A/C MATERIALS

Definitiom

Aircraft Materials :
are materials (Ferrous & Non Ferrous) that
usually use in aviation indsutry
 OBJECTIVE

To understand type of alloys using in the

aircrafts
Identify characteristics and properties
common alloys.
Heat treatment and application of alloy
steels.
Testing for hardness, tensile, fatigue and
impact.
 INTRODUCTION
Properties of Metals
Primary concern in general properties of metals
and their alloys:
Hardness
Strength
Density
Malleability
Ductility
Elasticity
Toughness
Brittleness
Fusibility
Conductivity contraction and Thermal Expansion
 INTRODUCTION
Hardness
Hardness and Strength are closely associated
properties of materials; Hardness refers to the
ability of a metal 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.
Strength
Strength is the ability of a material to resist
deformation also resist stress without breaking.
 INTRODUCTION
Density
Is the weight of a unit volume of a material. The
specified weight of a material per cubic inch is
preferred use in determining the weight of a part
before actual manufacture.
Malleable
A metal which can be hammered, rolled, or
pressed into various shapes without cracking,
breaking (Copper is an example of a malleable
metal).
 INTRODUCTION
Ductility
Is the property of a metal which permits it to be
permanently drawn, bent, or twisted without
breaking (greatly preferred for aircraft, ease of
forming and resistance to failure). Ductility is
similar to malleability.
Elasticity
Is that property which enables a metal to return to
its original shape when the force which causes the
change of shape is removed.
 INTRODUCTION
Toughness
A material which possesses toughness will
withstand tearing or shearing and may be
stretched or otherwise deformed without breaking.
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.
 INTRODUCTION
Fusibility
Is the ability of a metal to become liquid by the
application of heat (Steels fuse around 2,600 F
and aluminum alloys approximately 1,100F).
Conductivity
Is the property which enables a metal to carry
heat or electricity.
 INTRODUCTION
Thermal Expansion (Contraction and
Expansion)
Are reactions produced in metals as the result of
heating or cooling.
Strength, weight, and reliability are three factors
which determine the requirements to be met used
in airframe construction and repair.
 FERROUS METALS
All metals fall within two categories,
Ferrous
Are iron-base alloys with small percentages of
carbon and other elements added to achieve
desirable properties (normally, ferrous metals are
magnetic).
Non-ferrous.
Metals which have elements other than iron as
their base (copper, brass, bronze, copper-nickel
alloys, lead, zinc, tin, aluminum, etc), these
metals are nonmagnetic.
 FERROUS METALS
The term FERROUS, is group of metals having
iron as their principal element.
If carbon is added to iron app 1% percentages
carbon, the product to iron alone is classified as
carbon steel (forms the base of those alloy
steels, combining carbon 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.
 FERROUS METALS
STEEL is manufactured from pig iron by
decreasing the amount of carbonand other
impurities and adding specific amounts of
alloying elements, controlling amounts of
alloying elements, the composition of steel is
determined by application and the specifications
that were developed by:
American Society for Testing and Materials
(ASTM),
American Society of Mechanical Engineers
(ASME),
Society of Automotive Engineers (SAE), and
American Iron and Steel Institute (AISI).
 FERROUS METALS
SAE number consists of a group of digits:
Four numeral series, used to designate the
plain carbon and alloy steel.
Five numerals are used to designate certain
types of alloy steels.
The first two digits represents the type of steel;
The second digit, generally gives amount of the
major alloying element; and
The last two (three digits), to indicate the middle
of carbon range.
 FERROUS METALS
Small quantities of certain elements are present in
alloy steels that are not specified required,
example copper 0.35%, nickel 0.25%, chromium
0.20, etc.

XX
X
XXX 10,11,12,15 Carbon Steel
23,25 Manganese
31,32,33,34 Nickel chromium
Major alloying element

Carbon range
 FERROUS METALS
SAE NUMERICAL INDEX (Major Classification)
TYPE OF STEEL CLASSIFICATION
Carbon 1xxx
Nickel 2xxx
Nickel-chromium 3xxx
Molybdenum 4xxx
Chromium 5xxx
Chromium-vanadium 6xxx
Tungsten 7xxx
Nickel-chromium-vanadium 8xxx
Silicon-manganese 9xxx
 FERROUS METALS
Types, Characteristics of Alloyed Steels
Carbon steel is a term applied to broad
range of steel (between pure ingot iron and
the cast irons) classified into:
Low-Carbon Steel 0.10% - 0.30% carbon
For safety wire, cable bushings - tough and ductile,
easily machined, formed, and welded (SAE 1010 to
1030)
Med-Carbon Steel 0.30% - 0.50% carbon
For certain rod end, crane hooks, axles, shafts -
strong and hard but cannot be welded (SAE 1035)
High carbon steel 0.50-1.05 carbon
For flat spring - classes responds well to heat treatment
and can be welded (SAE 1095).
 FERROUS METALS
Nickel steel produced by combining nickel (3 to 3.75 %)
with carbon steel. Nickel increases the hardness, tensile
strength, and elastic limit without appreciably decreasing
the ductility also intensifies the hardening effect of heat
treatment.
SAE 2330 steel, is used extensively for aircraft parts, such as
bolts, terminals, keys, clevises, and pins.
Chromium steel is high in hardness, strength, and
corrosion resistant properties adaptable for heat-treated,
which require greater toughness and strength than may be
obtained in plain carbon steel.
Used for such articles as the balls and rollers of antifriction
bearings.
 FERROUS METALS
Nickel - for alloying steel as.
1% - 5 % nickle > improve strength and hardness without
lowering ductility.
25% nickle > becomes highly corrosion-resistance, heat
resistance and non magnetic.
36% nickle > (trade name INVAR) lowest coefficient of
expansion excellent for master gauge and instrument.
These alloys are used in thermostats spark-plug electrodes
because effect the expansion properties.
Nickel Alloy Most nickel-based alloy (Nimonics contains
50%-80% nickle).
MONEL (68% nickel, 29% copper with iron manganese,
silicon and carbon) is non-magnetic.
K-Monel - produced by adding a small amount of aluminum
to the Monel formula, can be hardened.
 FERROUS METALS
Chrome-nickel or Stainless steels corrosion
resistant steel. The principal alloy of stainless steel is
chromium often used in aircraft construction is known as 18-
8 steel (content of 18 percent chromium and 8 percent
nickel) its strength may be increased by cold working.
SAE 2330 steel, is used extensively for aircraft parts, such as
bolts, terminals, keys, clevises, and pins.
Stainless steel may be rolled, drawn, bent, or formed to any
shape. Used for almost any part of an aircraft. Some of its
common applications are in the fabrication of exhaust
collectors, stacks and manifolds, structural and machined
parts, springs, castings, tie rods, and control cables.
 FERROUS METALS
Chrome-vanadium steels (18% Vanadium and 1%
Chromium) When heat treated, they have strength,
toughness, and resistance to wear and fatigue. Can be
folded and flattened without signs of breaking or failure.
SAE 6150 is used for making springs; chrome-vanadium with
high carbon content. SAE 6195, is used for ball and roller
bearings.
Chrome-molybdenum steel (small percentages
Molybdenum combination with Chromium). Is a strong
alloying element, Molybdenum steels are tough and wear
resistant, and they harden throughout when heat treated,
adaptable for welding.
A series of chrome-molybdenum steel used in aircraft
construction is that series containing 0.25 to 0.55 % carbon,
0.15 to 0.25 % molybdenum, and 0.50 to 1.10 % chromium.
 FERROUS METALS
Inconel (nickel-chromium-iron alloy) closely resembling
stainless steel (corrosion resistant steel, CRES).
Inconel has a nickel content greater than 50 percent, and
the electrochemical test detects nickel.
 NON FERROUS METALS
All metals which have elements other than iron as their base
or principal constituent, includes such metals as aluminum,
titanium, copper, and magnesium.
Aluminum and Aluminum Alloys
Commercially pure aluminum is a white lustrous metal, high
in its resistance to corrosion.
Aluminum alloys in which the principal alloying ingredients
are manganese, chromium, or magnesium and silicon show
little attack in corrosive environments.
Alloys in which substantial percentages of copper are used
are more susceptible to corrosive action.
 NON FERROUS METALS
Aluminum most widely used metals in modern aircraft
construction its high strength to weight ratio and its
comparative ease of fabrication.
Commercially pure aluminum has a tensile strength 13,000
psi, its strength may be doubled by rolling or other cold
working processes.
By alloying with other metals, or by using heat-treating
processes, the tensile strength may be raised to as high
as 65,000 psi or to within the strength range of structural
steel.
The various types of aluminum may be divided into two
general classes:
1. Casting alloys (casting in SAND, PERMANENT MOLD,
DIE CASTINGS) and
2. Wrought alloys (which may be shaped by ROLLING,
DRAWING, or FORGING).
Wrought alloys are the most widely used in aircraft
construction, used for stringers, bulkheads, skin, rivets,
 NON FERROUS METALS
Aluminum casting alloys
Two basic groups:
Physical properties of the alloys are determined by the
alloying elements (cannot be changed after the metal is
cast)
The alloying elements make it possible to heat treat to
produce the desired physical properties
Identified by a letter preceding the alloy
number, casting alloy 214 when additional of
zinc to improve its qualities indicated by
A214.
When castings have been heat treated and the
composition of the casting is indicated by letter T
(casting alloy 355 designated by 355-T6, 355-T51)
 NON FERROUS METALS

