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Aviation Maintenance (FAA-H-8083-30A) Technician Handbook–General

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Aviation Maintenance Technician Handbook–General (FAA-H-8083-30A)
US Depatment of Transportation
Federal Aviation Administration
2018
698 pages

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Open: Aviation Maintenance Technician Handbook–General (FAA-H-8083-30A)

Related:

Aviation Maintenance Technician Handbook–Airframe (FAA-H-8083-31A) Volume 1
Aviation Maintenance Technician Handbook–Airframe (FAA-H-8083-31A) Volume 2
Aviation Maintenance Technician Handbook–Powerplant (FAA-H-8083-32A) Volume 1
Aviation Maintenance Technician Handbook–Powerplant (FAA-H-8083-32A) Volume 2

The Aviation Maintenance Technician Handbook–General (FAA-H-8083-30A) was developed as one of a series of three handbooks for persons preparing for mechanic certification with airframe or powerplant ratings, or both. It is intended that this handbook will provide basic information on principles, fundamentals, and technical procedures in the subject matter areas common to both the airframe and powerplant ratings. Emphasis in this volume is on theory and methods of application.

The handbook is designed to aid students enrolled in a formal course of instruction preparing for FAA certification as a maintenance technician as well as for current technicians who wish to improve their knowledge. This volume contains information on mathematics, aircraft drawings, weight and balance, aircraft materials, processes and tools, physics, electricity, inspection, ground operations, and FAA regulations governing the certification and work of maintenance technicians. New to this volume is a section addressing how successful aviation maintenance technicians incorporate knowledge and awareness of ethics, professionalism and human factors in the field.

Because there are so many different types of airframes and powerplants in use today, it is reasonable to expect that differences exist in the components and systems of each. To avoid undue repetition, the practice of using representative systems and units is implemented throughout the handbook. Subject matter treatment is from a generalized point of view, and should be supplemented by reference to manufacturers’ manuals or other textbooks if more detail is desired. This handbook is not intended to replace, substitute for, or supersede official regulations or the manufacturers’ instructions.

TOC

Volume Contents. ...................................................V
Preface..................................................................VII
Acknowledgments. ................................................IX
Table of Contents. ................................................XV

Chapter 1
Safety, Ground Operations, and Servicing .......1-1
Shop Safety....................................................................1-2
Electrical Safety .........................................................1-2
Physiological Safety ...............................................1-2
Fire Safety...............................................................1-2
Safety Around Compressed Gases.............................1-2
Safety Around Hazardous Materials ..........................1-3
Safety Around Machine Tools ...................................1-3
Flight Line Safety ..........................................................1-4
Hearing Protection......................................................1-4
Foreign Object Damage (FOD)..................................1-5
Safety Around Airplanes............................................1-5
Safety Around Helicopters.........................................1-5
Fire Safety..................................................................1-5
Fire Protection................................................................1-5
Requirements for Fire to Occur..................................1-5
Classification of Fires.................................................1-6
Types and Operation of Shop and Flight Line Fire Extinguishers........1-6
Inspection of Fire Extinguishers.................................1-8
Identifying Fire Extinguishers....................................1-8
Using Fire Extinguishers............................................1-9
Tie-Down Procedures ....................................................1-9
Preparation of Aircraft................................................1-9
Tie-Down Procedures for Land Planes ....................1-10
Securing Light Aircraft.........................................1-10
Securing Heavy Aircraft.......................................1-11
Tie-Down Procedures for Seaplanes ........................1-11
Tie-Down Procedures for Ski Planes .......................1-11
Tie-Down Procedures for Helicopters......................1-11
Procedures for Securing Weight-Shift-Control........1-12
Procedures for Securing Powered Parachutes..........1-12
Ground Movement of Aircraft.....................................1-13
Engine Starting and Operation .................................1-13
Reciprocating Engines..............................................1-13
Hand Cranking Engines............................................1-14
Extinguishing Engine Fires ......................................1-15
Turboprop Engines...................................................1-15
Turboprop Starting Procedures ................................1-15
Turbofan Engines .....................................................1-16
Starting a Turbofan Engine ......................................1-17
Auxiliary Power Units (APUs) ................................1-17
Unsatisfactory Turbine Engine Starts.......................1-17
Hot Start................................................................1-17
False or Hung Start ...............................................1-17
Engine Fails to Start..............................................1-19
Towing of Aircraft....................................................1-19
Taxiing Aircraft........................................................1-20
Taxi Signals ..........................................................1-21
Servicing Aircraft.........................................................1-22
Servicing Aircraft Air/Nitrogen Oil and Fluids .......1-22
Ground Support Equipment .....................................1-24
Electric Ground Power Units................................1-24
Hydraulic Ground Power Units ............................1-25
Ground Support Air Units ....................................1-25
Ground Air Heating and Air Conditioning...........1-25
Oxygen Servicing Equipment ..................................1-25
Oxygen Hazards .......................................................1-26
Fuel Servicing of Aircraft ............................................1-26
Types of Fuel and Identification ..............................1-26
Contamination Control.............................................1-26
Fueling Hazards........................................................1-27
Fueling Procedures...................................................1-27
Defueling..................................................................1-29

