplanes; 
Inspections methods for fabric; 
Types of defects in fabric; 
Repair of fabric covering. 
Sub-Module 04- Corrosion 
(a) Chemical fundamentals; 
Formation by, galvanic action process, microbiological, stress; 
(b) Types of corrosion and their identification; 
Causes of corrosion; 
Material types, susceptibility to corrosion. 
Sub-Module 05 - Fasteners 
6.5.1 - Screw Threads 
Screw nomenclature; 
Thread forms, dimensions and tolerances for standard threads used in aircraft; 
Measuring screw threads. 
6.5.2 - Bolts, Studs and Screws 
Bolt types: specification, identification and marking of aircraft bolts, international standards; 
Nuts: selflocking, anchor, standard types; 
Machine screws: aircraft specifications; 
Studs: types and uses, insertion and removal; 
Self tapping screws, dowels. 
6.5.3 - Locking Devices 
Tab and spring washers, locking plates, split pins, pal-nuts, wire locking, quick release 
fasteners, keys, circlips, cotter pins. 
6.5.4 - Aircraft Rivets 
Types of solid and blind rivets: specifications and identification, heat treatment. 
LEVELS 
B1 B2 
2 
2 
2 
1 1 
3 2 
2 2 
2 2 
2 2 
2 1 
vi Module 06 - Materials and Hardware 
CERTIFICATION CATEGORY -+ 
Sub-Module 06 - Pipes and Unions 
(a) Identification of, and types of rigid and flexible pipes and their connectors 
used in aircraft; 
(b) Standard unions for aircraft hydraulic, fuel, oil, pneumatic and air system pipes. 
Sub-Module 07 - Springs 
Types of springs, materials, characteristics and applications. 
Sub-Module 08 - Bearings 
Purpose of bearings, loads, material, construction; 
Types of bearings and their application. 
Sub-:-Module 09 -Transmissions 
Gear types and their application; 
Gear ratios, reduction and multiplication gear systems, driven and driving gears, idler gears, 
mesh patterns; 
Belts and pulleys, chains and sprockets. 
Sub-Module 10 - Control Cables 
Types of cables; 
End fittings, turnbuckles and compensation devices; 
Pulleys and cable system components; 
Bowden cables; 
Aircraft flexible control systems. 
Sub-Module 11 - Electrical Cables and Connectors 
Cable types, construction and characteristics; 
High tension and co-axial cables; 
Crimping; 
Connector types, pins, plugs, sockets, insulators, current and voltage rating, coupling, 
identification codes. 
Module 06 - Materials and Hardware 
LEVELS 
B1 B2 
2 2 
2 1 
2 1 
2 2 
2 2 
2 1 
2 2 
vii 
viii Module 06 - Materials and Hardware 
MATERIALS AND HARDWARE 
Welcome ...... .. ... ... .. .. .... .. ..................... .. ........ .... ... ... ...... . 
Revision Log ..... .. .. ......... ....... .. .. ... ... ...... ................... ..... . 
Forward ....... ...... ......... ..... .... ........ .. .. ..... .. ... .. .................. . 
Contents ...... ... .. ... ............................... .. .......... ...... .. .... .. . 
SUB-MODULE 01 
FERROUS 
iii 
iii 
iv 
ix 
Knowledge Requirements .. .......................................... 1.1 
Aircraft Metals .. .... .. . .. .. .. . .. .. .. .. .. . . .... .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . 1.2 
Properties Of Metals ... ...... ...... ........ .. .. .. .. .... .. .. .. ........... 1.2 
Hardness ... ...... . ... ....... ............. .... .. ........ .. . .... .. ...... .. .. 1.2 
Strength ......... .. .. .. .... .. . .... .. ............. ...... .. ........ . .. . .... .. . 1.2 
Density.. ....................... .... .... .... ...... ......... .. ................ 1.2 
Malleability .. .. .. ....... ... ... ...... .. .......... .... .... .. .. .. .. .... . ... . 1.2 
Ductility.. .......... ....... ................. ........... .. .... .. ...... ... .... 1.2 
Elasticity .. . .. . .... ... . ...... .... .. . ..... .. ... ...... .. ............... ...... 1.2 
Toughness ......................................... .... ....... ........ .. .. 1.2 
Brittleness ............................ .. .. .. ... .. .... .. ...... .. ........... 1.3 
Fusibility ........ ..... .... ...... .... ... ............. ............ .. ......... 1.3 
Conductivity ............................. ................... ... .. ....... 1.3 
Thermal Expansion ............................. .... ........ ...... .. . 1.3 
Ferrous Aircraft Metals ...... .. .......... ...... ........................ 1.3 
Iron.......... ........................... .. ............. ..... ........ .... ....... 1.3 
Steel And Steel Alloys.............. .. ........ .. .. .. .......... ...... 1.3 
Types, Characteristics, And Uses Of Alloyed Steels 1.5 
Electrochemical Test............................ .. ...... .. .. .. ...... 1.6 
Substitution of Aircraft Metals ....................... .. .. .. ....... 1. 7 
Metal working Processes ........ .... ...................... ............ 1. 7 
Hot Working............................................ ..... .. .... .... . 1.7 
Heat Treating................................................... ..... .... 1.9 
Internal Structure Of Metals ..... .... .. .... .. .. ............... 1.9 
Heat Treating Equipment.... .... .. .......................... .... 1.9 
Furnaces and Salt Baths ........ ............................ ...... 1.10 
Temperature Measurement and Control .. ........ .. 1.10 
Heating .. .... ................. .... ......................................... 1.11 
Soaking ....... .... .... ............ .... .. ...... ....... .. .................... 1.12 
Cooling ...... ... ...... ..... .. .............................................. 1.12 
Qyenching Equipment ......... .. .... .... .... .. .............. .. .. . 1.13 
Heat Treatment of Ferrous Metals .. .. .... .. .. ...... ........ 1.13 
Behavior of Steel During Heating and Cooling...... 1.13 
Hardening ................... .. ......................... ...... ......... .. . 1.13 
Hardening Precautions .. ................................ .......... 1.15 
Tempering ........... .. ........... ....... .. :.. .. .. .... .. .. .......... .. .... 1.15 
Annealing ........... .. .. .. .. .... .......... .. .... ......................... 1.16 
Normalizing.. .. ..... ...................... .. ........ .. ................... 1.16 
Case hardening .......... .... .......................................... 1.16 
Module 06 - Materials and Hardware 
CONTENTS 
Carburizing ....... .... ...... .. ........ .... ...... ...... ............... 1.16 
Nitriding.................... .. ........... .. .... .. .... .... ...... .. ..... 1.17 
Forging... ... ... ....... ... ..... ...... ...... ...... .. ................ ...... .... 1.17 
Casting....... .. .............. .. ............ .. .. .. .................. .... ..... 1.17 
Extruding...................................... ..... .... .. .. .. ...... .. ..... 1.18 
Cold Working/Hardening..... ........ ................. .. .. .. .... 1.18 
Hardness Testing ............ .................................. .. .......... 1.19 
Brinell Tester.... .. .............. .. .... .. .... .. ..... .... ................. 1.19 
Rockwell Tester.. ... .. ................................... ....... ....... 1.19 
Other Testing.. ......... ..... .. .. ............................. .. ...... .. ..... 1.21 
Tensile Strength Testing.................. .. ................ .. .... 1.21 
Fatigue Strength Testing............................ .. .. .......... 1.21 
Impact Testing..... ..................................................... 1.22 
Qyestions .. ..... ..... .. .. .... .... ............. ... ........ ..................... . 1.23 
Answers .. . .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . . .. .. .. . .... 1.24 
SUB-MODULE 02 
AIRCRAFT MATERIALS - NON-FERROUS 
Knowledge Requirements .... .. .... .. ........ .. .... .. .... .. .......... 2.1 
Aircraft Metals.... .. ..... .... .. ..... .... ..... ..... .. .. ...................... 2.2 
Properties of Metals...................... .. ..... .. .. .... ........ .... ..... 2.2 
Hardness ...................................... .. ............ ........ .. ... . 2.2 
Strength.... .. ................. .... .............................. .......... . 2.2 
Density...................................... ...... ... .......... .. ...... ..... 2.2 
Malleability ....................................... ............ ........... 2.2 
Ductility.... ...... ....... ..... .. ............ .... .. ....... .. .. ............ ... 2.2 
Elasticity .......... ......................... .. ............... ... . .......... 2.2 
Toughness ........................ . -...................... .. ............... 2.2 
Brittleness ....... .. .... ..... ... .. .... .. .. ...... .... ........ .. ............ . 2.3 
Fusibility ................... .. ............................ ... .............. 2.3 
Thermal Expansion ........................................ .... ...... 2.3 
Non-Ferrous Aircraft Metals.. .. .. .. ...... .... ...... ...... ........ .. 2.3 
Aluminum And Aluminum Alloys.................. ........ 2.3 
Wrought Aluminum ...................... .. ........ .. .... .. ........ 2.4 
