AMT

110 Sheet Metal

Herb Spenner

Introduc8on
Herb Spenner
herbspenner@gmail.com (408) 314-1610

Guidelines
Gavilan College FAA

Class Requirements
AC 43-1B/2B AC 65-15 Op8onal ASA Test Guides and SoQware
General and Airframe Test Guide books Prepware soQware

Safety
Glass Ear plugs Gloves Cloths

Class Room Tools

Calculator Machinist's Ruler (1/32, 1/64,1/100) Compass Right angle or triangle Op8onal
Graph paper Computer
Text books and handout available in soQ copy

Shop Tools
No stress risers
Envelop example M&M Test Use the correct tool

Drill bits 5 each

#40 bit 0.98 - #3 rivet 3/32 0.09375 #30 bit 0.1285 - #4 rivet 4/32 (1/8) 0.125 #21 bit 0.159 - #5 rivet 5/32 0.15625

Center punch
Automa8c - best

Shop Tools
Sharpie - Ultra Fine (no pencil for marking) File Scrape of wood Op8onal
Rivet Gauges Old dill bit deburring Clamps Rive8ng tape Caliper or Micrometer www.aircraQspruce.com & www.yardstore.com

Lets Do Some Math

Rivets
Start reading AC65-15 Chapter 5 - AircraQ Structural Repairs - page 127
Repairs must maintain the original strength of the structure.

Pop, Cherry, Solid Solid Rivet Heads

Fig 3.1 Universal - AN470 (MS20470) 100 Countersunk AN426 (MS20426) ush

Rivet Heads

Rivet Squeezer

Rivet Gun

Rivet Gun

Rivet Gun Process

Select set Select and install set retainer (spring) Adjust regulator Test regulator adjustment on wood
Never shoot gun with no load/in the air

Test on a sample

Solid Rivet Material

A 1100 Pure aluminum B 5056 - Magnesium AD 2117 Most common type D 2017 Ice box DD 2024 Ice box

Rivet Material

Rivet Dimensioning
Diameter is in 1/32s
#3 3/32, #4- 4/32 (1/8), #5- 5/32

Length is in 1/16
AN470 shaQ length AN426 full rivet length

Rivet Designa8on
(Head Type) (Material) (Diameter in 1/32s) (Length in 1/16s) Universal head, 2117, 3/32 diameter, 5/16 length
AN470AD3-5 or MS20470AD3-5

Countersunk head, 1100, 1/8 (4/32) diameter, 1/2 (8/16) length

AN426A4-8 or MS20426A4-8

Drill Sizes
#3 3/32 - #40 drill #4 1/8 (4/32) - #30 drill #5 5/32 - #21 drill

Shop Head Dimensions

D Rivet diameter 1/2 D Height 1 1/2 Wide Fig 3.3

Rivet Diameter
D At least 3X the thickest sheet
or what the aircraQ manufacturer used Remember to convert to 1/32s

D 3 X sheet thickness X 32 (conver8ng to 1/32s) Sheet thickness - 0.025

D = 3 X 0.025 X 32 = 2.4 -> 3

Sheet thickness 0.032

D = 3 X 0.032 X 32 = 3.072 -> 4

Sheet thickness 0.040

D = 3 X 0.040 X 32 = 3.84 -> 4

Rivet Length
Length = 1.5 X D + Total thickness of all sheets Length = (1.5 X D + Sheet 1 + Sheet 2. . .) X 16
X 16 is to convert to 1/16s Remember to add all the sheets

Rivet Length
2 Sheets of 0.025 3/32 rivet
(1.5 X 3/32 + 0.025 + 0.025) X 16 = 3.05 -> 4 AN470AD3-4 or AN426AD3-4

2 Sheets of 0.032 1/8 rivet (4/32)

(1.5 X 1/8+ 0.032 + 0.032) X 16 = 4.024 -> 4 or 5 AN470AD4-5 or AN426AD4-5

2 Sheets of 0.040 1/8 rivet (4/32)

(1.5 X 1/8+ 0.040 + 0.040) X 16 = 4.28 -> 5 AN470AD4-5 or AN426AD4-5

Rivet Length
3 Sheets of 0.025 3/32 rivet
(1.5 X 3/32 + 0.025 + 0.025 + 0.025) X 16 = 3.45-> 4 AN470AD3-4 or AN426AD3-4