Chapter 2
Regulations, Maintenance Forms, Records, and Publications .............2-1
Overview— Title 14oftheCode of Federal Regulations (14CFR)............2-1
Title 14 CFR Part 3—General Requirements.............2-4
Maintenance-Related Regulations..............................2-5
14 CFR Part 1—Definitions and Abbreviations.....2-5
14 CFR Part 21—Certification Procedures for Products and Parts...................................................2-5
14 CFR Part 23—Airworthiness Standards: Normal, Utility, Acrobatic, and Commuter Category Airplanes.................................................2-8
14 CFR Part 125—Certification and Operations: Airplanes Having a Seating Capacity of 20 or More Passengers or a Maximum Payload Capacity of 6,000 Pounds or More; and Rules Appendix D—Scope and Detail of Items To Be 14 CFR Part 25—Airworthiness Standards: Transport Category Airplanes.................................2-8
14 CFR Part 27—Airworthiness Standards: Normal Category Rotorcraft...................................2-8
14 CFR Part 29—Airworthiness Standards: Transport Category Rotorcraft................................2-8
14 CFR Part 33—Airworthiness Standards: Aircraft Engines......................................................2-8
14 CFR Part 35—Airworthiness Standards: Propellers ................................................................2-8
14 CFR Part 39—Airworthiness Directives .........2-10
14 CFR Part 43—Maintenance, Preventive Maintenance, Rebuilding, and Alteration.............2-10
14 CFR Part 45—Identification and Registration Marking............................................2-10
14 CFR Part 47—Aircraft Registration ................2-10
14 CFR Part 65—Certification: Airmen Other Than Flight Crewmembers .........................2-10
14 CFR Part 91—General Operating and Flight Rules...........................................................2-11
14 CFR Part 119—Certification: Air Carriers and Commercial Operators...................................2-11
14 CFR Part 121—Operating Requirements: Domestic, Flag, and Supplemental Operations.....2-12
Governing Persons on Board Such Aircraft .........2-13
14 CFR Part 135—Operating Requirements: Commuter and On-Demand Operations and Rules Governing Persons on Board Such Aircraft............2-13
14 CFR Part 145—Repair Stations.......................2-14
14 CFR Part 147—Aviation Maintenance Technician Schools...............................................2-14
14 CFR Part 183—Representatives of the Administrator........................................................2-14
Explanation of Primary Regulations (Parts 43 and 91) .........................................................................2-15
14 CFR Part 43—Maintenance, Preventative Maintenance Rebuilding, and Alteration..................2-15
Appendix A—Major Alterations, Major Repairs, and Preventive Maintenance...................2-20
Appendix B—Recording of Major Repairs and Major Alterations...........................................2-21
Appendix C—(Reserved) .....................................2-21
Included in Annual and 100-Hour Inspections.....2-21
Appendix E—Altimeter System Test and Inspection..............................................................2-21
Appendix F—ATC Transponder Tests and Inspections ............................................................2-21
14 CFR Part 91—General Operating and Flight Rules ..............................................................2-21
Subpart A—General ............................................2-21
Subpart E—Maintenance, Preventive Maintenance, and Alterations ...............................2-22
Civil Air Regulations (CAR) .......................................2-24
CAR 3—Airplane Airworthiness—Normal, Utility, Aerobatic, and Restricted Purpose Categories.............2-24
CAR 4a—Airplane Airworthiness ...........................2-26
Suspected Unapproved Parts (SUP).............................2-26
Other FAA Documents ................................................2-26
Advisory Circulars (AC) ..........................................2-26
The AC Numbering System..................................2-26
Types of Airworthiness Directives (AD)..............2-27
AD Content...........................................................2-27
AD Number ..........................................................2-27
Applicability and Compliance ..............................2-27
Alternative Method of Compliance ......................2-30
Special Airworthiness Information Bulletin (SAIB) ..........2-30
Aircraft Specifications..............................................2-30
Cessna; 182T; Locked Rudder Trim Wheel; A4A 2721.........2-30
Supplemental Type Certificates (STC) ....................2-30
Type Certificate Data Sheets (TCDS)......................2-33
FAA Handbooks and Manuals.....................................2-33
Non-FAA Documents ..................................................2-33
Air Transport Association A4A iSPec 2200 ............2-33
Manufacturers’ Published Data................................2-33
Airworthiness Limitations........................................2-37
Service Bulletins (SB)..............................................2-38
Structural Repair Manual (SRM) .............................2-38
Forms ...........................................................................2-39
Airworthiness Certificates........................................2-39
Aircraft Registration.................................................2-39
Radio Station License...............................................2-39
FAA Form 337—Major Repair and Alteration........2-40
Records ........................................................................2-41
Making Maintenance Record Entries.......................2-41
Electronic Records ...................................................2-44
Light Sport Aircraft (LSA) ..........................................2-45
Maintenance .............................................................2-45
Aircraft Maintenance Manual (AMM).....................2-46
Line Maintenance, Repairs, and Alterations ............2-46
Major Repairs and Alterations .................................2-46