Effect of Alloying Element............ .... .................... .. 2.6 
Hardness Identification.......... .... ............................ .. 2.6 
Magnesium And Magnesium Alloys .... .............. .. .. 2.6 
Titanium and Titanium Alloys................ .... ...... ...... 2. 7 
Titanium Designations .... ...... .. ...... .. .... .... .. ............ .. 2.8 
Corrosion Characteristics ........................ .. .... ...... .... 2.8 
Copper and Copper Alloys .......... .. .................. .... .. .. 2.9 
Nickel and Nickel Alloys.............. .... .. ............ .... ...... 2.9 
Monel ........... ... ................................... .. ........ .......... .. . 2.10 
Inconel ................................ .. ....... .. .. .. .... ...... .. ....... .... 2.10 
Substitution of Aircraft Metals ............ .. ...................... 2.10 
Heat Treatment of Non-ferrous Metals........ .......... .. .. .. 2.11 
Aluminum Alloys ...... .............................................. 2.11 
ix 
CONTENTS 
Alclad Aluminum ..... .. .. ...... .......... ........................... 2.11 
Solution Heat Treatment.. ... ... ... ... ... ........ .......... ..... .. 2.12 
Temperature ......... ............................................... 2.12 
Time at Temperature ......................... .......... ... .... 2.12 
Q.yenching ....................... ....... ....... ........................... 2.12 
Cold Water Q.yenching ..................... ...... .... ...... . 2.12 
Hot Water Q.yenching ................. .. .. .. .. .. .......... .. . 2.12 
Spray Q.yenching .. ............ ......... .... ..................... 2.12 
Lag Between Soaking and Q.yenching ....... ....... 2.13 
Reheat Treatment ... .................................... .... ......... 2.13 
Straightening After Solution Heat Treatment ........ 2.13 
Precipitation Heat Treating.................. ........... ... .... .. 2.13 
Precipitation Practices....................... ................... 2.14 
Annealing of Aluminum Alloys.. ...... ...................... 2.14 
Heat Treatment of Aluminum Alloy Rivets............ 2.14 
Heat Treatment of Magnesium Alloys........ ............ 2.15 
Solution Heat Treatment .. ...... ................. .... ... .... 2.15 
Precipitation Heat Treatment......... ... ... ... ........... . 2.16 
Heat Treatment of Titanium.................. ........ .... ...... 2.16 
Stress Relieving...... .. ........... .... ............................. 2.16 
Full Annealing........................... ........ ... .................... 2.16 
Thermal Hardening.. ............................. ............. ...... 2.16 
Case hardening ............................. ........... ....... ......... 2.16 
Hardness Testing.............. ...... ..... ................ .......... ....... 2.16 
Brinell Tester....... ........................ .. .... ....... ...... ....... ... 2.17 
Rockwell Tester.... .................................................... 2.17 
Barcol Tester ... .............. ............. ........ ...................... 2.18 
Casting.................. ...... .. .. ... .. .... ... .......... .................... 2.18 
Extruding... .. ..... .. ................................ .... ...... .. ..... ... .. 2.19 
Q.yestions ............... ....... ........ .. ..... .. ...... ............ ............. 2.21 
Answers ................. ....................................................... 2.22 
SUB-MODULE 03 
AIRCRAFT MATERIALS - COMPOSITE AND 
NON-METALLIC 
Knowledge Requirements .... ... .. ...... ............................. 3.1 
Non-Metallic Aircraft Materials.... ... ........................... 3.2 
X 
Wood........................................................................ 3.2 
Plastics...... ......... .... ...... .... ...... .... ... ... .. ....................... 3.2 
Transparent Plastics.. .... .... ... .. .... ............................... 3.2 
Composite Materials ............................. ............. ...... 3.3 
Advantages/Disadvantages of Composites ........ 3.3 
Composite Safety ................................................ 3.3 
Laminated Structures ............. ........... .................. 3.4 
Reinforced Plastic ................................. ........ ........... 3.4 
Rubber... .... ........... ......... .. ... ....... .. .. .. ......................... 3.5 
Natur;l Rubber. ... ..... ........ ........ .... ..... ............. ..... 3.5 
Synthetic Rubber....... ... ............... ... ... .... ............... 3.5 
Sealing Compounds ...... .. ..... .... .. .......................... ... 3.6 
One-Part Sealants.............. ..... .......... ................. .. 3.6 
Two Part Sealants............................................ .... 3.6 
Advanced Composite Materials .... ... ................... ..... ..... 3.8 
Laminated Structures................... ........ .. .............. ......... 3.8 
Major Components of A Laminate.......................... 3.8 
Strength Characteristics ... ........... ....... ................ ... .. 3.8 
Fiber Orientation ................... .................... .... ..... 3.8 
Warp Clock.......................................................... 3.9 
Fiber Forms..................... .......... .. .... .. ....... ...................... 3.10 
Roving ... .. .......... ..................................................... .. 3.10 
Unidirectional (Tape) .............................................. 3.10 
Bidirectional (Fabric) ........... ........ ...... ................ ....... 3.10 
Nonwoven (Knitted or Stitched).............................. 3.11 
Types Of Fiber. .. ........................................................... 3.12 
Fiberglass...................... .............. ... .... ... ... .... .... ......... 3.12 
Kevlar"'.. .... ........ ....... ................ .......................... .... ... 3.12 
Carbon/Graphite................................. ........... .......... 3.12 
Boron ................... .... .. .............. ................ ................. 3.12 
Ceramic Fibers..................................................... ..... 3.13 
Lightning Protection Fibers ............. ............... ... ..... 3.13 
Matrix Materials..... .......... .... .... .. ...... .... .. ............. ...... ... . 3.13 
Thermosetting Resins ................. ........ ............ ......... 3.13 
Polyester Resins.................................. ..... ..... ....... . 3.13 
Vinyl Ester Resin .... ....... .. ................................... 3.13 
Phenolic Resin .. ... ... ... .......... .............. .... .. .... ....... 3.14 
Epoxy .............. ............ .................... ...... .............. 3.14 
Polybenzimidazoles (PBI) ............................. ..... 3.14 
Bismaleimides (BMI) .. ............. .... ... .................. .. 3.14 
Thermoplastic Resins ....... ....................... .................. 3.14 
Semicrystalline Thermoplastics ... ... .... .. .............. 3.14 
Amorphous Thermoplastics ............. ......... .. ........ 3.15 
Polyether Ether Ketone (PEEK) ............... ......... 3.15 
Curing Stages of Resins.... ... .......... .. ... ............. .. ....... .... 3.15 
Pre-Impregnated Products (Prepregs) .......................... 3.15 
Dry Fiber Material.................................. ... .. ................. 3.16 
Thixotropic Agents........... ....... ... .......... ......................... 3.16 
Adhesives ............................................................. ......... 3.16 
Film Adhesives ... ......... ... ................ .. ... ......... ... ........ 3.16 
Paste Adhesives ..... .... .... ......... ........ ....... ............ ....... 3.16 
Foaming Adhesives...... ....................... ........... .......... 3.17 
Sandwich Structures...................................................... 3.18 
Properties.... ... .......... .. ...................... .. ... .......... .. ........ 3.18 
Facing Materials ................ ...................................... 3.18 
Core Materials......... .. ............ .......... ..... .......... .......... 3.18 
Honeycomb........................................... ..... ......... . 3.18 
Module 06 - Materials and Hardware 
Foam ...................... ..................................... .. ... ... . 3.19 
Balsa Wood............. ... ..... .......... ... ........... ............. 3.20 
Manufacturing Defects ................................... ....... .... .. 3.20 
Fiber Breakage............................. .. .. .. .. ............... ... .. . 3.21 
Matrix Imperfections.................. ... .. ......... ................ 3.21 
Delamination and Debonds .................. .............. .... 3.21 
Combinations of Damages ....................... ...... ..... .... 3.21 
Flawed Fastener Holes.. ...... .. ..... ..... .. ........................ 3.21 
In-Service Defects ................................. .... .......... ......... 3.21 
Corrosion .... .. ... ............. ... .. .......... ..... ... ...... ...... ........ ..... 3.23 