A 214 T 6
Improve its qualities
Casting alloy
Heat treated
Composition alloying of casting
 NON FERROUS METALS
To produce aluminum alloys casting
Three are basic methods :
Sand mold
Permanent mold
The permanent metal mold with metal
cores
The semi permanent types containing
sand cores
Die cast, used in aircraft are usually
aluminum or magnesium alloys (by forcing
molten metal under high pressure into a mould cavity)
NON FERROUS METALS
 NON FERROUS METALS
Wrought Aluminum and Wrought Aluminum
Alloys
Non Heat treatable:
Mechanical properties are determined by the amount of
cold work introduced after the final annealing
operation.
Heat treatable:
Mechanical properties are obtained by heat treating to
a suitable temperature, holding at that temperature
long enough to allow the alloying constituent to enter
into solid solution, and then quenching to hold the
constituent in solution.
 NON FERROUS METALS
Wrought aluminum and wrought aluminum alloys
designated by a four-digits index system,
divided into three group:
1xxx group,
2xxx through 8xxx group,
9xxx group.
 NON FERROUS METALS
Group 1xxx

XX XX
XX XX
Alloy Type
Alloy Modification
0: original alloy (no special
control)
1-9: alloy
The modification
hundredths of 1% >
original 99%.
30 - 99.30% pure aluminum
90 - 99.90% pure aluminum.
 NON FERROUS METALS
1030 indicates

Aluminum of 99.00 %
Aluminumwithout special control.
1, 2, 3 with special control on one
or more impurities.
Indicates99.30 % aluminum.
1075, 1175, 1275 indicate 99.75
% aluminum.

1100 99.00% pure all, one control

1130 99.30% pure all, one control
1275 99.75% pure all, two control
 NON FERROUS METALS
Group 2xxx 8xxx

X
XX
X XX
XX
Major Alloy Type
Alloy Modification
0: original alloy
1-9: alloy modification
Different alloys in group.
 NON FERROUS METALS
Designations for Aluminum Alloy Groups

Aluminum 99.0% min and greater 1 xxx

Aluminum alloys, grouped by major alloying elements

Copper 2 XXX

Manganese 3 XXX

Silicon 4 XXX

Magnesium 5 XXX

Magnesium and Silicon 6 XXX

Zinc 7 XXX

Other elements 8 XXX

NON FERROUS METALS
 NON FERROUS METALS
Effect of Alloying Element:
1000 series. 99 % aluminum or higher, excellent
corrosion resistance, high thermal and electrical
conductivity, low mechanical properties, excellent
workability. Iron and silicon are major impurities ,
2000 series. Copper is the principal alloying element. t is
usually clad with 6000 or high purity alloy. Its best known
alloy is 2024.
3000 series. Manganese is the principal alloying. The
most popular is 3003, which is of moderate strength.
4000 series. Silicon is the principal alloying. Its primary
use is in welding and brazing.
5000 series. Magnesium is the principal alloying. It has
good welding and corrosion resistant characteristics.
6000 series. Silicon and magnesium form magnesium
silicide which makes alloys heat treatable. It is of medium
strength,
 NON FERROUS METALS
Effect of Alloying Element:
7000 series. Zinc is the principal alloying, the most
popular alloy of the series is 6061. When coupled with
magnesium, usually has copper and chromium added. The
principal alloy of this group is 7075.
 NON FERROUS METALS
Hardness identification designated the alloy designation
and shows the actual condition of the metal, separated
from the alloy designation by a dash.
F following the alloy designation indicates the as
fabricated condition.
O indicatesdead soft, or annealed, condition.
H indicates strainhardened, cold-worked, hand-drawn, or
rolled.
H1, strain hardened
H2, strain hardened and partially annealed
H3, strain hardened and stabilized
Numbers 1, 2, 3 indicates degrees of strain hardening.
 NON FERROUS METALS
Some different symbols are designated by:
W indicates solution heat treated (consists of heating the
metal to a high temperature followed by a rapid quench in
cold water.
T indicates fully heat treated.
T2 Annealed (cast product only)
T3 Solution heat treated, cold worked
T4 Solution heat treated
T5 Artificially aged only
T6 Solution heat treated, artificially aged
T7 Solution heat treated, stabilized
T8 Solution heat treated, cold worked, artificially aged
T9 Solution heat treated, artificially aged, cold worked
T10 Artificially aged and then cold worked.
 NON FERROUS METALS
Magnesium and Magnesium Alloys
Lightest structural metal (a silvery white material) only
two-thirds as much as aluminum in weight.
Magnesium does not possess sufficient strength in its
pure state for structural uses, but when alloyed with
zinc, aluminum, and manganese it produces an alloy
having the highest strength to weight ratio of any of
the commonly used metals.
Magnesium embodies fire hazards of an unpredictable
nature, it will not burn until the melting point of 1,204
F is reached.
Precautions must be taken to avoid of magnesium dust
and fine chips (are ignited easily). Should a fire occur, it
can be extinguished with an extinguishing powder,
such as soapstone or graphite.
 NON FERROUS METALS
Titanium and Titanium Alloy
In aircraft construction and repair used for
fuselage skins, engine shrouds, firewalls,
longerons, frames, fittings, air ducts, and
fasteners.
In turbine engine used for making compressor
disks, spacer rings, compressor blades and vanes.
Titanium falls between aluminum and stainless
steel (elasticity, density, and elevated
temperature strength), melting point of from 2,730
F to 3,155 F, low thermal conductivity, and a low
coefficient of expansion.
 NON FERROUS METALS
Titanium Designation
Titanium and Titanium Alloys are basically
have three basic types of crystals:
A (Alpha), good weld ability; tough and strong,
resists to oxidation.
B (Beta), bend ability; excellent bend ductility
but sensitive to contamination.
C (Alpha and Beta) strong when cold and
warm, weak when hot.
Easily identified when touched with a grinding
wheel, it makes white spark traces that end in
brilliant white bursts.
When rubbed with a piece of glass, moistened
titanium will leave a dark line similar in
appearance to a pencil mark.
 NON FERROUS METALS
Copper and Copper Alloy
Its use as a structural material is limited because
of its great weight, its high electrical and heat
conductivity.
Used primarily in the electrical system for bus
bars, bonding, and as lock-wire.
Beryllium copper - the copper base alloys
developed containing about 97% copper, 2%
beryllium, and sufficient nickel to increase of
elongation.
Brass - copper alloy containing zinc and small
amounts of aluminum, iron, lead, manganese,
magnesium, nickel, phosphorous, and tin.
 NON FERROUS METALS
Copper and Copper Alloy
Muntz metal - brass composed of 60% copper
and 40% zinc, has excellent corrosion resistant
qualities in salt water.
Red brass (bronze) - its are copper alloys tin
content (up to 25%).
Copper alloys - the copper aluminum alloys of
which the aluminum bronzes, Wrought aluminum
bronzes are almost as strong and ductile as
medium carbon steel, contain up to 16% of
aluminum (usually 5 to 11%), to which other
metals, such as iron, nickel, or manganese, may
be added.
Cast aluminum bronzes, using 89% copper, 9%
aluminum, and 2% of other elements (high
 NON FERROUS METALS
Manganese bronze - is an exceptionally high
strength, tough, corrosion resistant copper zinc alloy
containing aluminum, manganese, iron and,
occasionally, nickel or tin.
Silicon bronze - is a more recent development
composed of about 95% copper, 3% silicon, and 2%
manganese, zinc, iron, tin, and aluminum, has high
strength and great corrosion resistance.
Monel (high nickel alloy) have properties of high
strength and excellent corrosion resistance, consists of
68% nickel, 29% copper, 0.2% iron, 1% manganese,
and 1.8% of other elements. It cannot be hardened by
heat treatment.
K-Monel - containing mainly nickel, copper, and
aluminum. Is produced by adding a small amount of
aluminum to the Monel formula. Corrosion resistant and
 NON FERROUS METALS
Nickel and Nickel Alloy
Basically two nickel alloys used in aircraft:
Inconel alloys of nickel produce a high strength,
high temperature alloy containing approximately
80% nickel, 14% chromium, and small amounts
of iron and other elements (corrosion resistance
under extremely high temperature conditions).
 NON FERROUS METALS
Substitution of Aircraft Metals
The most important for repair and maintenance to
check the appropriate structural repair manual
(maintaining the original strength of the
structure), others:
Maintaining contour (aerodynamic smoothness),
Maintaining original weight, if possible, and
Maintaining the original corrosion resistant
properties of the metal.
 METAL WORKING PROCESSES
There are three methods of metal working:
Hot-working
From the ingot into some of process either
hot or cold-worked to the finished shape,
stripped ingot from its mold (surface solid,
interior molten); then placed in soaking
process (loosing heat to solid interior)
make it throughout the ingot by rolling
more readily handled.
 METAL WORKING PROCESSES
There are three methods of metal working:
Cold-working
Mechanical working performed at below
critical range of temperature (make it
strain harden, difficult to forming without
softening by annealing).
There are two cold-working processes are:
Cold-rolling (working at room
temperature)
Cold-drawing (making wire, dried in a
steam room).
These processes give the metals desirable
qualities reduced ductility, increase
 METAL WORKING PROCESSES
Cold-rolling usually refers to the working of
metal at room temperature, this operation,
the materials that have been hot-rolled to
approximate sizes are pickled to remove
any scale, after which they are passed
through chilled finished rolls.
 METAL WORKING PROCESSES
Cold-drawingis used in making seamless
tubing, wire, streamline tie rods, and
other forms of stock (made from hot-
rolled rods of various diameters).
Drawn rod Drawing jaw