Chapter 3
Mathematics in Aviation Maintenance...............3-1
Introduction....................................................................3-1
Whole Numbers.............................................................3-2
Addition of Whole Numbers......................................3-2
Subtraction of Whole Numbers..................................3-2
Division of Whole Numbers.......................................3-2
Fractions.........................................................................3-2
Finding the Least Common Denominator..................3-3
Addition of Fractions .................................................3-3
Subtraction of Fractions .............................................3-3
Multiplication of Fractions.........................................3-3
Division of Fractions..................................................3-4
Reducing Fractions.....................................................3-4
Mixed Numbers .............................................................3-4
Addition of Mixed Numbers ......................................3-4
Subtraction of Mixed Numbers..................................3-4
The Decimal Number System........................................3-5
Origin and Definition.................................................3-5
Addition of Decimal Numbers...................................3-5
Subtraction of Decimal Numbers...............................3-6
Multiplication of Decimal Numbers...........................3-6
Division of Decimal Numbers....................................3-6
Rounding Off Decimal Numbers ...............................3-7
Converting Decimal Numbers to Fractions................3-7
Converting Fractions to Decimals..............................3-8
Decimal Equivalent Chart..........................................3-8
Ratio...............................................................................3-8
Aviation Applications.................................................3-8
Proportion ....................................................................3-10
Extremes and Means ................................................3-10
Solving Proportions..................................................3-10
Percentage....................................................................3-10
Expressing a Decimal Number as a Percentage .......3-10
Expressing a Percentage as a Decimal Number .......3-11
Expressing a Fraction as a Percentage .....................3-11
Finding a Percentage of a Given Number ................3-11
Finding What Percentage One Number is of Another..............3-11
Finding a Number When a Percentage of it is Known .................3-11
Positive and Negative Numbers...................................3-12
(Signed Numbers) ........................................................3-12
Addition of Positive and Negative Numbers............3-12
Subtraction of Positive and Negative Numbers .......3-12
Multiplication of Positive and Negative Numbers...3-12
Powers..........................................................................3-12
Special Powers .........................................................3-12
Squared .................................................................3-12
Cubed....................................................................3-12
Power of Zero .......................................................3-12
Law of Exponents.....................................................3-13
Powers of Ten...........................................................3-13
Roots.........................................................................3-13
Square Roots ............................................................3-13
Cube Roots .............................................................. 3-13
Fractional Powers.....................................................3-16
Functions of Numbers Chart........................................3-16
Scientific Notation .......................................................3-16
Converting Numbers from Standard Notation to Scientific Notation................................................3-16
Converting Numbers from Scientific Notation to Standard Notation.................................................3-16
Addition, Subtraction, Multiplication, and Division of Scientific Numbers................................3-17
Algebra.........................................................................3-17
Equations..................................................................3-17
Algebraic Rules ........................................................3-17
Solving for a Variable ..............................................3-17
Use of Parentheses....................................................3-18
Order of Operation ...................................................3-18
Order of Operation for Algebraic Equations............3-18
Computing Area of Two-Dimensional Solids .............3-18
Rectangle..................................................................3-19
Square.......................................................................3-19
Triangle ....................................................................3-19
Parallelogram............................................................3-20
Trapezoid..................................................................3-20
Circle ........................................................................3-21
Ellipse.......................................................................3-21
Units of Area ............................................................3-22
Computing Volume of Three-Dimensional Solids ......3-22
Rectangular Solid .....................................................3-23
Cube .........................................................................3-23
Cylinder....................................................................3-24
Sphere.......................................................................3-24
Cone .........................................................................3-25
Units of Volume .......................................................3-25
Computing Surface Area of Three-Dimensional Solids............................3-25
Rectangular Solid .....................................................3-25
Cube .........................................................................3-25
Cylinder....................................................................3-25
Sphere.......................................................................3-25
Cone .........................................................................3-25
Trigonometric Functions..............................................3-26
Right Triangle, Sides, and Angles............................3-26
Sine, Cosine, and Tangent........................................3-26
Calculator Method: ...............................................3-26
Trigonometry Table Method: ...............................3-26
Pythagorean Theorem...............................................3-26
Measurement Systems .................................................3-27
Conventional (U.S. or English) System ...................3-27
Metric System ..........................................................3-27
Measurement Systems and Conversions ..................3-28
The Binary Number System.........................................3-28
Place Values .............................................................3-28
Converting Binary Numbers to Decimal Numbers ...........................3-28
Converting Decimal Numbers to Binary Numbers ....................3-28