Non-Destructive Inspection (NDI) of Composites ... . 3.23 
Visual Inspection................. .... ........ ........ ....... .. ........ 3.23 
Audible Sonic Testing (Coin Tapping). ................... 3.23 
Automated Tap Test ................. .. ........................... .. 3.24 · 
Ultrasonic Inspection............... .. ........ ..... .. ... ............. 3.24 
Through Transmission Ultrasonic Inspection .... 3.25 
Pulse Echo Ultrasonic Inspection ... ... ....... ... .. ... . 3.25 
Ultrasonic Bond Tester Inspection........... ........... 3.26 
Phased Array Inspection.. ... .. ............................... 3.26 
Radiography................. .... ........................................ . 3.26 
Thermography .... ... .......... .. ..... ..... .... .. .. .. ................... 3.26 
Neutron Radiography ................. ........ ..... ...... ....... ... 3.27 
Moisture Detector... .... .............................. ..... ...... .... 3.27 
Composite Repairs ........ .............. ....... .. .... .. ........ ........... 3.28 
Layup Materials and tools........... ............................. 3.28 
Air Tools .............. ................................................ 3.28 
Caul Plate ........ ...... ........... .... .... .. ... ..... ... .............. 3.28 
Support Tooling and Molds .. .. .......... ............... ... 3.28 
Vacuum Bag Materials............. .. .............................. . 3.28 
Release Agents .... .. .......... .. ... ....... ..... ...... ............. 3.29 
Bleeder Ply .......................................... ..... ...... ..... 3.29 
Peel Ply ... ...... .. ....... .... ...... .. ... ... .......... .................. 3.29 
Layup Tapes ..... .... ... ............. ..... .... ..... ................ . 3.29 
Perforated Release Film ........ ......................... ..... 3.29 
Solid Release Film ...... ................... .. ......... .......... 3.29 
Breather Material ..... ......... ....... ........................... 3.29 
Vacuum Bag ........... ...... ... .................................... 3.29 
Vacuum Equipment........ .. ............ ..... .. .......... .... .... ... 3.30 
Vacuum Compaction Table ............... ................. 3.30 
Heat Sources....... ........................................................... 3.31 
Oven .............................. ... ......................... ......... ....... 3.31 
Autoclave.................. ................... ..... .................. ... ... 3.31 
Heat Bonder and Heat Lamps ............... ... ... ... .... 3.32 
Heat Bonder .......... ..... ...... ...... .... .. ........ ... ............ 3.32 
Heat Blanket......................... ............................... 3.32 
Hot Air System....... .. ... .... ...... .............................. 3.32 
Heat Press Forming....... .. ............ ............. ................ 3.33 
Module 06 - Materials and Hardware 
CONTENTS 
Thermocouples.................. ..... ... .... ............. ............... 3.33 
Thermocouple Placement ......... .... ... ......... ...... ... .. 3.33 
Thermal Survey of Repair Area...... .. ........ .. ....... ....... 3.34 
Temperature Variations in Repair Zone.............. 3.34 
Thermal Survey............................................... .. ... 3.34 
Solutions to Heat Sink Problems ..... ... ... ............. 3.34 
Types of Layups......... ...... ....... ... .... .............. .. ............... 3.34 
Wet Layups ............... ............ ................ .... ... ........... . 3.34 
Prepregs ............ ... ............... ...................................... 3.35 
Co-Curing .......... .... .... ........................................ 3.36 
Co-Bonding ...................... ............ ..... .... ............. 3.37 
Wet Laminated Layup Techniques.............................. 3.37 
Bleedout Technique... ............ .......... .. .. .... ....... ......... . 3.37 
No Bleedout ... ..... ..... ... ............ ..... ... ... .... ... ................ 3.38 
Ply Orientation Warp Clock.................................... 3.38 
Mixing Resins ..................... .... ........ ....... ..... ... ...... ... ... .. 3.39 
Saturation Techniques .. ............. ... ...... ... .......... .... ......... 3.39 
Fabric Impregnation With a Brush or Squeegee..... . 3.39 
Fabric Impregnation Using a Vacuum Bag........... ... 3.39 
Vacuum Bagging Techniques ............................ ............ 3.40 
Envelope Bagging ................................... ...... ...... ..... 3.41 
Alternate Pressure Application .................................... 3.41 
Shrink Tape... .. .. ..... ....... ...... ... .. .... ..... ... .................... 3.41 
C-Clamps............... ............. .... .... ........... ... ...... ... .. .. .. . 3.41 
Shotbags and Weights. ...................................... .. ..... 3.41 
Curing of Composite Materials.. ... ..... ... ...... .. .......... ..... 3.41 
Room Temperature Curing............ ..... .... ....... ........ .. 3.41 
Elevated Temperature Curing.............. ................... . 3.42 
Composite Honeycomb Sandwich Repairs ... ............... 3.42 
Damage Classification........................................ ... .. . 3 .42 
Minor Core Damage (Filler and Potting Repairs).. 3.42 
Damage Requiring Core Replacement and Repair 
to One or Both Face Plates ...................................... 3.43 
Solid Laminates ................................................. ...... ..... 3.48 
Bonded Flush Patch Repairs.......................... .... ...... 3.48 
Trailing Edge and Transition Area Patch Repairs 3.50 
Resin Injection Repairs ....... .. ... .. ..... .... ....... .. ............ 3.50 
Composite Patch Bonded to Aluminum Structure 3.50 
Fiberglass Molded Mat Repairs .......... .......... ..... .. ... 3.51 
Radome Repairs....... .... ...... ........... ........... ... .............. 3.51 
External Bonded Patch Repairs ... ............ ... ............ 3.51 
External Bonded Repair With Prepreg Plies .......... 3.52 
External Repair Using Wet Layup And Double 
Vacuum DebulkMethod (DVD) .......... ... ... .. ....... .. . 3.52 
Double Vacuum Debulk Principle ...................... 3.52 
Patch Installation on the Aircraft........................ 3.53 
External Repair Using Precured Laminate Patches 3.53 
xi 
CONTENTS 
Bonded versus Bolted Repairs ............ .. ... ..... ... .. ........... 3.54 
Bolted Repairs .. ............... .... ........ ....................... ...... 3.55 
Fasteners Used with Composite Laminates. .. .... .... .. .... . 3.57 
Corrosion Precautions ........ .. ..... ...... ... .. ..... .. ... ... ....... 3.57 
Fastener Materials ....... ... .... ... .. ...... .................... ....... 3.57 
Fastener System For Sandwich Honeycomb 
Structures...... ... .... ................. .. .................................. 3.57 
Adjustable Sustain Preload Fastening System 
(ASP) ..... .. ............. ..... ... ......... .... ... .... ... .... ...... .... ... 3.57 
Hi-Lok0 and Huck-Spin° Lockbolt Fasteners.... ...... 3.57 
Eddie-Bolt° Fasteners .......... ....... ........................ ..... 3.58 
Cherry's E-Z Buck0 (CSR90433) Hollow Rivet.. .... 3.58 
Blind Fasteners..... ..... ..... ..................... .... .... .............. 3.59 
Blind Bolts ... ...... .. ........ .. ........... ...................... ...... ... . 3.59 
Fiberlite ............ ....... ........ .. .... .... ...... ....... ... .. .. ...... ..... 3.60 
Screws and Nutplates in Composite Structures ...... 3.60 
Machining Processes and Equipment ...... .. ... .. .. ........... 3.62 
Drilling ............................ .. ...... .. ..... ......... ... ... .......... 3.62 
Equipment....... .......... .. ... ..... .. ....... ..... ....................... 3.62 
Processes and Precautions.................. .... ......... ..... .... 3.62 
Countersinking ..... ........ ... ..... .. .. ......... ...................... 3.63 
Cutting Processes and Precautions .......................... 3.64 
Cutting Equipment............................ .... ..... ....... ...... 3.64 
Repair Safety ........... ...... .... ...... ...... .. .... ................ ...... ... 3.65 
Eye Protection ..... ... .. .......... ....... ...... ......................... 3.65 
Respiratory Protection...... .. .......... .... .. .... ....... .. .. .. ..... 3.65 
Downdraft Tables .... .... ... .......... ...... ..................... ... . 3.65 
Skin Protection .................................................. ... ... 3.65 
Fire Protection............... .. ... ..... ....... ....... ..... .............. 3.65 
Transparent Plastics ... ....... ..... .. ............... ........... .... .. ..... 3.66 
xii 
Optical Considerations .... .......... ... ... ... .... ...... .... ... .... 3.66 
Storage and Handling ....... ......... .............................. 3.66 
Forming Procedures and Techniques .......... .......... .. 3.66 