Three sheets - 0.025, 0.032 and 0.040 sheets

#4 rivet because of 0.040 (1.5 X 1/8 + 0.025 + 0.032 + 0.040) X 16 = 4.552-> 5 AN470AD4-5 or AN426AD4-5

Rivet Dimensions
D At least 3X the thickest sheet
or what the aircraQ manufacturer used Remember to convert to 1/32s

D 3 X sheet thickness X 32 (conver8ng to 1/32s) Length = 1.5 X D + Total thickness of all sheets
Remember to convert to 1/16s

Length = (1.5 X D + Sheet 1 + Sheet 2 . . .) X 16

X 16 is to convert to 1/16s Remember to add all the sheets

Rivet Spacing
Distance is measured from the center of the rivet Edge distance 2 to 4 D Distance between rivets 3 to 10 D per AC43.13-1B
Handout says 3 to 12

Read AC43-13.1B Par 4-57 Rive8ng

Rivet Plates
4 X 6 #3, #4 and #5 rivet plates 2D edge distance 6 direc8on about 6D 4 direc8on about 75% of 6 Get paper design approved
Show math

Rivet Plate - #4
D = 1/8 = 0.125 6 side
Distance between rst and last
6 2D 2D = 6 4D 6 4 * 0.125 = 5.5

Rivet spacing is about 6D or 0.75

5.5 /0.75 = 7.3333 (use 7) 5.5 / 7 = 0.7857 = ~ 25.1/32

Rivet Plate - #4
4 side
Distance between rst and last
4 2D 2D = 4 4D 4 4 * 0.125 = 3.5

Rivet spacing is about 75% of 0.7857

0.7857 X 75% = 0.5893 3.5 / 0.5893 = 5.9392 (use 6) 3.5 / 6 = 0.5833 = ~18.6/32

Rivet Plate - #4

Remaining Topics
Aluminum sheet metal proper8es Bending Patch design Sheet metal fasteners Flush rive8ng

Aluminum Sheet Metal Strength

Alloys (e.g. 1100, 2024 & 6061) Treatment/tempering Thickness Shape Look at 43.12-1B Page 4-8 Table 4-5

Aluminum Sheet Hardness Temper

Work hardening
Work hardening Cold hardening Strain hardening

Heat trea8ng/hardening Age hardening Look at 43.12-1B Page 4-4

Metal Bending

Layout Procedure
1. Determine stock size or where to cut 2. Locate brake reference lines or where to bend 3. Mark centers or where to drill

Radius

Bending Brake

Bending Brake

Bending Brake

Bend Radius

Neutral Line

Bend

Deni8ons
MLD Mold Line Dimension the length of the side from the edge to the center of a perfect bend (0 radius) BTLD Bend Tangent Line Dimension the length of the side from the edge to the beginning of the bend BA Bend Allowance The area that will be bent Developed Width Length of the material used to make bracket

Bend

Set Back
SB Set Back the dierence between the Mold Line Distance and Bend Tangent Line Dimension
SB = MLD BTLD

Brake Reference
Brake Reference (Line) The line were the brake is lined up

Open Angle
Open Angle Bent less than 90

Page 3-19

Closed Angle
Closed Angle Bent greater than 90

Non 90 Angles
Set Back K * (T + R)
K is found 5-25A page 150 in AC 65-15

Bend Allowance: # of degrees * small number in 5-24 page 149 in AC 65-15

Countersinking

From AC65-15

Countersinking

Countersink

Microstop Countersink Cage

Dimple

Dimple

Also called a nest or well

Dimple Set

Dimple Set

Dimple Tool

Dimple Tools

Dimple Tools

Dimple Tools

Cold Dimpling
If possible use a smaller drill size
Die can stretch the rivet hole

Dont cold dimple hard metal Coin dimpling

Using a rivet as the male die Use a normal female die in special bucking bar Buck dimple Hard to reach places