Chapter 4
Aircraft Drawings.................................................4-1
Computer Graphics........................................................4-2
Purpose and Function of Aircraft Drawings..................4-2
Care and Use of Drawings.............................................4-2
Types of Drawings.........................................................4-3
Detail Drawing...........................................................4-3
Assembly Drawing.....................................................4-3
Installation Drawing...................................................4-3
Sectional View Drawings...........................................4-3
Full Section.............................................................4-3
Half Section............................................................4-3
Revolved Section....................................................4-3
Removed Section....................................................4-3
Title Blocks....................................................................4-3
Drawing or Print Numbers.........................................4-7
Reference and Dash Numbers....................................4-8
Universal Numbering System........................................4-8
Drawing Standards.........................................................4-8
Bill of Material...............................................................4-8
Other Drawing Data.......................................................4-9
Revision Block...........................................................4-9
Notes...........................................................................4-9
Zone Numbers............................................................4-9
Station Numbers and Location Identification on Aircraft ...................4-9
Allowances and Tolerances........................................4-9
Finish Marks...............................................................4-9
Scale .........................................................................4-11
Application ...............................................................4-11
Methods of Illustration.................................................4-11
Applied Geometry....................................................4-11
Orthographic Projection Drawings.......................4-11
Pictorial Drawings ................................................4-11
Diagrams...............................................................4-15
Flowcharts.............................................................4-17
Lines and Their Meanings ...........................................4-17
Centerlines................................................................4-18
Dimension Lines ......................................................4-18
Extension Lines ........................................................4-19
Sectioning Lines.......................................................4-19
Phantom Lines..........................................................4-19
Break Lines...............................................................4-19
Leader Lines.............................................................4-19
Hidden Lines ............................................................4-19
Outline or Visible Lines ...........................................4-19
Stitch Lines...............................................................4-19
Cutting Plane and Viewing Plane Lines...................4-19
Drawing Symbols.........................................................4-20
Material Symbols .....................................................4-20
Shape Symbols .........................................................4-21
Electrical Symbols....................................................4-21
Reading and Interpreting Drawings.............................4-21
Drawing Sketches ........................................................4-23
Sketching Techniques...............................................4-23
Basic Shapes.............................................................4-23
Repair Sketches ........................................................4-23
Care of Drafting Instruments .......................................4-23
Graphs and Charts........................................................4-25
Reading and Interpreting Graphs and Charts ...........4-25
Nomograms ..............................................................4-25
Microfilm and Microfiche............................................4-25
Digital Images..............................................................4-26