Heating .................. ........... .. .......... .......... ........... .. 3.66 
Forms................................................................. ... 3.67 
Forming Methods. ... ......... ..... ..... ...... ... .... ................ 3.67 
Simple Curve Forming..... ... .. .............................. 3.67 
Compound Curve Forming ........... ...... ... .. ... ... .... 3.67 
Stretch Forming .... ..... ... ........... .............. ............. 3.67 
Male and Female Die Forming ....... ................... 3.67 
Vacuum Forming Without Forms ..... ................. 3.67 
Vacuum Forming With a Female Form .. ............ 3.67 
Sawing and Drilling ... .... ...... ..... ........ .. .......... .......... 3.68 
Sawing............................................ ..... .... ... ..... .. ... 3.68 
Drilling ...... .... ... ...... .... ........ ...... .. ......................... 3.68 
Cementing...................... .................. ..... ........ .. ... .. 3.68 
Application of Cement .................. ...................... 3.68 
Repairs ........... ........ . ,........... ............. .... ... ... .... ........ ... 3.69 
Cleaning ..... ........ .. :· ······ ··· ········· ··· ···· ······ ··· ·· ··· ····· ······· 3.69 
Polishing ..... .......... ...... ............... ........ .. ... .... ...... ....... 3.70 
Windshield Installation............... .. ........................ ... 3. 70 
Installation Procedures.... ... ................... .............. 3.70 
Aircraft Wood and Structural Repair.......................... 3.71 
Wood Aircraft Construction and Repairs......... ... ..... ... 3. 71 
Inspection of Wood Structures ........................ .......... .. 3.72 
External and Internal Inspection ..... .. .......... ..... ...... 3.72 
Glued Joint Inspection..................................... ..... .... 3.73 
Wood Condition...................................................... 3.74 
Repair of Wood Aircraft Structures ... .... ........... .. .. ... ... 3.76 
Suitable Wood.......... ................. ... .......... ....... ...... ..... 3.77 
Defects Permitted ..................... .......... .......... ... ........ 3.77 
Defects Not Permitted..... .. ............ ..... ...................... 3.78 
Glues (Adhesives) ....... .. ........ ................................ ... 3.79 
Definition of Terms Used in the Glue Process........ 3.80 
Preparation of Wood for Gluing.. ....... ...... ............... 3.80 
Preparing Glues for Use ................. ........ .... ...... .... ... 3.81 
Applying the Glue/Adhesive ... ....... ....... _......... ... ....... 3.81 
Pressure on the Joint.......................................... ...... 3.81 
Testing Glued Joints .... .. ........... .......... ..................... 3.82 
Repair of Wood Aircraft Components .. ...... .......... ... ... 3.83 
Wing Rib Repairs ................................. .... ....... .. ...... 3.83 
Wing Spar Repairs ............ ... .......... ........... ..... ......... _ 3.86 
Bolt and Bushing Holes ... .. .. .............. .. ............... .......... 3.89 
Plywood Skin Repairs .............. ..... ...... .............. .. ........ . 3.89 
Fabric patch........................................................ ...... 3.89 
Splayed Patch......... ..... ......... .. ......................... ..... ..... 3.90 
Surface Patch ............... ,............. ....... ....... .... ........... .. 3.90 
Plug Patch ................. .. .......... ..... ...... ... ... ..... .. .. ......... 3.92 
Scarf Patch........ ........... ...... .. .... .................. ........ ....... 3.92 
The Back Of The Skin Is Accessible For Repair...... 3.94 
The Back Of The Skin Is Not Accessible For Repair 3.94 
Finishing Wood Structures ... ................ .. ......... ..... .... ... 3.96 
Acceptable Finishes................. .................... .... ......... 3.97 
Precautions.............................................. ............... ... 3.97 
Finishing Ofinterior Surfaces ...... ....... ...... ... ....... ... 3.97 
Finishing Of Exterior Surfaces............ ...... ........ .... .. 3.97 
Finishing Of End Grain Surfaces.... ......... .............. . 3.98 
Finishing With Fabric Or Tape .............................. 3.98 
Sealing Of Bolt Holes. .......... ...................... ..... ........ 3.98 
Aircraft Fabric Coverings................ ....... ... ............... ... .. 3.98 
Applicability Notice..... ....... ... ..... ... ... ... ...... ............... 3.98 
General History........ ......................... ......... .............. 3.98 
Legal Aspects of Fabric Covering ........... ....... ......... ..... 3.100 
Fabric Terms ... ...... .. ....... ............................ ...... ....... .. ... .. 3.101 
Module 06 - Materials and Hardware 
Approved Materials ...................................................... 3.101 
Fabric ........................... ........................................ ... .. 3.101 
Other Fabric Covering Materials ............................ 3.102 
Anti-Chafe Tape ................ ... ... .... ...... .................. 3.102 
ReinforcingTape .......................................... ... ..... 3.102 
Rib Bracing .......................................................... 3.102 
Surface Tape ........................................................ 3.102 
Rib Lacing Cord ...................................... ..... ....... 3.102 
Sewing Thread .................................................... 3.103 
Special Fabric Fasteners ...................................... 3.103 
Grommets ....................................................... ..... 3.103 
Inspection Rings .................................................. 3.104 
Primer .................................................................. 3.104 
Fabric Cement ................. ...... ........ ...... ..... ........... . 3.105 
Fabric Sealer ................................................. ....... 3.105 
Fillers .................................................................... 3.105 
Topcoats .............................................................. 3.106 
Available Covering Processes ........................................ 3.106 
Determining Fabric Condition-Repair Or Recover? 3.107 
Fabric Strength .............................................................. 3.107 
How Fabric Breaking Strength is Determined ........ 3.108 
Fabric Testing Devices .............................................. 3.109 
General Fabric Covering Process ........................ .......... 3.110 
Blanket Method Versus Envelope Method ...... ....... . 3.110 
Preparation for Fabric Covering Work .................... 3.111 
Removal of Old Fabric Coverings ...................... 3.112 
Preparation of the Airframe Before Covering .... 3.113 
Attaching Polyester Fabric to the Airframe .... ........ 3.113 
Seams .................................................. ....... ......... 3.114 
Fabric Cement ...................................................... 3.114 
Fabric Heat Shrinking ................... .... ....................... 3.115 
Attaching Fabric to the Wing Ribs .......................... 3.116 
Rib Lacing ............................................................ 3.117 
Rings, Grommets, and Gussets ................................ 3.119 
Finishing Tapes ..................... ................................... 3.120 
Coating the Fabric .................................................... 3.121 
Polyester Fabric Repairs .................................... ... ......... 3.122 
Applicable Instructions ............................................ 3.122 
Repair Considerations ........... .................................. . 3.122 
Cotton-Covered Aircraft ........................................... ... 3.123 
Fiberglass Coverings ............................... ..................... 3.123 
Qpestions ......... ............. ....... .... ..... ................... ............. 3.126 
Answers ...... ...... .. ...................... ... ......... ..... ......... .......... 3.127 
Module 06 - Materials and Hardware 
CONTENTS 
SUB-MODULE 04 
CORROSION 
Knowledge Requirements ............................................ 4.1 
Introduction To Corrosion............................................ 4.2 
Corrosion .... ......................... ... ............ .......................... 4.2 
Common Corrosion Agents ............................... .. ... 4.3 
Micro Organisms............. ......................................... 4.4 
Corrosion Types .. ............ ............... ............................... 4.4 
General Surface Corrosion ......... ............................. 4.4 
Pitting Corrosion...................................................... 4.5 
Concentration Cell Corrosion ........ .......................... 4.5 
Active-Passive Cells............................. ... .................. 4.6 
Filiform Corrosion....................................... ............. 4.6 