Hot rolled rod

25% - 45% reduction

Steel die for each draw
 METAL WORKING PROCESSES
There are three methods of metal working:
Extruding
Forcing of the metal through die opening
(flexible), to shape desired for the cross
section (Channel, angles, T-sections, and
Z-sections).
 METAL WORKING PROCESSES
To relieve strain and reduce brittleness, it is
tempered after being hardened. This consists of
heating in a furnace to a specified temperature
and then cooling it in air, oil, water, or a special
solution. Temper condition refers to the condition
of metal.
Heat treatment is accomplished in:
Stage 1, Heating the metal slowly to ensure a
uniform temperature.
Stage 2, Soaking (holding) the metal at a given
temperature for a given time (soaking period).
Stage 3, Cooling the metal to room temperature
with cooling medium.
 METAL WORKING PROCESSES
Rolling, hammering, or bending these alloys, or
heat treating causes to become tougher and
harder, have to be re-heat treated or annealed.
Annealed to relieve internal stresses, soften the
metal, make it more ductile (heating the metal to a
prescribed temperature, holding it there for a
specified length of time, and then cooling the metal
back to room temperature).
 METAL WORKING PROCESSES
There are five basic stresses which metals
may be required to withstand, these are:
Tension,
Its resistance to a force which tends to
pull it apart, is measured in p.s.i and is
calculated by dividing the load, in pounds
by its cross-sectional area, in square
inches.
Compression,
Its resistance to a crushing force which is
the opposite of tensile strength.
Compression strength is also measured in
p.s.i.
 METAL WORKING PROCESSES
There are five basic stresses which metals
may be required to withstand, these are:
Shear,
Is the tendency on the part of parallel
members to slide in opposite directions, the
shear strength is the shear force in p.s.i. at
which a material fails.
Bending,
Strength of material is the resistance it offers
to deflecting forces.
Torsion.
Is a twisting force (a member fixed at one
end and twisted at the other).
 METAL WORKING PROCESSES
To develop certain desirable characteristics
of metal which involves controlled heating
and cooling of metals (called heat
treatment or heat treating)
Heat Treatment Theory - processes are
similar (involve the heating and cooling),
differ in the heating temperature and
cooling rates used.
METAL WORKING PROCESSES
METAL WORKING PROCESSES
METAL WORKING PROCESSES
 METAL WORKING PROCESSES
HEAT TREATMENT OF FERROUS METAL:
HARDENING
Heating the steel to a set temperature and
then cooling it rapidly by plunging it into
oil, water, or brine.
Air-cooled, increases the hardness and strength
of the steel but makes it less ductile more brittle.
To remove some of the brittleness should temper
the steel after hardening.
 METAL WORKING PROCESSES
HEAT TREATMENT OF FERROUS METAL:
TEMPERING
After the hardeningtreatment, steel is often
harder and too brittle also severe internal
stresses are set up during the rapid cooling from
hardening temperature. To relieve the internal
stresses and reduce brittleness, temper the steel
after it is hardened.
Tempering, heating the steel to a specific
temperature (below its hardening temperature),
holding it at that temperature and then cooling it
usually instill air.
 METAL WORKING PROCESSES
HEAT TREATMENT OF FERROUS METAL:
NORMALIZING
The metal is heated to a higher
temperature (upper critical point) and then
removed from the furnace for air cooling.
The purpose of normalizing is to remove the
internal stresses induced by heat treating,
welding, casting, forging, forming, or machining.
 METAL WORKING PROCESSES
HEAT TREATMENT OF FERROUS METAL:
ANNEALING
The opposite of hardening, to relieve
internal stresses, soften and make them more
ductile, refine their grain structures.
Heating a metal to a specific temperature (just
above the upper critical point), holding it at that
temperature then cooling the metal to room
temperature.
 METAL WORKING PROCESSES
HEAT TREATMENT OF FERROUS METAL:
CASE HARDENING
Produces a hard, wear-resistant surface,
the principal forms of casehardening:
Carburizing,
Cyaniding, and
Nitriding.
 METAL WORKING PROCESSES
Carburizing
A case-hardening process by which carbon is
added to the surface of low-carbon steel. The
case of steel becomes hardened and the core
remains soft and tough.
Method of carburizing
Pack Carburizing
Packed in a container with charcoal or other material
rich in carbon, heated to approximately 1,700 F and
soaked at that temperature for several hours.
Gas Carburizing
A material rich in carbon introduced into the furnace
atmosphere by the use of various gases or by the
burning of oil, wood, or other materials.
 METAL WORKING PROCESSES
Carburizing
A case-hardening process by which carbon is
added to the surface of low-carbon steel. The
case of steel becomes hardened and the core
remains soft and tough.
Method of carburizing
Liquid Carburizing
The steel is placed in a molten salt bath contains the
chemicals required to produce a case.
 METAL WORKING PROCESSES
Cyaniding
Type of case hardening that is fast and efficient.
Preheated steel is dipped into a heated cyanide bath
and allowed to soak this process produces a thin, is not
used in aircraft work; that cyanide salts are a
deadlypoison.
Nitriding
This method produces the hardest surface.
It differs from the other methods in that the individual
parts have been heat-treated and tempered before
nitriding, heated in a furnace that has an ammonia gas.
The part is placed in a special nitriding furnace and
heated to a temperature of approximately 1,000 F
 METAL WORKING PROCESSES
Alclad, is a protective covering of a thin sheet
pure aluminum 5.5% on the surface of an
aluminum alloy (Zinc chromate is a protective
that can be applied to an aluminum surface,
used a primer on steel surfaces).
Alclad is the name given to standard aluminum
alloys that have been coated on both sides with
a thin layer of pure aluminum, has very good
corrosion-resisting qualities and is used
exclusively for exterior surfaces of aircraft.
Alclad sheets are available in all tempers of 2014,
2017, 7075, and 7178.
 METAL WORKING PROCESSES
HEAT TREATMENT OF ALUMINUM
ALLOY RIVETS
Alloy 1100 rivets as fabricated for riveting aluminum
alloy condition (low strength rivet)
Alloy 5056 rivets as fabricated condition for riveting
magnesium alloy
Alloy 2117 rivets moderately high strength receive only
one heat treatment (no further heat treatment before they
are used), after heat treatment and can be driven anytime.
Alloy 2017 and 2024 rivets high strength rivets (heat-
treated condition), must be reheat treated before they are
to be used.
Alloy 2017 rivets - become too hard for driving in
approximately 1 hour after quenching.
Alloy 2024 rivets - become hardened in 10 minutes after
quenching
These rivets are stored in a refrigerator (temp lower than
 METAL WORKING PROCESSES
HEAT TREATMENT OF NON FERROUS
METAL:
Solution Heat Treatment
Precipitation Heat Treatment
The hardening of an aluminum alloy by heat
treatment process consists:
Heating to predetermined temperature
(solution heat treatment),
Soaking at temperature (specified length of
time),
Rapidly quenching (relatively low
temperature) and
Aging or precipitation hardening
(spontaneously at room temperature).
METAL WORKING PROCESSES
 HARDNESS TEST
Method of determining the results of heat
treatment metal prior to heat treatment,
hardness testing equipments use the
resistance to penetration as a measure
of hardness are:
Brinell
Uses a hardened spherical ball
0.3937 inch (10MM) , which is
forced into the surface of the metal.
3,000 kilograms (6,600 pounds) be
maintain at least 10 sec is used for
ferrous metals and 500 kilograms at
least 30 sec for nonferrous metals.
 HARDNESS TEST
Method of determining the results of heat
treatment metal prior to heat treatment,
hardness testing equipments use the
resistance to penetration as a measure
of hardness are:
Brinell
The load is applied by hydraulic
pressure (hand pump or an electric
motor), a press gauge indicates the
amount of pressure. To determine the
Brinell hardness number, the diameter
of the impression is first measured,
using microscope than converted into
the Brinell hardness number.
HARDNESS TEST
HARDNESS TEST
 HARDNESS TEST
Rockwell
Measures depth and hardness is
indicated directly on a dial
attached.
Types of penetration are used a
Diamond cone and hardened
steel Ball. The results of each
penetrator and load combination
are reported on separate scales,
designated by letters
(Penetrator, Major load, and the
Scale vary with the kind of
metal being tested)
HARDNESS TEST
 HARDNESS TEST
Vickers
VHN, measured by average diagonals (d1 and d2),
convert to the table.
 HARDNESS TEST
Barcol Tester
A portable unit designed for testing
relatively soft materials aluminum
alloys, copper, brass.
Only necessary to exert a light
pressure against the instrument to
drive the spring loaded indenter into
the material to be tested. The
hardness reading is instantly
indicated on the dial.
 NON METALLIC MATERIALS
Airframe construction
Reinforced plastics and
Advanced composite
Plastics
Thermosetting plastics,
Harden upon heating, and reheating has no softening
effect. These plastics cannot be reshaped once being
fully cured
Thermoplastic.
Will soften when heated and harden when cooled can
be heated until soft, and then formed into the desired
shape. When cooled, they will retain this shape.
 NON METALLIC MATERIALS
Non metallic aircraft construction
Reinforced plastics and
Advanced composite
Material is defined as a mixture of different materials or
things to enhance the strength, ductility.
Composite materials is a combination of reinforcement
surrounded and held in place by a resin.
 NON METALLIC MATERIALS
Combination of two or more materials (reinforcing
elements, fillers, and composite matrix binder).
Used in aircraft structures due to good
combination of weight saving and mechanical
properties.
Composite structures are made of a number of
fibers and epoxy resin laminates bonded to a
substructure such as aluminum or nonmetallic
honeycomb.
Numerous combinations of composite materials:
Graphite/epoxy, Kevlar/epoxy, Boron polyamide,
graphite polyamide, Boron-coated boron
aluminum, Coated boron titanium, Boron graphite
epoxy hybrid, and Boron/epoxy.
 NON METALLIC MATERIALS