Chapter 5
Physics for Aviation............................................5-1
Matter.............................................................................5-2
Characteristics of Matter............................................5-2
Mass and Weight ....................................................5-2
Attraction ................................................................5-2
Porosity...................................................................5-2
Impenetrability........................................................5-2
Density....................................................................5-2
Specific Gravity......................................................5-2
Energy............................................................................5-4
Potential Energy.........................................................5-4
Kinetic Energy............................................................5-4
Force, Work, Power, and Torque...................................5-4
Force...........................................................................5-4
Work...........................................................................5-5
Friction and Work ......................................................5-5
Static Friction..........................................................5-6
Sliding Friction.......................................................5-6
Rolling Friction.......................................................5-6
Power..........................................................................5-7
Torque ........................................................................5-7
Simple Machines............................................................5-8
Mechanical Advantage of Machines..........................5-8
The Lever ...................................................................5-9
First Class Lever.....................................................5-9
Second Class Lever.................................................5-9
Third Class Lever .................................................5-10
The Pulley ................................................................5-10
Single Fixed Pulley...............................................5-10
Single Movable Pulley..........................................5-10
Block and Tackle ..................................................5-11
The Gear...................................................................5-11
Inclined Plane...........................................................5-13
Stress............................................................................5-13
Tension.....................................................................5-14
Compression.............................................................5-14
Torsion .....................................................................5-14
Bending ....................................................................5-15
Shear.........................................................................5-15
Strain ........................................................................5-15
Motion..........................................................................5-15
Uniform Motion .......................................................5-16
Speed and Velocity...................................................5-16
Acceleration..............................................................5-16
Newton’s Law of Motion .........................................5-17
First Law...............................................................5-17
Second Law ..........................................................5-17
Third Law .............................................................5-18
Circular Motion ........................................................5-18
Heat..............................................................................5-19
Heat Energy Units ....................................................5-19
Heat Energy and Thermal Efficiency.......................5-19
Heat Transfer............................................................5-20
Conduction............................................................5-20
Convection............................................................5-21
Radiation...............................................................5-21
Specific Heat ............................................................5-22
Temperature..............................................................5-22
Thermal Expansion/Contraction...............................5-23
Pressure........................................................................5-23
Gauge Pressure.........................................................5-24
Absolute Pressure.....................................................5-24
Differential Pressure.................................................5-24
Gas Laws......................................................................5-25
Boyle’s Law .............................................................5-25
Charles’ Law ............................................................5-26
General Gas Law......................................................5-26
Dalton’s Law ............................................................5-26
Fluid Mechanics...........................................................5-26
Buoyancy..................................................................5-26
Fluid Pressure...........................................................5-28
Pascal’s Law.............................................................5-28
Bernoulli’s Principle.................................................5-30
Sound ...........................................................................5-31
Wave Motion............................................................5-31
Speed of Sound.........................................................5-32
Mach Number...........................................................5-32
Frequency of Sound..................................................5-32
Loudness...................................................................5-32
Measurement of Sound Intensity..............................5-33
Doppler Effect..........................................................5-33
Resonance.................................................................5-33
The Atmosphere...........................................................5-33
Composition of the Atmosphere...............................5-34
Atmospheric Pressure...............................................5-34
Atmospheric Density................................................5-35
Water Content of the Atmosphere............................5-35
Absolute Humidity................................................5-36
Relative Humidity.................................................5-36
Dew Point .............................................................5-36
Vapor Pressure......................................................5-37
Standard Atmosphere ...............................................5-37
Aircraft Theory of Flight .............................................5-37
Four Forces of Flight................................................5-37
Bernoulli’s Principle and Subsonic Flow.................5-37
Lift and Newton’s Third Law...................................5-38
Airfoils .....................................................................5-39
Camber .................................................................5-39
Chord Line ............................................................5-39
RelativeWind .......................................................5-39
AngleofAttack .....................................................5-39
Boundary Layer Airflow ..........................................5-40
Boundary Layer Control.......................................5-40
Wingtip Vortices ......................................................5-40
Axes of an Aircraft...................................................5-41
Aircraft Stability.......................................................5-41
Static Stability.......................................................5-41
Dynamic Stability .................................................5-42
Longitudinal Stability ...........................................5-42
Lateral Stability ....................................................5-43
Directional Stability..............................................5-43
Dutch Roll.............................................................5-43
Flight Control Surfaces ............................................5-43
Flight Controls and the Lateral Axis ....................5-43
Flight Controls and the Longitudinal Axis ...........5-44
Flight Controls and the Vertical Axis...................5-44
Tabs.......................................................................5-45
Supplemental Lift-Modifying Devices.................5-46
High-Speed Aerodynamics.......................................5-47
Compressibility Effects ........................................5-47
The Speed of Sound..............................................5-48
Subsonic, Transonic, and Supersonic Flight.........5-48
Shock Waves ........................................................5-48
High-Speed Airfoils..............................................5-49
Aerodynamic Heating...........................................5-50
Helicopter Aerodynamics.........................................5-51
Helicopter Structures and Airfoils........................5-51
Helicopter Axes of Flight .....................................5-54
Helicopters in Flight .............................................5-56
Weight-Shift Control, Flexible Wing Aircraft Aerodynamics...........5-58
Powered Parachute Aerodynamics...........................5-60