Intergranular Corrosion............................................ 4.7 
Exfoliation Corrosion ............... ............................... 4.7 
Galvanic Corrosion................................. ... .............. 4.7 
Stress Corrosion Cracking........................................ 4.7 
Fatigue Corrosion ............... ... .................................. 4.8 
Fretting Corrosion....................... ............................. 4.8 
Material Types And Corrosion .................................... 4.9 
Aluminum And Aluminum Alloys.......................... 4.9 
Magnesium And Magnesium Alloys ...................... 4.9 
Ferrous Metals............................................... ....... .... 4.9 
Noble Metals .. ............. ..... .. ... ... .... ............................ 4.10 
Chromium And Nickel-Plated Parts ...................... 4.10 
Cadmium And Zinc-Plated Parts............................ 4.10 
Water And Corrosion......................... ............ ............... 4.10 
Corrosion Prone Areas............. .... .............. .. ................. 4.10 
Battery Compartments And Battery Vent Openings 4.11 
Lavatories, Buffets, And Galleys..................... .... ..... 4.11 
Bilge Areas....................................... ... ...................... 4.11 
External Skin Areas.................................................. 4.13 
Water Entrapment Areas.......................................... 4.15 
Engine Frontal Areas And Cooling Air Vents........ 4.15 
Electronic Package Compartments.......................... 4.16 
Miscellaneous Trouble Areas .................................. 4.17 
Factors In Corrosion Control........................................ 4.19 
Preventative Maintenance........... ............................. 4.21 
Qpestions ...................................................................... 4.23 
Answers ................... ...... ..... .............................. ............ 4.24 
SUB-MODULE 05 
FASTENERS 
Knowledge Requirements ............................................ 5.1 
Fasteners........................................................................ 5.2 
Screw Threads .......................................................... 5.2 
Identification............................................. ........... 5.3 
xiii 
xiv 
CONTENTS 
Threaded Fasteners .... ... ...................... .. .. ...... ..... .. 5.3 
Bolts, Studs And Screws... .... .. .. .. ... ..... ..... .... ............ 5.3 
Classification of Threads.... ..... ............. ...... ..... ... .. 5.3 
Aircraft Bolts ..... ..... .... ..... ............. .... ... .. ... ... ....... 5.4 
Identification and Coding........ .... .. ... ... ... ....... 5.4 
General Purpose Bolts........ ....... .. ....... ... .. ... ... . 5.4 
Close Tolerance Bolts... .... ......... ...... ............... . 5.5 
Internal Wrenching Bolts .. ............... ............ . 5.5 
Special-Purpose Bolts ....... ..... ......... .... .... .......... ... 5.6 
Clevis Bolts....... .... .. ....... ....... ... ...... ... .. ........ ..... 5.6 
Eyebolt ........ ....... .... ..... ............... ... ....... ........... 5.6 
Jo-Bolt .... .... ... .... .... .... .... ............ ... .... ..... ... ...... 5.6 
Lockbolts ............... ......... .......... ..... .. ... .. ... .... .. . 5.6 
Aircraft Nuts..................... ... ....... ... ...................... 5.8 
Identification and Coding ........ .... .. ... ...... ...... . 5.8 
Non-Self-Locking Nuts. ... ....... ...... .. ..... .. ... ..... 5.9 
Self-Locking Nuts ......... .................... ............. 5.10 
Boots Self-Locking Nut...... ....... .... ....... ..... ..... 5.10 
Stainless Steel Self-Locking Nuts ...... ...... ..... . 5.11 
Elastic Stop Nuts ....... ... ........ ................. ......... 5.11 
Anchor Nuts ... ... ... ... ... ... ............ ... ........... ...... .. 5.12 
Pal Nuts .... .. ......... .............. ....... ..... .... ... ... ....... 5.12 
Sheet Spring Nuts ............ ..................... .. ... .... 5.12 
Internal and External Wrenching Nuts... ...... . 5.13 
Screws .......... ....... ... ....... ... ....... .. ... ... ... ...... ... .. ....... 5.13 
Identification and Coding for Screws ... ... ..... . 5.13 
Structural Screws... ..... ... .. ..... ....... .......... ......... 5.14 
Machine Screws.... .. .. .. ...... .. ............ ................ 5.14 
Self-Tapping Screws.................. ... ... ... .... .. .... ... 5.14 
Drive Screws ... ..... ... .. ... ..... ... .......................... 5.14 
Studs....... ............... ........... .... ... .... ........................ 5.15 
Standard Studs ...... ... .. ... ..... ..... ..... ....... ... .. ... .... 5.15 
Waisted Studs.......... ................................... .... . 5.15 
Stepped Studs.... ........... ......... .... .... ..... ....... .. ... . 5.15 
Shouldered Studs .... ... ..... .. .... .... ....... ............... 5.16 
Dowels... .. ..... .. ..... ...... ........ ........ ..... ... ... ... ..... .... .... 5.16 
Locking Devices ... ... ...... ... .. ...... ....... ........ ....... ... ...... 5.16 
Aircraft Washers.............. ... .................... ............. 5.16 
Plain Washers. ... .......... ... ..... ... ........ ................. 5.16 
Lockwashers....... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 .17 
ShakeproofLockwashers ....... ... ...... ..... ..... ... .. . 5.17 
Special W ashers ............ .......... .......... ........ ..... . 5.17 
Nutplates ........ ... ... .......... .......... ... ...... ...... ...... ....... 5.17 
Sealing Nutplates .......... .... ...... .................. ...... 5.18 
Riveted and Rivetless Nutplates ... .... ............. 5.18 
Rivnuts ................ ... .... .... ... ..... .......... ......... ...... 5.18 
Lock Plates ....... ... ... .. .... .... .. ... ......... ........... ........ .. 5.20 
Pins ..... ........ .. :. ................... ..... ........... .................. 5.20 
Cotter Pins........ ... ..... .. .. .... .... ..... ..... .. ...... .. ..... . 5.20 
Cotter Pin Safetying .... ..... ........ ... ... ..... ..... .... . 5.20 
Roll Pins................... ........ .. ....... ........... .. ......... 5.20 
General Safety Wiring Rules..... .. ..... ...... ....... . 5 .21 
Oil Caps, Drain Cocks, and Valves...... ..... ..... 5.22 
Electrical Connectors...... ................ ...... ...... .. .. 5.22 
Turnbuckles ....... ..... ... .. ..... ..... .... .... ........ .... .... . 5.22 
Captive Fasteners ..... ................. ................. ..... .... 5.23 
Turnlock Fasteners................................ ... ....... 5.23 
Dzus Fasteners .. ...... ... .. ...... .. ......... .... .. .......... .. 5.25 
Airloc Fasteners .................................... ...... ... . 5.26 
Keys ....... .... ........ .... .... ...................................... ..... 5.27 
Snap rings ... ... ... .................. .... ...... ..... .. .... ........... . 5.27 
Aircraft Rivets... .. ...... ........ ...... ................................. 5.27 
Identification .............................................. ... .. .... . 5.27 
Standards and Specifications .... .... .. .... ...... ...... .... 5.30 
Solid Shank Rivets ............................. ........ ... ... ... 5.30 
Blind Rivets.......................................... ........ .. ... .. . 5.32 
Mechanically Expanded Rivets ....... ............... 5.32 
Self-Plugging Rivets (friction lock)... ... ... .. ... .. 5. 32 
Pull-Thru Rivets........... ......... .... ... ... ... ..... .. ...... 5.33 
Self-Plugging Rivets (Mechanical Lock) ...... 5.34 
Wiredraw Cherrylock Rivets.... ...... ........ .... .... 5.35 
Huck Mechanical Locked Rivets ......... ... ... ... 5.35 
Material .... ... .. .......... .. .... ..... ...... ................... ... 5.35 
Head Styles.... ........ ............. ....... .. .... ..... .... ... .... 5.36 
Diameters.. ......... ... ... ... ... .. ... ... .. .... .... ... .. ...... .... 5.36 
Grip Length...... ................... ........... ............. .. . 5.36 
Rivet Identification ... ............ .... .. .. ...... .......... . 5.36 
Special Shear And Bearing Load Fasteners........ 5.38 
Pin Rivets ...... ... ...... ...... .. ....... ....... .... ... ..... ... ........ 5.38 
Taper-Lok ...... ........... ...... ................................ ..... 5.38 
Hi-Tigue ..... .. .. ..................... ........................ ... .... .. ... 5.38 
Dill Lok-Skrus and Dill Lok-Rivets .. ............. ... 5.40 
Deutsch Rivets .................. ........... ..... .. ..... .... .. .... . 5.40 
Installation of Nuts, Washers, and Bolts .. ........... ..... , 5.41 
Bolt and Hole Sizes.......... ..... .. .... ........ ...... ... ........ 5.41 
Installation Practices....... .. .... .. ... .... ... ... ... .. ........... 5.41 
Safetying of Bolts and Nuts .... ... ....... ... .. .. ........... 5.41 