Thermal Dimple Tools

Thermal Dimpling
Heated dies Use for hard metals
Reduces changes of cracking 7075-T6, magnesium or 8tanium

Radius
Solid female die

Coin
Sliding ram female die Forms a more uniform dimple (nest or well)

Thermal Dimpling

Countersink/Dimple

Flush Rivet Guidelines

Patching Skin Damage

Stop drill cracks or cut out damage.
Leave no stress risers no sharp corners

Calculate the number of rivets Make a paper design of a patch

Mark holes to insure no interference

Create a patch
Same material and same thickness or greater Patch will go under skin if possible

Patching Skin Damage

Make ller plug if needed Drill holes Apply corrosion inhibitor/primer Rivet Prime and Paint

Stop Drill

Rivet Spacing
Rivet pitch - the distance between the centers of adjacent rivets in the same row.
Minimum 3D; Maximum 10D Typical 6D to 8D

Transverse pitch - the perpendicular distance between rivet rows

75% of rivet pitch Minimum 2 1/2D

Edge Distance 2D to 4D

Rivet Spacing

Rivet Spacing

Elongated Octagonal Patch

AC65-15 Fig. 5-74 Page 190

Elongated Octagonal Patch

Round Patch

AC65-15 Fig. 5-76 Page 191

Turn Down Edge

AC65-15 Fig. 5-77 Page 192

Panel Repair

AC65-15 Fig. 5-78 Page 192

Patch Ideas
AC43.13 Fig. 1-15 Page 1-29

Patch Ideas

AC43.13 Fig. 1-17 Page 1-32

Your Guides
Follow manufacturers instruc8ons
Maintenance/Repair manual Copy hole rivet payern Use same material and rivets

Use AC43.13-1B Par 4-58 Read AC65-15 189-198

Number of Rivets
When any kind of repair to an aircraft structure is made. the basic requirement is to restore all of the strength that has been lost. There must be enough rivets on one side of the damage to carry all of the required stresses into the patch, with enough rivets on the opposite side to put the stresses back into the skin.

Number of Rivets - AC65-15

# Rivets = Length of Crack X Thickness of Metal Shear Strength N = L X T / Shear Strength Book says Shear or Bearing strength, which ever is less
A good joint should be based on Shear strength

User g 5-1 for Shear strength or g 5-2 for Bearing strength (page 128 or 129)

Number of Rivets AC43.13-1B

Use Tables 4-9, 4-10 or 4-11 for rivets per inch.
Page 4-37, 4-38 or 4-39

# Rivets = Length of crack X Rivets per inch # Rivets is only for one side. The rivet used is 2 X # Rivets

Crack

Patch

Blind Rivets
Also called Mechanically Expanded Rivet Installed by pulling on rivet stem
Installed with a pulling tool Blind Rivet need to access only on side No hammering
Used with some plas8cs and plywood

Nonstructural
Pop rivet Stem doesnt add strength Commonly used for engine baing and interiors

Structural Rivets
Cherry Rivets Cherrylock or Huck ShaQ mechanically locks inside rivet and creates the strength of the rivet Cherry 2000 one size larger than solid rivet CherryMax or 3000 same size as solid rivet
Only blind rivet interchangeable structurally with solid rivets

hyp://www.cherryaerospace.com/images/ anima8ons/cherrymax/CherryMax_100MS.swf

Structural Rivets Dimension

Diameter in 1/32s
Also available in oversize 1/64 over

Length in 1/16s
Also specied in grip length

Rivet specied like solid rivets

e.g. 4-3 or 5-4

Structural Rivets Grip

Structural Rivets Heads

Remove Blind Rivet

Hi-Shear
Same strength as a bolt Less labor to install than a bolt Lighter than a bolt Needs very specialized tools

Hi-Lok
Like Hi-Shear but can be installed with standard tools
Allen wrench and socket/box wrench

Turnlock Fasteners
Ayach inspec8on panels, cowls, and fairings Self contained hardware Half turn on or o Limited shear and bearing strength

Dzus

Camloc

Airloc

Nutplates

Rivnut