Chapter 6
Aircraft Weight and Balance...............................6-1
Introduction....................................................................6-1
Requirements for Aircraft Weighing.............................6-2
Weight and Balance Terminology.................................6-2
Datum .........................................................................6-2
Arm.............................................................................6-3
Moment ......................................................................6-3
Center of Gravity (CG)...............................................6-4
Maximum Weight.......................................................6-4
Empty Weight.............................................................6-4
Empty Weight Center of Gravity (EWCG)................6-5
Useful Load................................................................6-5
Minimum Fuel............................................................6-5
Tare Weight................................................................6-6
Procedures for Weighing an Aircraft.............................6-6
General Concepts .......................................................6-6
Weight and Balance Data...........................................6-7
Manufacturer-Furnished Information.........................6-8
Weight and Balance Equipment.....................................6-8
Scales..........................................................................6-8
Spirit Level ...........................................................6-12
Plumb Bob ............................................................6-13
Hydrometer...........................................................6-13
Preparing an Aircraft for Weighing..........................6-13
Fuel System ..........................................................6-14
Oil System ............................................................6-14
Miscellaneous Fluids ............................................6-14
Flight Controls......................................................6-14
Other Considerations ............................................6-14
Weighing Points....................................................6-15
Jacking the Aircraft ..................................................6-15
Leveling the Aircraft ................................................6-15
Safety Considerations...............................................6-16
CG Range .................................................................6-16
Empty Weight Center of Gravity (EWCG) Range ....................................................................6-16
Operating CG Range.............................................6-16
Standard Weights Used for Aircraft Weight and Balance..................................................6-17
Example Weighing of an Airplane...........................6-17
EWCG Formulas ......................................................6-18
Datum Forward of the Airplane–Nosewheel Landing Gear............................................................6-19
Datum Aft of the Main Wheels–Nosewheel Landing Gear............................................................6-19
Location of Datum....................................................6-19
Datum Forward of the Main Wheels–Tail Wheel Landing Gear ................................................6-20
Loading an Aircraft for Flight......................................6-20
Example Loading of an Airplane..........................6-20
Adverse-Loaded CG Checks....................................6-21
Example Forward and Aft Adverse-Loaded CG Checks................................................................6-22
Equipment Change and Aircraft Alteration .................6-23
Example Calculation After an Equipment Change ..................................................................6-23
Use of Ballast ...........................................................6-23
Temporary Ballast ................................................6-23
Permanent Ballast .................................................6-25
Loading Graphs and CG Envelopes.............................6-25
Helicopter Weight and Balance ...................................6-27
General Concepts .....................................................6-27
Helicopter Weighing ................................................6-28
Weight and Balance—Weight-Shift Control Aircraft and Powered Parachutes.................................6-28
Weight-Shift Control Aircraft ..................................6-28
Powered Parachutes..................................................6-30
Built-In Electronic Weighing...................................6-30
Mean Aerodynamic Chord .......................................6-30
Weight and Balance Records.......................................6-32