GLASS FIBER ARMID FIBER CARBON FIBER HYBRID FIBER

 NON METALLIC MATERIALS
Composite products can be very harmful to the skin, eyes,
become sensitized to the materials with serious irritation
and health .
 NON METALLIC MATERIALS
Advantages:
High strength to weight ratio stiffness-to-weight-ratio
20 to 30% than aluminum.
Bonded construction eliminates joints and fasteners.
Higher corrosion resistance.

Disadvantages:
Inspection methods difficult to conduct. NDI is
required to analyze damage.
Very expensive processing equipment.
Lack of standardized methodology for construction
and repairs.
 NON METALLIC MATERIALS
RUBBER
Natural Rubber
Flexibility, elasticity, tensile strength, tear strength,
general purpose product.
Synthetic Rubber
Widely used are the Butyls, Bunas, and Neoprene
Butyl is a hydrocarbon rubber resist oxygen, vegetable
oils, used with phosphate ester hydraulic fluids (Skydrol),
silicone fluids, gases, ketones, and acetones.
Buna-S rubber is as water resistant as natural rubber
resistance to heat, is normally used for tires and tubes as a
substitute for natural rubber.
Buna-N have good resistance to temperatures up to 300
F, Buna-N is used for oil and gasoline hose, tank linings,
gaskets, and seals.
 NON METALLIC MATERIALS
RUBBER
Silicone Rubber
Silicone rubbers are a group of plastic rubber materials
made from silicon, oxygen, hydrogen, and carbon excellent
heat stability and very low temperature flexibility.
 NON METALLIC MATERIALS
SEALS
Used to prevent fluid from passing a certain point,
as well as to keep air and dirt out of the system
in which they are used.
Satisfactory for all installations depend
Pressure at which the system operates.
The type fluid used
The metal finish and the clearance
The type motion
Seals are divided into three main classes:
(1) Packings
(2) Gaskets, and
(3) Wipers
 NON METALLIC MATERIALS
Packings
Made of synthetic or natural rubber, generally
used as running seals, contain moving parts,
such as actuating cylinders, pumps, selector
valves.
Packings are made in the for:
O-rings.
Used to prevent both internal and external
leakage, effectively in both directions, backup
rings are
Color used
codes on with O-rings
O-rings
indicates fluid compatibility:
RED for fuel, BLUE for
hydraulic fluid
 NON METALLIC MATERIALS
Packings
Made of synthetic or natural rubber, generally
used as running seals, contain moving parts,
such as actuating cylinders, pumps, selector
valves.
Packings are made in the for:
V-rings.
One-way seals and are always installed with the
open a
end of the
andV facing the pressure
Have male female
adapter to hold them in the
proper position after
installation
 NON METALLIC MATERIALS
Packings
Made of synthetic or natural rubber, generally
used as running seals, contain moving parts,
such as actuating cylinders, pumps, selector
valves.
Packings are made in the for:
U-rings.
U-ring and U-cup will seal pressure in only one
direction used
used with
in brake
Primarily low assemblies and brake
master cylinders.
pressure less than 1,000
psi.
 NON METALLIC MATERIALS
Gaskets
Used as static (stationary) seals between two flat
surfaces, common gasket materials are asbestos,
copper, cork, and rubber.
Wipers
Used to clean and lubricate the exposed portions
of piston shafts, prevent dirt from entering the
system and help protect the piston shaft.
 NON METALLIC MATERIALS
Sealing Compounds
To prevent leakage of fuel, to prevent passage of
fumes, or to prevent corrosion by sealing against
the weather, to withstand pressurization by air.
Consist of two or more ingredients properly
proportioned and compounded to obtain the best
results. Some materials are ready for use as
packaged (one part sealant), but others will
require mixing before application (two part
sealants).
 NON METALLIC MATERIALS
Sealing Compounds
Two-part sealants are mixed by combining equal
portions (by weight) of base compound and
accelerator.
Carefully weighed in accordance with the sealant
manufacturers recommendations. Sealant
material is usually weighed with a balance scale
equipped with weights specially prepared for
various quantities of sealant and accelerator.
 APPRAISAL SELFTEST

The high purity aluminum code number

1100 identifies what type of aluminum?