Repair of Damaged Internal Threads...... ..... .. .. ... 5.41 
Helicoils ..... ...... ....... ... ................ ... ... ....... ..... ... 5.42 
Fastener Torque ............................................ ..... .. .. ... 5.42 
Torque and Torque Wrenches. ........ ...... ..... .... ...... 5.42 
Cotter Pin Hole Line Up ......... ... .. ... ... ....... . .... .... 5.44 
Hole Repair and Hole Repair Hardware ...... .. ........ 5.44 
Acres Fastener Sleeves ...... ....... ..... .... ... .... ........ ... 5.44 
Module 06 - Materials and Hardware 
Advantages and Limitations ........... .... ........... 5.46 
Identification ......... ........ .. .......... .. ...... .. ....... ... . 5.46 
Installation ......... .... .......... .. .... ......................... 5.46 
Sleeve Removal...... .... .... ... ....... ............. ........... 5.46 
O!,testions ···································································:·· 5.49 
Answers .. ................ ... ..................... ......... .. ................... 5.50 
SUB-MODULE 06 
PIPES AND UNIONS 
Knowledge Requirements ............................................ 6.1 
Pipes And Unions...... ..... ..... .. ... ....... ............... ... ............ 6.2 
Rigid Fluid Lines.......................................................... 6.2 
Tubing Materials....................... .. ..... .. ...................... 6.2 
Copper Tubing .................................................... 6.2 
Aluminum Alloy Tubing .................................... 6.2 
Steel Tubing ........................................................ 6.2 
Titanium Tubing 3AL-2.5V..... ....... .. ............. .... . 6.2 
Material Identification.................................... .......... 6.2 
Fluid Line End Fittings ......................... ........ .. ....... 6.2 
Universal Bulkhead Fittings ...... ..... .. ................... 6.3 
AN Flared Fittings............................... .. ... ......... . 6.3 
Flareless Fittings......................................... ... .. .. .. 6.4 
Swaged Fittings .......... ..... .. ........... ...... ... .......... ... 6.7 
Cryofit™ Fittings ................................................ 6. 7 
Flexible Hose Fluid Lines ............................................ 6.8 
HoseMaterials And Construction........................ .. 6.8 
Teflon™............................................... ............. .... 6.9 
Low, Medium, And High Pressure Hoses.......... 6.9 
Hose Identification ... .... ......... ..... ..... ............ ........ ... . 6.9 
Hose Fittings .......................... .................................. 6.10 
Fluid Line Identification ...... ... ..................................... 6.10 
O!,testions ....... .. .......... ..... ....... .... ... .................... ........... . 6.13 
Answers ...... ......................... .......... .. ... ... ................. ...... 6.14 
SUB-MODULE 07 
SPRINGS 
Knowledge Requirements ............................................ 7.1 
Types Of Springs And Applications .... ..... ................... 7.2 
Flat Springs .. . .. ... ..... .. ......... .. .. .. .... ... . ...... .. ... .. ... .. ...... 7.2 
Leaf Springs................................................... .. ..... .... 7.2 
Spiral Springs...... ......... ........ ............ ............. ..... ....... 7.2 
Helical Compression And Tension Springs ............ 7.2 
Helical Torsion Springs..... ...... ....... .. ....................... . 7.2 
Belleville (Cone Disc) Springs ................ .... ..... ..... .. 7.3 
Torsion Bar Springs...... ...... ... ... ... .... ........... .............. 7.3 
Spring Dimensions .. ..... ...... ... ......... ... ... .. ...... .. .. .... ... 7.4 
Spring Characteristics .. .... ... .. .. ....... .... ................... _. .. 7.4 
Module 06 - Materials and Hardware 
CONTENTS 
O!,iestions ..... ........... . .... .. ... ... .... .. .... ....... ............. ........ ... 7. 7 
Answers ........................................................................ 7.8 
SUB-MODULE 08 
BEARINGS 
Knowledge Requirements ............................................ 8.1 
Bearings ........................................................................ 8.2 
Plain Bearings ...... ......... .. ....... .... ..... ... .. ... .... ...... ..... .. 8.2 
Ball Bearings ............................................................ 8.3 
Roller Bearings ........................................................ 8.3 
O!,testions . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 8 .5 
Answers ........................................................ .. ...... ........ 8.6 
SUB-MODULE 09 
TRANSMISSIONS 
Knowledge Requirements ............................................ 9.1 
Transmissions ................................................................ 9.2 
The Gear .................................................................. 9.2 
Propeller Reduction Gearing ...... ..... ........ .. ......... 9.4 
Gear Terms... .... .... .... ... ... ................................ ..... 9.4 
Backlash (or lash) ............................................ 9.4 
Idler Gear......... ......................... ....... ...... ......... 9.4 
Intermediate Gear .......................................... 9.4 
Compound Gear ............ .. .................. ........ .... 9.4 
Pinion......... .. ........... ....................... ................ . 9.4 
Lay-shaft ....... .. ........ ....................... ............ ... . 9.5 
Rack and Pinion...... ............ ... .......... ... ........ ... . 9.5 
Step-Up Drive ................................... ........ ..... 9.5 
Step-Down Drive. .. ...... .... ............................... 9.5 
Gear Lash and Pattern............ ..................... .. ..... 9.6 
Chains and Sprockets .............................................. 9.8 
Belts and Pulleys ........... .. ... ......... .. ... .. .... ........ ... .. ..... 9.8 
O!,testions ...................................................................... 9.11 
Answers ..................................... ...... ............................. 9.12 
SUB-MODULE 10 
CONTROL CABLES 
Knowledge Requirements ............. ... ............................ 10.1 
Control Cables and Terminals ........ ......... .... ................. 10.2 
Cable Construction .................. ...... ............... ........... 10.2 
Cable Fittings ....... .... ...... ......................................... 10.2 
Cable System Installation........ ......... ..... ..... ................... 10.3 
Cable Guides ................................................. ...... ..... 10.3 
Travel Adjustment................. .... .... ........ ........ ......... .. 10.4 
Cable Tension ................................................ .......... 10.4 
Tension Regulators ....... ... ....... ........ .. ... .................... 10.5 
Turnbuckles .............................................................. 10.5 
xv 
CONTENTS 
Cable Connectors ... .................................... ....... ..... . 10.5 
Spring-Back......... ..... ..................................... ........... 10.5 
Push Rods (Control Rods)........................ ................... . 10.6 
Torque Tubes ...... .. ................................. .............. ..... 10.7 
Cable Drums.. ...... .... ...... ............ .................... ... .. ..... 10.7 
Bowden Cable ....................................................... .. . 10.7 
O!,iestions ................................................. ... ..... ... ... ...... . 10.9 
Answers .. ...... ........ ..... .. .... .. ........ ....... ... ... ...................... 10.10 
SUB-MODULE 11 
ELECTRICAL CABLES AND CONNECTORS 
Knowledge Requirements ....................... .. ........ ........ .. . 11.1 
Wire Types ............. ... ........ ................. ..... ... ................... 11.2 
Conductors ................ .. .. ......... .......... ... .................. .... 11.2 
Insulation .............................. ... ... ..... ...... ..... .................. 11.3 
Wire Shielding........ ................................. .... ... ... ....... ... . 11.4 
Wire Substitutions ..... ....... ....................... ... .................. 11.4 
Severe Wind and Moisture................... ......... ......... . 11.4 
Problem (SWAMP).................................. ... ........ .... . 11.4 
Wire Size Selection ... ... ... ..... .................................... 11.4 
Current Carrying Capacity...................... ... ............. 11.6 
Maximum Operating Temperature........... .. ...... ....... 11.6 
Computing Current Carrying Capacity.................. 11.9 
Allowable Voltage Drop ........... ............ .. .... ... ... .... .. .. ..... 11.11 
Electric Wire Chart Instructions ...... ..................... . 11.12 
Wire Identification ...................... .......... .. ......... ........ ..... 11.13 
Placement ofidentification Markings ............ ..... ..... 11.13 