Chapter 7
Aircraft Materials, Hardware, and Processes ..7-1
Properties of Metals....................................................7-2
Hardness .................................................................7-2
Strength...................................................................7-2
Density....................................................................7-2
Malleability.............................................................7-2
Ductility ..................................................................7-2
Elasticity .................................................................7-2
Toughness...............................................................7-2
Brittleness ...............................................................7-2
Fusibility.................................................................7-2
Conductivity ...........................................................7-2
Thermal Expansion.................................................7-2
Ferrous Aircraft Metals..............................................7-3
Iron..........................................................................7-3
Steel and Steel Alloys.............................................7-3
Electrochemical Test..................................................7-5
Nonferrous Aircraft Metals........................................7-6
Aluminum and Aluminum Alloys..........................7-6
Wrought Aluminum................................................7-7
Effect of Alloying Element.....................................7-8
Hardness Identification...........................................7-9
Magnesium and Magnesium Alloys.......................7-9
Titanium and Titanium Alloys..............................7-10
Copper and Copper Alloys ...................................7-11
Nickel and Nickel Alloys......................................7-12
Substitution of Aircraft Metals.................................7-12
Metalworking Processes...........................................7-12
Hot Working .........................................................7-12
Internal Structure of Metals..................................7-14
Heat-Treating Equipment .....................................7-15
Heating..................................................................7-16
Soaking .................................................................7-16
Cooling .................................................................7-16
Quenching Media..................................................7-17
Quenching Equipment ..........................................7-19
Heat Treatment of Ferrous Metals............................7-19
Behavior of Steel During Heating and Cooling....7-19
Hardening .............................................................7-19
Hardening Precautions..........................................7-19
Tempering.............................................................7-20
Annealing..............................................................7-20
Normalizing ..........................................................7-20
Casehardening.......................................................7-20
Heat Treatment of Nonferrous Metals......................7-21
Aluminum Alloys .................................................7-21
Alclad Aluminum .................................................7-22
Solution Heat Treatment.......................................7-22
Quenching.............................................................7-22
Lag Between Soaking and Quenching..................7-23
Reheat Treatment..................................................7-23
Straightening After Solution Heat Treatment ..........7-23
Precipitation Heat Treating ......................................7-23
Precipitation Practices ..........................................7-24
Annealing of Aluminum Alloys...............................7-24
Heat Treatment of Aluminum Alloy Rivets.............7-24
Heat Treatment of Magnesium Alloys .....................7-25
Solution Heat Treatment.......................................7-25
Precipitation Heat Treatment................................7-26
Heat Treatment of Titanium.....................................7-26
Stress Relieving ....................................................7-26
Full Annealing ......................................................7-26
Thermal Hardening...............................................7-26
Casehardening.......................................................7-26
Hardness Testing ......................................................7-26
Brinell Tester ........................................................7-26
Rockwell Tester....................................................7-27
Barcol Tester.........................................................7-28
Forging .....................................................................7-29
Casting......................................................................7-29
Extruding..................................................................7-29
Cold Working/Hardening.........................................7-29
Nonmetallic Aircraft Materials....................................7-30
Wood ........................................................................7-30
Plastics......................................................................7-30
Transparent Plastics..................................................7-30
Composite Materials.................................................7-31
Advantages/Disadvantages of Composites...........7-31
Composite Safety..................................................7-32
Fiber Reinforced Materials...................................7-32
Laminated Structures............................................7-32
Reinforced Plastic.................................................7-32
Rubber ......................................................................7-33
Natural Rubber......................................................7-33
Synthetic Rubber ..................................................7-33
Shock Absorber Cord...............................................7-34
Seals .............................................................................7-34
Packings ...................................................................7-35
O-Ring Packings...................................................7-35
V-Ring Packings...................................................7-36
U-Ring Packings...................................................7-36
Gaskets .....................................................................7-36
Wipers ......................................................................7-36
Sealing Compounds..................................................7-37
One Part Sealants..................................................7-37
Two Part Sealants .................................................7-37
Aircraft Hardware ........................................................7-37
Identification ............................................................7-37
Threaded Fasteners...................................................7-38
Classification of Threads ......................................7-38
Aircraft Bolts............................................................7-39
General Purpose Bolts ..........................................7-39
Close Tolerance Bolts...........................................7-39
Internal Wrenching Bolts......................................7-39
Identification and Coding .....................................7-39
Special-Purpose Bolts...........................................7-41
Aircraft Nuts.............................................................7-43
Non-Self-Locking Nuts ........................................7-44
Self-Locking Nuts.................................................7-44
Sheet Spring Nuts .................................................7-46
Internal and External Wrenching Nuts .................7-46
Identification and Coding .....................................7-47
Aircraft Washers.......................................................7-48
Plain Washers .......................................................7-48
Lock Washers .......................................................7-48
Special Washers....................................................7-48
Installation of Nuts, Washers, and Bolts ..................7-48
Bolt and Hole Sizes ..............................................7-48
Installation Practices.............................................7-49
Safetying of Bolts and Nuts .....................................7-49
Repair of Damaged Internal Threads....................7-49
Fastener Torque........................................................7-51
Torque...................................................................7-51
Torque Wrenches..................................................7-51
Torque Tables .......................................................7-52
Cotter Pin Hole Line Up.......................................7-52
Aircraft Rivets..........................................................7-52
Standards and Specifications ................................7-52
Solid Shank Rivets................................................7-54
Identification.........................................................7-56
Blind Rivets ..........................................................7-57
Mechanically-Expanded Rivets................................7-58
Self-Plugging Rivets (Friction Lock) ...................7-58
Pull-Thru Rivets....................................................7-59
Self-Plugging Rivets (Mechanical Lock) .............7-60
Material.................................................................7-61
Head Styles ...........................................................7-61
Diameters..............................................................7-61
Grip Length...........................................................7-62
Rivet Identification ...............................................7-63
Special Shear and Bearing Load Fasteners ..............7-6
3 Pin Rivets..............................................................7-64
Taper-Lok .............................................................7-64
Hi-Tigue................................................................7-65
Captive Fasteners..................................................7-65
Turn Lock Fasteners .............................................7-65
Dzus Fasteners......................................................7-65
Camloc Fasteners..................................................7-66
Airloc Fasteners....................................................7-66
Screws ......................................................................7-67
Structural Screws..................................................7-67
Machine Screws....................................................7-67
Self-Tapping Screws.............................................7-68
Identification and Coding for Screws...................7-68
Riveted and Rivetless Nut Plates..............................7-68
Nut Plates..............................................................7-68
Rivnuts..................................................................7-69
Dill Lok-Skrus and Dill Lok-Rivets .....................7-70
Deutsch Rivets......................................................7-71
Sealing Nut Plates.................................................7-71
Hole Repair and Hole Repair Hardware...................7-71
Repair of Damaged Holes with Acres Fastener Sleeves ..................................................................7-71
Control Cables and Terminals ..............................7-72
Push-Pull Tube Linkage .......................................7-75
Safetying Methods....................................................7-75
Pins .......................................................................7-76
Safety Wiring ...........................................................7-76
Nuts, Bolts, and Screws........................................7-76
Oil Caps, Drain Cocks, and Valves ......................7-77
Electrical Connectors............................................7-77
Turnbuckles ..........................................................7-77
General Safety Wiring Rules....................................7-80
Cotter Pin Safetying..............................................7-80
Snap Rings............................................................7-81