Al All containing 11 percent copper.

99% commercially pure aluminum.
 APPRAISAL SELFTEST

Tempering, Normalizing,Hardening, and

Annealing are common forms of what
process?

Heat treatment of nonferrous metals.

Heat treatment of ferrous metal.
 APPRAISAL SELFTEST

A metal alloy is a

Having metallic properties.

Pure metal compound.
 APPRAISAL SELFTEST

A numbering system that classifies

different aluminum alloys, the letter T
signifies that what action has occurred?

The alloying elements have been

tempered.
The metal has been heat-treated.
 APPRAISAL SELFTEST

What case-hardening method produces

the hardest surface of any of the
hardening processes?

Cyaniding.
Carburizing.
 APPRAISAL SELFTEST

What is the type and composition of SAE

5135 steel?

Nickel steel,5%steel, 1% nickel, and

0.35% carbon.
Chromium steel, 1% chromium and
0.35% carbon.
 APPRAISAL SELFTEST

An aluminum alloy that is fully heat

treated will have what letter
designation?

F.
T.
 APPRAISAL SELFTEST

Which of the following penetrations are

used with the Rockwell hardness tester?

Diamond cone and Steel ball.

Spiral point and Steel ball.
 APPRAISAL SELFTEST

In the aluminum alloy designation A355-

T51, what does the prefix A indicate?

The type of casting.

The composition of the casting.
 APPRAISAL SELFTEST

The resistance to stretching of an object

produced by two forces pulling in
opposite directions along the same
straight line is known as what type of
stress?

Bending.
Tension.
 APPRAISAL SELFTEST

Whichof the following statements is

correct concerning an aluminum sheet
designated 1075?

It is 99.75 percent aluminum.

It contains 0.75 percent carbon.
 APPRAISAL SELFTEST

What are the three basic methods of

metal working?

Hot-working, Cold-working, and

Extruding.
Hot-working, Cold-working, and Rolling.
 APPRAISAL SELFTEST

What are the most important factors in

aircraft construction?

Maintaining original strength.

Speed, strength, and weight.
 APPRAISAL SELFTEST

The damage to advanced composite

materials may be categorized in which of
the following ways?

Physical or environmental.
Organic or environmental.
A/C HARDWARE
 INTRODUCTIONS

Aircraft Hardware is types of fasteners are used in

the manufacture and repair of aircraft.
The importance overlooked of aircraft
hardware:
Safe
Efficient operation
Dependent upon the correct selection and use of
aircraft hardware.
 INTRODUCTIONS
Fastening devices allow quick or replacement of
aircraft parts.
Bolts,
Rivets,
Screws,
Welding,
Bonding.
 INTRODUCTIONS
Identified by specification number or trade name,
usually identified by:
AN (Air Force-Navy),
NAS (National Aircraft Standard),
MS (Military Standard).
Quick-release fasteners are usually identified by
factory trade names and size designations.
 INTRODUCTIONS
Fastening devices allow quick dismantling or
replacement that must be taken apart and put
back together.
Some joints require tensile strength and stiffness
than rivets can provide.
Bolt and screw are two type fastening which
required security for attachment.
Bolts are used where great strength is required,
screws are used where strength is not the deciding
factor.
 INTRODUCTIONS
A bolt assembly is generally tightened by turning
the nut, head of bolt may or may not be designed
for turning.

A screw is always tightened by turning its head.

Replacement of aircraft fasteners, a duplicate of

the original fastener should be used. If not
available caution selecting substituted.
 INTRODUCTIONS
Classification of Threads
NC (American National Coarse) thread series,
UNC (American Standard Unified Coarse) thread
series,
NF (American National Fine) thread series,
UNF (American Standard Unified Fine) thread
series.
NF thread specifies14 threads per inch (1-14
NF),
UNF
For thread
example, specifies
a 4-28 thread12indicates
threads per
thatinch (1-12
a 14-
inchUNF)
(416 inch) diameter bolt has 28 threads in 1
inch of its threaded length.
 INTRODUCTIONS
Classification fit of threads:
Class 1 is a loose fit
Class 2 is a free fit
Class 3 is a medium fit
Class 4 is a close fit
Also produced with Right-Hand and Left-Hand
threads. A right-hand thread tightens when
turned clockwise; a left-hand thread tightens
when turned counterclockwise.
 BOLTS
The three principal parts of a bolt are
theHead, Grip, andThreads.
 BOLTS
Fabricated form:
Cadmium or zinc-plated corrosion resistance
steel
Anodized aluminum alloys.
Bolts used in aircraft structures are:
General-purpose (AN),
Internal wrenching (MS or NAS),
Close tolerance (AN or NAS).
Special bolts are usually stamped by S on the
head.
 BOLTS
AN bolts come in three head styles; hex head,
clevis, and eyebolt.
NAS bolts are countersunk, internal wrenching,
and hex head styles.
MS bolts come in; hex head, internal wrenching.

Hex head Clevis bolt Eye bolt

Internal wrenching Countersunk

 BOLTS
General-purpose Bolts.
Hex-head bolts include all part numbers beginning
with AN 3, AN 4, through AN 20; used for general
application involving tension or shear loads for a
5/8 inch hole.
Alloy steel bolt < No. 10-32 and all alloy bolt <
inch are not used in primary structure.
Al all bolt and nut are not used where they
repeatedly removed for maintenance or
inspection.
AN 73 drilled head similar to standard hex bolt, AN
3 and AN 73 series are interchange.
 BOLTS
Close Tolerance Bolts (More accurately).
This type is machined bolts
AN-173 through AN-186 hex-headed or
NAS-80 through NAS-86 have 100O countersunk
head.
They are used in tight application, will move into
position when struck with 12 14 ounce
Internal-Wrenching
hammer. Bolts.
MS-20004 through MS-20024 or
NAS-495.
Fabricated from high-strength steel used in tension
and shear applications.
 BOLTS
IDENTIFICATION AND CODING.
Bolts can be identified by:
The shape of the head,
Method securing,
Material used.
Markings on the bolt heads.
Generally denote:
Manufacturer,
Material,
Standard types.
 BOLTS
AN standard steel bolts are marked with:
Raised dash (-) or asterisk (*),
Corrosion-resistant steel by single raised dash
(-),
AN all alloy bolts are marked with two raised
dash (- -).
 BOLTS
AN4-20A
AN Air Force
4 Navy
4/16 inch (1/4
- inch)
Material (corrosion
20 resist steel)(2
Grip length
A inch)
Safe tying provisions
Bolt is not drilled, no
letter bolt shank would
be drilled.
 BOLTS
AN3DD5A
AN Air Force
3 Navy
3/16 inch
DD C corrosion
Material (2024resistant
Al all)
5 Grip
steellength (5/8)
A A shank undrilled
H 5A Head drilled for
safetying.
 BOLTS
NAS part number (special internal wrenching)
NAS144-25
NAS National Aircraft Standard
14 First two digits (class bolt)
4 in sixteenths (4/16 inch)
25 Grip length (25/16 inch)

MS part number
MS20004-H-9
MS Military Standard
20004 Series class bolt inch
H Drilled head for safe tying
9 Grip length (9/16 inch)
 BOLTS
Special Purpose bolts:
Clevis Bolts,
Eye Bolts,
Jo-Bolts,
Lock Bolts
 BOLTS
Clevis Bolts,
Head of clevis bolt is round and have slotted for
common screw driver or recessed for cross-point screw
driver, used where shear load occur.