Types of Wire Markings ..... ..... .......... ...... ..... ........... 11.13 
Wire Installation and Routing ................. ..................... 11.14 
Open Wiring ......... .... .... .. ... ..... ..... ... ...... ................... 11.14 
Wire Groups and Bundles and Routing .................. 11.14 
Slack in Wire Bundles ..... ...... ............. ......... .... .... ..... 11.15 
Twisting Wires .................. .... ...................... ...... .... .. 11.16 
Spliced Connections ........ ............. .... ..... ..... ..... ........ 11.16 
In Wire Bundles ....... ... .. ........ .... ... .... ....... ................ 11.16 
Bend Radii ..... ... ....... ..... ..................... ....................... 11.16 
Protection Against Chafing ... ................ ...... ....... ...... 11.17 
Protection Against High Temperature ................. .. . 11.17 
Protection Against Solvents and Fluids ...... ........... . 11.17 
Protection of Wires in Wheel Well Areas .............. 11.18 
Clamp Installation ...... ....................................... ....... 11.18 
Wire and Cable Clamp Inspection ........... .... ... .... 11.19 
Movable Controls Wiring Precautions ...... .......... 11.20Conduit ....... .. ................................... ........................ ... ... 11.21 
Rigid Conduit ...................... ......... .. ........... .... ....... ... 11.21 
Flexible Conduit ........ ... ......... .... ....... ....................... 11.21 
Wire Shielding ............ .. .... ..... .... ...... ... .... ... .. ......... .... 11.21 
xvi 
Bonding and Grounding ............................... ... ... ..... 11.22 
Grounding .... ..... .................................... .......... ......... 11.22 
Bonding ........ ........................... ..... ............. ............... 11.23 
Testing of Bonds and Grounds .... ........ .......... .......... 11.24 
Bonding Jumper Installation .. ........... .... .. .. ... .......... .. 11.24 
Lacing and Tying Wire Bundles ............. ... ...... .... .... 11.24 
Tying ...... ....... ....................................................... .... 11.26 
Wire Termination ........ ... ......... ... ............ ... ... ... .... ..... ..... 11.27 
Stripping Wire .. .... ..... ...... ................................. .... .... 11.27 
Terminal Strips ......... ..................................................... 11.28 
Terminal Lugs ...... ..... ............ .. ...... ....... ........ .. .......... 11.28 
Copper Wire Terminals .......... ......................... .. .... ... 11.29 
Aluminum Wire Terminals ............................... ...... . 11.29 
Pre-Insulated Splices ............................. ................... 11.29 
Crimping Tools ........................................... ............. 11.29 
Emergency Splicing Repairs ............................. .. ... .. 11.29 
Junction Boxes ....... .... ..... ..... .... ........ .............. ...... ......... 11.30 
AN/MS Connectors ................ ..... ............................ ..... 11.30 
Types of Connector ........... .... .......... ....... ..... ...... ....... 11.31 
Voltage and Current Rating ... ............. .......... ... ...... . 11.31 
Spare Contacts for Future Wiring ..... ........ ............. 11.31 
Wire Installation Into the Connector .. ... .... ... .......... 11.32 
Adjacent Locations ......... .. .................... ................... 11.33 
Sealing .................. ... ........ .. ... ............ .......... .... .......... 11.33 
Drainage .................. ....... ............ ....... ..... ................ ... 11.33 
. Wire Support .... .... ............................................... ..... 11.33 
Coaxial Cable ....... .... ........ ... ................ ......... ............. 11.33 
Wire Inspection ..... .............. ..................... ................. ... 11.34 
O!,iestions ............ ....................................... .. .... ............. 11.35 
Answers ....................... ............ ...... ....... ........................ 11.36 
Acronym Index............... .......... ..... ... .. ... ....... ..... .. ........ .. A.l 
Index ........... .. ......... .. .. .... . ,.. .............. ... .... ................ .... ... I.1 
Module 06 - Materials and Hardware 
Sub-Module 01 
FERROUS 
Knowledge Requirements 
6.1 -Ferrous 
SUB-MODULE 
PART-66 SYLLABUS LEVELS 
CERTIFICATION CATEGORY - B1 B2 
2 1 
(a) Characteristics, properties and identification of common alloy steels used in aircraft; 
Heat treatment and application of alloy steels. 
(6) Testing of ferrous materials for hardness, tensile strength, fatigue strength and impact resistance. 1 1 
Level 1 
A familiarization with the principal elements of the subject. 
Objectives: 
(a) The applicant should be familiar with the basic elements of the 
subject. 
(b) The applicant should be able to give a simple description of the 
whole subject, using common words and examples. 
(c) The applicant should be able to use typical terms. 
Module 06 - Materials and Hardware 
Level2 
A general knowledge of the theoretical and practical aspects of the subject 
and an ability to apply that knowledge. 
Objectives: 
(a) The applicant should be able to understand the theoretical 
fundamentals of the subject. 
(b) The applicant should be able to give a general description of the 
subject using, as appropriate, typical examples. 
(c) The applicant should be able to use mathematical formula in 
conjunction with physical laws describing the subject. 
(d) The applicant should be able to read and understand sketches, 
drawings and schematics describing the subject. 
(e) The applicant should be able to apply his knowledge in a practical 
manner using detailed procedures. 
1.1 
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AIRCRAFT METALS 
Knowledge and understanding of the uses, strengths, 
limitations, and other characteristics of structural metals 
is vital to properly construct and maintain any equipment, 
especially airframes. In aircraft maintenance and repair, 
even a slight deviation from design specification, or 
the substitution of inferior materials, may result in the 
PROPERTIES OF METALS 
Of primary concern in aircraft maintenance are such 
general properties of metals and their alloys as hardness, 
malleability, ductility, elasticity, toughness, density, 
brittleness, fusibility, conductivity contraction and 
expansion, and so forth. These terms are explained to 
establish a basis for further discussion of structural metals. 
HARDNESS 
Hardness refers to the ability of a material to resist 
abrasion, penetration, cutting action, or permanent 
distortion. Hardness may be increased by cold working 
the metal and, in the case of steel and certain aluminum 
alloys, by heat treatment. Structural parts are often 
formed from metals in their soft state and are then heat 
treated to harden them so that the finished shape will be 
retained. Hardness and strength are closely associated 
properties of metals. 
STRENGTH 
One of the most important properties of a material is 
strength. Strength is the ability of a material to resist 
deformation. Strength is also the ability of a material to 
resist stress without breaking. The type of load or stress 
on the material affects the strength it exhibits. 
DENSITY 
Density is the weight of a unit volume of a material. 
In aircraft work, the specified weight of a material 
per cubic inch is preferred since this figure can be 
used in determining the weight of a part before actual 
manufacture. Density is an important consideration 
when choosing a material to be used in the design of a 
part in order to maintain the proper weight and balance 
of the aircraft. 
MALLEABILITY 
A metal which can be hammered, rolled, or pressed into 
various shapes without cracking, breaking, or leaving 
1.2 
loss of both lives and equipment. The use of unsuitable 
materials can readily erase the finest craftsmanship. The 
selection of the correct material for a specific repair job 
demands familiarity with the most common physical 
properties of various metals. 
some other detrimental effect, i's said to be malleable. 
This property is necessary in sheet metal that is worked 
into curved shapes, such as cowlings, fairings, or 
wingtips. Copper is an example of a malleable metal. 
DUCTILITY 
Ductility is the property of a metal which permits it 
to be permanently drawn, bent, or twisted into various 
shapes without breaking. This property is essential for 
metals used in making wire and tubing. Ductile metals 
are greatly preferred for aircraft use because of their ease 
of forming and resistance to failure under shock loads. 
For this reason, aluminum alloys are used for cowl rings, 
fuselage and wing skin, and formed or extruded parts, 
such as ribs, spars, and bulkheads. Chrome molybdenum 
steel is also easily formed into desired shapes. Ductility 
is similar to malleability. 