Chapter 8
Cleaning and Corrosion Control........................8-1
Corrosion........................................................................8-1
Factors Affecting Corrosion.......................................8-2
Pure Metals.............................................................8-2
Climate....................................................................8-2
Geographical Location............................................8-3
Foreign Material .....................................................8-3
Micro-organisms.....................................................8-3
Manufacturing Processes........................................8-3
Types of Corrosion.....................................................8-4
Direct Chemical Attack ..........................................8-4
Electrochemical Attack...........................................8-5
Forms of Corrosion ....................................................8-6
Surface Corrosion...................................................8-7
Filiform Corrosion..................................................8-7
Pitting Corrosion.....................................................8-7
Dissimilar Metal Corrosion ....................................8-7
Concentration Cell Corrosion.................................8-7
Intergranular Corrosion ..........................................8-9
Exfoliation Corrosion .............................................8-9
Stress-Corrosion/Cracking......................................8-9
Fretting Corrosion.................................................8-10
Fatigue Corrosion .................................................8-10
Galvanic Corrosion...............................................8-11
Common Corrosive Agents......................................8-11

Interior Cleaning.......................................................8-25
Types of Cleaning Operations ..............................8-25
Nonflammable Aircraft Cabin Cleaning Agents and Solvents .............................................8-25
Flammable and Combustible Agents....................8-26
Container Controls................................................8-26
Fire Prevention Precautions..................................8-26
Fire Protection Recommendations........................8-26
Powerplant Cleaning....................................................8-27
Solvent Cleaners ..........................................................8-27
Dry Cleaning Solvent ...............................................8-28
Aliphatic and Aromatic Naphtha..............................8-28
Safety Solvent ..........................................................8-28
Methyl Ethyl Ketone (MEK)....................................8-28
Kerosene...................................................................8-28
Cleaning Compound for Oxygen Systems...............8-28
Emulsion Cleaners .......................................................8-28
Water Emulsion Cleaner ..........................................8-28
Solvent Emulsion Cleaners ......................................8-28
Soaps and Detergent Cleaners .....................................8-28
Cleaning Compound, Aircraft Surfaces ...................8-29
Nonionic Detergent Cleaners ...................................8-29
Mechanical Cleaning Materials ...................................8-29
Mild Abrasive Materials...........................................8-29
Abrasive Papers........................................................8-29
Chemical Cleaners .......................................................8-29
Phosphoric-citric Acid..............................................8-29

Chapter 9
Fluid Lines and Fittings ......................................9-1
Introduction....................................................................9-1
Rigid Fluid Lines ...........................................................9-2
Tubing Materials ........................................................9-2
Copper.....................................................................9-2
Aluminum Alloy Tubing ........................................9-2
Steel ........................................................................9-2
Titanium 3AL–2.5V ...............................................9-2
Material Identification................................................9-2
Sizes ...........................................................................9-2
Fabrication of Metal Tube Lines................................9-2
Tube Cutting ...........................................................9-3
Tube Bending..........................................................9-3
Alternative Bending Methods ....................................9-5
Tube Flaring............................................................9-5
Instructions for Rolling-Type Flaring Tools ..............9-6
Double Flaring............................................................9-6
Double Flaring Instructions ....................................9-7
Fittings ....................................................................9-7
Flareless Fittings.....................................................9-7
Beading...................................................................9-7
Fluid Line Identification.............................................9-8
Fluid Line End Fittings ..............................................9-9
Universal Bulkhead Fittings...................................9-9
AN Flared Fittings..................................................9-9
MS Flareless Fittings................................................9-12
Swaged Fittings ....................................................9-12
Cryofit Fittings....................................................