Eye Bolts,
Used where external tension load, designed for
attachment such as fork of turnbuckle, clevis or cable
shackle. Threaded end may or may not be drilled for
safe tying.
 BOLTS
Jo Bolts,
Consists of a threaded steel alloy bolt, a
threaded steel nut, expandable stainless
steel sleeve.
Installation, by turning a bolt while the nut
is held; causes the sleeve to expand over
the end of nut, forming the blind head.
When driving complete, a portion of bolt breaks off.
Installed for permanent structure attachment (not
often to replacement), excellent resist to vibration.
 BOLTS
Jo Bolts,
Are available in:
200 series have approximately 3/16 in .
260 series have 1/4 in .
312 series have 5/16 in .
375 series have 3/8 in .
Available in three head styles F (flush), P (hex
head), FA (Flush millable).
 BOLTS
Lock Bolts,
Like rivet, requires a pneumatic hammer or pull
gun to installation are:
Pull type,
Stump type,
Blind type.
 BOLTS
Pull type,
Require a special pneumatic pull-gun when
installation, accomplished by one person since
bucking is not required.
 BOLTS
Stump type,
Do not have the extended stem with pull groove,
are companion to pull-type lock bolts.
Used where clearance will not permit installation
of the pull type, standard pneumatic rivet hammer
and bucking bar are necessary use for installation.
 BOLTS
Blind type,
Installation of this type same manner as a
pull-type.
Complete unit assemblies, are used
where only one side of work is accessible
where it is difficult to drive a conventional
rivet.
 BOLTS
Common feature of lock-bolts are the annular
locking grooves on the pin and the locking collar
which is swaged into the pin lock grooves to lock
the pin
The pinsinoftension.
the pull-type and
blind-type lock bolts are
extended for installation.
The extension is provided with
pulling grooves and a tension
break-off groove.
 BOLTS
Grip Range is required should be determined by
measuring the thickness of the material, selected by
referring to the charts.

The lock bolt collar should be

swaged, throughout the
complete length of the collar.
 BOLTS
Numbering system
ALPP H T 8 8 Head type
ALPP Pan head
ALPB Brazier head
ALP 509 Standard c-sink
Class fit H
Hole filling
N Non hole filling

Pin material
E 75S-T7 al all T
Heat treat all steel

Body in 32nds inch

Grip length in 16ths inch
 BOLTS
Numbering system
BL 8 4
B Blind lock bolt
L
8 in 32nds inch
4 Grip length in 16ths
inch
 BOLTS
LC C 8

LC Lock bolt collar

Material
C 24ST al all (green color)
C F 61ST al all (plain
color) R Mild steel (cad
plated)
8 pin in 32nds inch
 NUTS
Made of cadmium-plated carbon steel, stainless steel, or
anodized 2024T aluminum alloy; with either right or left
hand threads.
No identifying marking or lettering appears on the nuts,
identification only by:
Color or characteristics metallic,
The insert when the nut is of the self-locking type,
Their construction.
 NUTS
Two groups aircraft nuts:
Non-self locking nuts.
Must be safe tied by external locking device.
Self locking nuts.
Contain locking feature as integral part.
 NUTS
Non-self locking nuts.
Most of type:
Plain Nut,
Castle Nut,
Castellated Shear Nut,
Plain Hex Nut,
Light Hex Nut,
Plain Check Nut,
Wing Nut.
 NUTS
Plain check nut AN316.
As a locking device for plain nuts, set screws,
threaded rod ends.

Castle nut AN310.

Used with drilled shank bolts, can be withstand
large tension load.
Slot in nut for use safe tied (cotter pin).
 NUTS
Castellated shear nut AN 320.
Subject to shearing stress only.

Plain hex nut AN315 and AN335.

Suitable for carrying large tension loads.
 NUTS
Light hex nut AN340 and AN 345.
Much lighter than plain hex nut, must be locked by
an auxiliary device.

Wing nut AN350.

Use where tightness and the assembly frequently
to be removed, obtained with the fingers to tight.
NUTS
 NUTS
Self Locking Nuts,
No need auxiliary of safe tying but have safe tying
integral part of their construction.
Designed has become quite at attachment, to
provide tight connection will not loose under
severe vibration.
Do not
Two use attype
general subject thethey
in use nut are:
or bolt to rotation.
All-metal type,
Elastic stop nut.
 NUTS
All-metal type (Boot-self locking, steel-self locking)
Threads in the load-carrying portion of the nut.
The locking action depends upon the elasticity of
the metal.
 NUTS
Elastic stop nut (Fiber-insert type).
Constructed with a non metallic (nylon) insert,
which is designed to lock the nut in place.
The insert is unthreaded and has a smaller
diameter than the inside diameter of the nut.

Self-locking nuts are generally suitable for reuse in

non-critical applications (threads have not been
damaged).
NUTS
NUTS
NUTS
 NUTS
Sheet spring nuts.
Used with standard and sheet metal self-tapping
screws.
Arched spring prevents the screw from loose.
 NUTS
Identification and Coding.
AN310D5R
Letters and digits following part number indicates:
Material,
B Brass.
D 2017-T aluminum alloy
DD 2024-T aluminum alloy
C Stainless steel
-xx (dash in place of letter) cadmium-plated
carbon steel.
Size,
Thread per inch,
Type of threads (right or left).
 NUTS
AN 310 D 5 R
Castle Nut
2017 Al All
5/16 inch
RH thread
AN 320 - 10
Castellated
Nut

5/8 inch
 WASHERS
Used in aircraft structures may be grouped into
three general classes:
Plain washer,
Lock washer,
Special type washer.
 WASHERS
Plain washer, AN960 and AN970
Used under hex nuts, provide smooth
bearing surface as shim to obtain
correct grip length.
Should be used under lock washer to
prevent damage surface.
AN970 steel washer (greater bearing)
than the AN960 washer and is used on
wooden structure.
Aluminum and aluminum alloy washer
may be used under bolt or nut on
aluminum alloy or magnesium
(corrosion caused by dissimilar metal).
 WASHERS
Lock washer
AN 935 and AN 936 are used in machine screws or
bolts where the self locking or castellated type nut
is not appropriate.
Spring action to provide prevent loosening nut
from vibration.
 WASHERS
Lock washer
Shakeproof lock washers are round washers
designed with tabs or lips (Eternal or Internal tabs)
that are bent upward across the sides of a hex nut
or bolt to lock the nut in place.
 WASHERS
Never be use lock washer at:
With fasteners primary and secondary structures.
Screw subject to frequent removal.
Washer subject to corrosive condition.
Washer is against soft material.

Special washer (Ball socket and seat washers)

AC 950 and AC 955 used where a bolt is installed
at an angle to a surface to provide alignment.
 WASHERS
Installation of bolt and nut.
Use applicable MM and IPC in replacement.
The washers are used under both the heads bolt
and nut.
Bolt head positioned on top or forward position
(prevent the bolt from slipping out).
Grip length must be correct (equal the thickness
of material to be bolted).
If slightly greater (use the washer under the nut
and bolt head).
Safe tied after installation.
 WASHERS
Repair Damage Internal threads.
Bolt holes are to provide full bearing
surface for the bolt head and nut (not be
oversized or elongated).
In cases of oversized or elongated usually
can be drilled to the next larger size.
Damaged threads on bolts or nuts only
require replacement of the defective part.
Damage internal threads: part may be
replaced or the threads repaired or
replaced (by replacement bushings or
helicoils).
 WASHERS
Repair Damage Internal threads.
Replacement Bushings.
Is installed, a thread lock compound may
or may not be used and staked to prevent
loosening with LH threads external and
RH threads internal.
Insert Helicoils.
Formed screw thread coils has a driving
tang to facilitate removal of the tang after
the insert is screwed into a helicoil tapped
hole.
WASHERS
 RIVETS
Is metal pin used to hold two or more metal
sheets, to fasten or join in aircraft construction
and repair.
Manufactured head,
Shank of rivet,
Upset to from the second head (Shop Head).
Manufactured head
Shank rivet
Shop head
 RIVETS
Lay-out of rivet consists:
Shank, correspond to thickness of the material.
Diameter of rivet,
Upset to from the second head (Shop Head).
Function shop head same as the nut on a bolt.
Countersunk
angle
Shank

A= Total Rivet
Length/shank
B= Grip Length (thickness
material)
C= Shop head Length (
D) Rivet
D=
B

Shop head wide (1 D)

C

D
 RIVETS
Two of major type rivets:
Solid-shank type, must be driven using bucking
bar.
Special (Blind) rivet, may be installed where
impossible to use bucking bar.
 RIVETS
Solid-shank type are identified by:
Kind of material they made,
Head type,
Size of shank, and
Temper condition (indicated by special marking
on head).