ELASTICITY 
Elasticity is that property that enables a metal to return 
to its original size and shape when the force which 
causes the change of shape is removed. This property 
is extremely valuable because it would be highly 
undesirable to have a part permanently distortedafter 
an applied load was removed. Each metal has a point 
known as the elastic limit, beyond which it cannot be 
loaded without causing permanent distortion. In aircraft 
construction, members and parts are so designed that 
the maximum loads to which they are subjected will not 
stress them beyond their elastic limits. This desirable 
property is present in spring steel. 
TOUGHNESS 
A material which possesses toughness will withstand 
tearing or shearing and may be stretched or otherwise 
deformed without breaking. Toughness is a desirable 
property in aircraft metals. 
Module 06 - Materials and Hardware 
BRITTLENESS 
Brittleness is the property of a metal which allows little 
bending or deformation without shattering. A brittle 
metal is apt to break or crack without change of shape. 
Because structural metals are often subjected to shock 
loads, brittleness is not a very desirable property. Cast 
iron, cast aluminum, and very hard steel are examples of 
brittle metals. 
FUSIBILITY 
Fusibility is the ability of a metal to become liquid by 
the application of heat. Metals are fused in welding. 
Steels fuse around 2 600 °F and aluminum alloys at 
approximately 1 100 °F. 
FERROUS AIRCRAFT METALS 
Many different metals are required in the repair of 
aircraft. This is a result of the varying needs with 
respect to strength, weight, durability, and resistance to 
deterioration of specific structures or parts. In addition, 
the particular shape or form of the material plays an 
important role. In selecting materials for aircraft repair, 
these factors plus many others are considered in relation 
to the mechanical and physical properties. 
Among the common materials used are ferrous metals. 
The term "ferrous" applies to the group of metals having 
iron as their principal constituent. 
IRON 
If carbon is added to iron, in percentages ranging up to 
approximately 1 percent, the product is vastly superior 
to iron alone and is classified as carbon steel. Carbon 
steel forms the base of those alloy steels produced by 
combining carbon steel with other elements known to 
improve the properties of steel. A base metal (such as 
iron) to which small quantities of other metals have been 
added is called an alloy. The addition of other metals 
changes or improves the chemical or physical properties 
of the base metal for a particular use. 
STEEL AND STEEL ALLOYS 
To facilitate the discussion of steels, some familiarity 
with their nomenclature is desirable. A numerical index, 
Module 06 - Materials and Hardware 
CONDUCTIVITY 
Conductivity is the property which enables a metal to 
carry heat or electricity. The heat conductivity of a metal 
is especially important in welding because it governs 
the amount of heat that will be required for proper 
fusion. Conductivity of the metal, to a certain extent, 
determines the type of jig to be used to control expansion 
and contraction. In aircraft, electrical conductivity must 
also be considered in conjunction with bonding to 
eliminate radio interference. 
THERMAL EXPANSION 
Thermal expansion refers to contraction and expansion 
that are reactions produced in metals as the result of 
heating or cooling. Heat applied to a metal will cause 
it to expand or become larger. Cooling and heating 
affect the design of welding jigs, castings, and tolerances 
necessary for hot rolled material. 
sponsored by the Society of Automotive Engineers 
(SAE) and the American Iron and Steel Institute 
(AISI), is used to identify the chemical compositions 
of the structural steels. In this system, a four-numeral 
series is used to designate the plain carbon and alloy 
steels; five numerals are used to designate certain types 
of alloy steels. The first two digits indicate the type of 
steel, the second digit also generally (but not always) 
gives the approximate amount of the major alloying 
element, and the last two (or three) digits are intended 
to indicate the approximate middle of the carbon range. 
However, a deviation from the rule of indicating the 
carbon range is sometimes necessary. 
Small quantities of certain elements are present in 
alloy steels that are not specified as required. These 
elements are considered as incidental and may be present 
to the maximum amounts as follows: copper, 0.35 
percent; nickel, 0.25 percent; chromium, 0.20 percent; 
molybdenum, 0.06 percent. 
The list of standard steels is altered from time to time 
to accommodate steels of proven merit and to provide 
for changes in the metallurgical and engineering 
requirements of industry. (Figure 1-1) 
1.3 
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100xx 
11xx 
12xx 
13xx 
*23xx 
*25xx 
31xx 
33xx 
40xx 
41xx 
43xx 
44xx 
45xx 
46xx 
47xx 
48xx 
50xx 
50xxx 
51xx 
51xxx 
52xxx 
61xx 
81xx 
86xx 
87xx 
88xx 
92xx 
93xx 
94xx 
98xx 
Nonsulphurized carbon steels 
Resulphurised carbon steels (free machining) 
Rephosphorized and resulphurised carbon steels (free machining) 
Manganese 1.75% 
Nickel 3.50% 
Nickel 5.00% 
Nickel 1.25%, chromium 0.65% 
Nickel 3.50%, chromium 1.55% 
Molybdenum 0.20 or 0.25% 
Chromium 0.50% or 0.95%, molybdenum 0.12 or 0.20% 
Nickel 1.80%, chromium 0.5 or 0.80%, molybdenum 0.25% 
Molybdenum 0.40% 
Molybdenum 0.52% 
Nickel 1.80%, molybdenum 0.25% 
Nickel 1.05% chromium 0.45%, molybdenum 0.20 or 0.35% 
Nickel 3.50%, molybdenum 0.25% 
Chromium 0.25, or 0.40 or 0.50% 
Carbon 1.00%, chromium 0.50% 
Chromium 0.80, 0.90, 0.95 or 1.00% 
Carbon 1.00%, chromium 1.05% 
Carbon 1.00%, chromium 1.45% 
Chromium 0.60, 0.80, 0.95%, vanadium 0.12%, 0.10% min., or 0.15% min. 
Nickel 0.30%, chromium 0.40%, molybdenum 0.12% 
Nickel 0.55%, chromium 0.50%, molybdenum 0.20% 
Nickel 0.55%, chromium 0.05%, molybdenum 0.25% 
Nickel 0.55%, chromium 0.05%, molybdenum 0.35% 
Manganese 0.85%, silicon 2.00%, chromium 0 or 0.35% - ~ 
Nickel 3.25%, chromium 1.20%, molybdenum 0.12% 
Nickel 0.45%, chromium 0.40%, molybdenum 0.12% 
Nickel 1.00%, chromium 0.80%, molybdenum 0.25% 
Figure 1-1 . SAE numerical index. 
Metal stock is manufactured in several forms and shapes, 
including sheets, bars, rods, tubing, extrusions, forgings, 
and castings. Sheet metal is made in a number of sizes 
and thicknesses. Specifications designate thicknesses in 
thousandths of an inch. Bars and rods are supplied in 
a variety of shapes, such as round, square, rectangular, 
hexagonal, and octagonal. Tubing can be obtained in 
round, oval, rectangular, or streamlined shapes. The size 
of tubing is generally specified by outside diameter and 
wall thickness. 
Spark testing is a common means of identifying various 
ferrous metals. In this test the piece of iron or steel is 
held against a revolving grinding stone and the metal is 
identified by the sparks thrown off. Each ferrous metal 
has its own peculiar spark characteristics. The spark 
streams vary from a few tiny shafts to a shower of sparks 
several feet in length. (Few nonferrous metals give off 
sparks when touched to a grinding stone. Therefore, these 
metals cannot be successfully identified by the spark test.) 
The sheet metal is usually formed cold in such machines as 
presses, bending brakes, drawbenches, or rolls. Forgings 
are shaped or formed by pressing or hammering heated 
metal in dies. Castings are produced by pouring molten 
metal into molds. The casting is finished by machining. 
1.4 
Identification by spark testing is often inexact unless 
performed by an experienced person, or the test pieces 
differ greatly in their carbon content and alloying 
constituents. Wrought iron produces long shafts that are 
straw colored as they leave the stone and white at the 
end. Cast iron sparks are red as they leave the stone and 
turn to a straw color. Low carbon steels give off long, 
Module 06 - Materials and Hardware 
straight shafts having a few white sprigs. As the carbon 
content of the steel increases, the number of sprigs along 
each shaft increases and the stream becomes whiter in 
color. Nickel steel causes the spark stream to contain