Universa Countersun Round Flat Brazier

l k
 RIVETS
Material solid-shank rivet for aircraft is aluminum
alloy, temper condition are strengthness rivets.
There five grades available:
1100 rivet, (99.45% pure al alloy) for riveting non
structural (strength is not factor),
2017-T and 2024-T rivets, these rivets are annealed and
must be kept refrigerated until they are to be driven.
2017-T app 1 hr, 2024-T 10-20 min be driven after remove
from refrigeration.
(same size 2217-T rivet), used in al alloy structure, more
strength is needed.
2117-T (field rivet) ready for used, no need further heat-
treating or annealing, used for riveting al alloy structure.
5056 rivets used for riveting magnesium alloy its
corrosion-resistant in combination with magnesium.
 RIVETS
Mild steel rivets are used for riveting steel parts,
Monel rivets uses for riveting nickel-steel alloys,
Copper rivets used only on copper alloy or non-
metallic materials.
2017-T and 2024-T rivets are heat-treatable rivet,
they must be used immediately after quenching or
be placed in cold storage (referred as ice-box
rivets), will remain soft for driving for periods up to
2 weeks, after that time should be re-heat
treating.
 RIVETS
Heat treatment of rivets
 RIVETS
Most metals are subjected to corrosions, it is
common experience to inspect the rivets which
the aircraft operated near salt water to find
corrosion.
Remember two dissimilar metals are in contact
which each other can cause an electrical current,
therefore commonly use aluminum alloy divided
into two groups.
RIVETS
 RIVETS
Identification.
Markings on the head of rivets are used to classify
their characteristic.
A raised teat
Two raised teats
Dimple
A raised dash
Double raised dash
Raised cross
Single triangle
No marking.
 RIVETS
Identification.
Rivet head is identified by AN or MS standard.

AN426 or MS20426 C-sunk head 100O

AN430 or MS20430 Round head
AN441 Flathead
AN456 Brazier head
AN470 or MS20470 Universal head.
 RIVETS
Identification.
Letters identified for alloy designation.

A Al All, 1100 or 3003

composition
AD Al All, 2117-T composition
D Al All, 2017-T composition
DD Al All, 2024-T composition
B Al All, 5056 composition
C Copper
M Monel
Absence of a letter following AN standard and
number indicates a rivet manufacture from mild
steel.
 RIVETS
Roundhead rivets, a head is large enough to strengthen
the sheet, resistant to tension.
Used in the interior side aircraft.
AN 430
AN 435

Flathead rivets, used on interior side where max

strength is needed, where there is not sufficient
clearance to use a roundhead rivet.
AN 441
AN 442
 RIVETS
Brazier head rivets, large head diameter adaptable for
riveting thin sheet, slight resist to the airflow.
Used for riveting skin exterior surface.
AN 455
AN 456

Universal head rivets, a combination of roundhead,

flathead, brazier head.
Used in aircraft both interiors or exteriors location.
AN 470
 RIVETS
Countersunk head rivets, beveled toward the shank
flush with the material surface.
The angle at the head from 78O to 120O, commonly
100O type rivets
Used in exterior surfaces only slight resistance to
minimize turbulence airflow.

AN 425 Countersunk 780

AN 426 Countersunk 1000
 RIVETS
AN 470 AD 3-5

AN Standard
Universal head
2117-T All Alloy
Diameter 3/32 inch
Length 5/16 inch
 RIVETS
Special (Blind) rivets:
Manufactured with unique characteristics, require
special procedures installation and removal.
These rivets are inserted in location where shop
head can not be seen.
 RIVETS
Mechanical Expanded Rivets.
Two classes mechanically expanded rivets, installed
with equipment used to pull the stem of rivet, both
manually operated and power operated guns.
1. Non-Structural
Self-plugging (Friction Lock) rivets,
Pull-thru rivets.

2. Mechanical lock, flush

fracturing, self-plugging
rivets
 RIVETS
SELF-PLUGGING (FRICTION LOCK) RIVETS.
Blind rivets are fabricated in two head;
Protruding head AN 470 or Universal head rivet
A 1000 countersunk head
With hollow shank or sleeve and serrated stem that
extends through the hollow shank.
Serrated stem/Mandrel

Material thick/Grip

Break notch

Mandrel head
 RIVETS

The stem is pulled into the rivet shank.

The mandrel of the stem forces the rivet shank to expand.
Pulling action will break off groove on stem, plugged retain
the shank.
RIVETS
RIVETS
 RIVETS
Self-plugging (friction lock) rivets installation
requires only one person (not necessary have
access opposite side).
Thickness material being riveted determines the
over length of the shank rivet.
Should extend beyond material thickness
approximately 3/64 inch to 1/8 inch before the
stem is pulled.

3/64 1/8 inch

SHAN

Thickness
K

material
 RIVETS
PULL-THRU RIVETS.
Same general information their fabricated in two
common head style;
Protruding head MS20470 or Universal head rivet
A 1000 countersunk head
Requires only one person for installation, not
necessary have access opposite side.
 RIVETS
SELF-PLUGGING (MECHANICAL LOCK) RIVETS.
Similar to self-plugging (friction lock) rivets except,
for manner in which the stem is retained (rivet
stem breaks off flush with the head, does not
require further stem trimming).
 RIVETS
Shank diameter measured in 1/32 inch, identified by
the first dash number (-3 = 3/32 inch, -4 = 1/8 inch).
Grip length refers to maximum thickness sheet to be
riveted and measured in /16 of an inch, measured with
a grip selection gage.
Used 3 =
3/16 inch

3
2
RIVETS
 RIVETS
IDENTIFICATION.
Self-plugging (friction lock) manufacture has a
code number:
9SPB A 6 - 3
9SP B Brazier or Universal head
9SP - 100 1000 countersunk head
A 2017 Aluminum Alloy
B 5056 Aluminum Alloy
R Mild steel
Shank diameter
4= 1/8 inch 6= 3/16 inc 5
= 5/32 inch 8= inch

Grip range (material thickness) 3/16 inch

 RIVETS
IDENTIFICATION.
Olympic screw and Rivet Corporation:
RV 2 0 0 - 6 - 3
Manufacture, Olympic Rivet and Screw
Corporation
Rivet type
2 = Self-plugging (friction lock)
5 = Hollow pull-thru
Material of shank
0= 2017 al alloy 7= Mild steel
5= 5056 al alloy

Head style 0
= Universal head
1= 1000 countersunk
Shank diameter
4= 1/8 inch 6 = 3/16 inch
5 = 5/32 inch 8=
inch
Grip range in 16ths of an inch
2 = 1/8 inch
 RIVETS
IDENTIFICATION.
Military Standard:
MS 20600 B 4 K 2
Military Standard

Type of rivet and head style

20600 = self-plugging (friction lock)
protruding 20601 = self-plugging (friction lock)
1000 countersunk
Material of sleeve
B = 5056 aluminum alloy
AD = 2117 aluminum
alloy
Shank diameter in 32nds of an inch
4 = 1/8 inch 6 = 3/16
inch 5 = 5/32 inch 8 = inch

Type of stem
K = knot head stem
W = serrated stem
Grip range in 16ths of an inch
2 = 1/8 inch
 RIVETS
IDENTIFICATION.
Townsend Company, Cherry Rivet Division:
CR 163 - 6 - 6

Cherry Rivet
Series number
Designates rivet material, type of rivet and
head style; 163 = 2117 al alloy, self-plugging
(friction lock) protruding head.
Shank diameter in 32nds of an inch
4 = 1/8 inch 6 = 3/16
inch 5 = 5/32 inch 8 = inch

Grip range in 16ths of an inch

2 = 1/8 inch
 RIVETS

Sheet gap
 RIVETS

Start to form bulged

blind head
 RIVETS

Rivet head firmly seated

 RIVETS

Shearing start pull into

rivet
 RIVETS

Locking collar ready to

be inserted
 RIVETS

Completely installed
 RIVETS
Pin (Hi-shear) rivets have the same
shear strength as bolts of equal
diameters.
Classified as special rivets but are
not of the blind type.
Consists of;
Headed at one end and is grooved
about the circumference at the
other.
Metal collar is swaged onto the
grooved end.
 TURN LOCK FASTENERS
To secure inspection plates, doors and other removable
panels; as quick-opening, quick action, they permit
quick and easy removal of access panel for
inspection.
Commonly used:
Dzus Fasteners,
Camloc Fasteners,
Airloc Fasteners.
 TURN LOCK FASTENERS
Dzus Fasteners, consists of:
A stud,
Grommet/retainer,
Holding device for stud.
Receptacle.
Spring supplies force that locks or secures the stud in
place.
 TURN LOCK FASTENERS
The total amount of material thickness to be secured must
be known, to correct a length of stud for installation; they
stamped on the head.

F - Flush head.
6 - Body in 16th of inch.
.50 - Length 50/100th of inch.

Manufactured two types: Rigid and Floating types, with three

types of head; Oval, Flush, and Wing types.
 TURN LOCK FASTENERS
Camloc Fasteners, consists of:
A stud assembly,
Grommet/retainer,
Are installed in the removable portion.
Receptacle.
Riveted to the structure.

STUD ASSY
GROMMET

A quarter turn clockwise of the stud locks the fastener, unlocked by

turning the stud counterclockwise.
Two types Rigid and Floating.
 TURN LOCK FASTENERS
Airloc Fasteners, consists of:
A stud,
Cross pin,
Receptacle.

Should never be used the second time; once removed from

the stud, the pin should be replaced.
 TURN LOCK FASTENERS
The total amount of material thickness to be secured, must
be known before the correct length of stud can be selected
for installation.
Is stamped on the head of the stud in thousandths of an inch
(0.040, 0.070, 0.190)
TURN LOCK FASTENERS
TURN LOCK FASTENERS
TURN LOCK FASTENERS
TURN LOCK FASTENERS
TURN LOCK FASTENERS
TURN LOCK FASTENERS
TURN LOCK FASTENERS
TURN LOCK FASTENERS
TURN LOCK FASTENERS
TURN LOCK FASTENERS
TURN LOCK FASTENERS
 SCREWS
The most common fastener (screw) used in
aircraft uses threaded types screw are:
Structural screw (have same strength as equal
size bolts),
The machine screw (majority used for general
repair), and
Self-tapping screw (used for attaching lighter
part).
Drive screws (not actually screws but nail), driven
with a mallet or hammer, no slot or recessed on
their head.
Has three head slots:
Straight,
Phillips, and
Reed and Prince.
 SCREWS
Structural screw (NAS 204 through NAS 235,
AN 509 and AN 525 series) used for assembly of
structural parts, as are structural bolts have a
definite grip length and the same shear and
tensile strengths as the equivalent size bolt.
Available in:
Countersunk head,
Round head, and
Brazier head types.
 SCREWS
The AN509 (100) flathead screw is used in
counter-sunk holes where a flush surface is
necessary.
The AN525 washer head structural screw is used
where raised heads are not objectionable. The
washer head screw provides a large contact area.
 SCREWS
Machine Screws usually of:
The flathead (countersunk),
Roundhead or washer-head types.
These screws are general purpose screws, low
carbon steel, brass, corrosion-resistance steel,
and aluminum alloy.
Roundhead screws AN515 (coarse thread), AN520
(fine threads).
Countersunk screws AN505 and AN510 for 820,
AN507 for 1000.
 SCREWS
The fillister head screw, AN500 through AN503
(general purpose screw) used as a cap screw in
light mechanisms.
The AN500 (coarse threads) and AN501 (fine
threads) screws are available in low carbon steel,
corrosion-resistant steel, and brass.
The AN502 and AN503 fillister head screws are
made of heat-treated alloy steel, have a small
grip, and are available in fine and coarse threads.
These screws are used as capscrews where great
strength is required.
 SCREWS
Self-tapping Screws.
AN504 (round head) and AN506 (820
countersunk) for attaching removable part such
as name plate to casting
AN530 and AN531 such as Parker-Kalon Z type
sheet metal screw (blunt or the end), use as
temporary attachment.
Should not be used to replace standard screws,
nuts, bolts or rivets.
AN535 Drive screw Parker-Kalon U-type (plain
head), not intended to be removed after
installation.
 SCREWS
Identification and Coding.
Same with the bolt code, there are AN and NAS
screw (structural screws).
D place in B indicates 2017-T all alloy.
C designated corrosion resistant steel.
A before material indicates the head is drilled
for safe tying.
 SCREWS
AN501B 416
-7 Air Force Navy Standard

Fillister head fine threads

Brass

4/16 inch

Length 7/16 inch

 SCREWS
NAS 144 DH - 22
National Aircraft Standard

Internal wrenching -28 Bolt

Drilled head

Length 1 3/8 inch

 SCREWS
When access to the back of a
screw or bolt installation is
impractical, riveted or
rivetless nut-plates are used
to secure the connection of
panels.
Nut-plates.
To allow bolts and screws to
be inserted without having
to hold the nut, to make
installation easier of bolt or
screw a floating anchor nuts
are used which have self-
locking nut-plates are made
under several standards.
 SCREWS
When access to the back of a
screw or bolt installation is
impractical, riveted or
rivetless nut-plates are used
to secure the connection of
panels.
Rivnut.
This is the trade name of a
hollow, blind rivet installed by one
person using a special tool. May
be used as a rivet in secondary
structures or for the attachment
of accessories such as brackets,
fairings, instruments, or
soundproofing materials
SCREWS
 SCREWS
When access to the back of a
screw or bolt installation is
impractical, riveted or
rivetless nut-plates are used
to secure the connection of
panels.
Dill Lok-Skrus and Dill
Lok -Rivets.
Similar to the Rivnut in
appearance and application.
 SCREWS
Deutsch Rivets is a high-strength blind rivet and
can be installed by one person.
Consists of;
The stainless steel sleeve and
Hardened steel drive pin.
Pin and sleeve are coated with lubricant and a
corrosion inhibitor, a hammer or a pneumatic
gun and flathead set are used when driving a
Deutsch rivet.
 CONTROL CABLES
Mostly used linkage in primary flight control
system and other linkages to system throughout
aircraft.
Advantages;
Strong and light in weight,
Flexible,
Easy to route.
Disadvantages;
Tension must be adjusted frequently due to
stretching and temperature changes.
Aircraft control cables are fabricated from carbon
steel or stainless steel.
CONTROL CABLES
 CONTROL CABLES
Basic construction of cable:
A wire, numbers of wires are performed into
spiral and,
Formed into a strand.
These preformed strands are laid around to form a
cable.
Cable designation base on the number of strands
and numbers of wires in each strand.
 CONTROL CABLES

Strand
Cable

Cable designated:
7 x 7 cable (7 strands, 7 wires) medium
flexibility.
CONTROL CABLES
 CONTROL CABLES

Cable designated:
7 x 19 cable (7 strands, 19 wires) extra
flexibility.
CONTROL CABLES
CONTROL CABLES

Diamete
r cable
 CONTROL CABLES
Cable fitting such as terminals, thimbles, bushings
and shackles; generally swaged.
Threaded end,
Fork end,
Eye end,
Single-shank ball end,
Double-shank ball end.
 CONTROL CABLES
Mechanical screw device consisting two threaded
terminals and a threaded barrel, purpose
adjustment of cable length and tension.
Turnbuckle
Barrel

Slot
 CONTROL CABLES
Turnbuckles are fitted in the cable assembly for the
purpose of making minor adjustments in cable
length and adjustment cable tension.
It is necessary to screw both of the terminals an
equal number of turns into the barrel, until not
more than three threads are exposed on either side
of the turnbuckle barrel.
After a turnbuckle is properly adjusted, it must be
safetied.
 CONTROL CABLES
One terminal has right-thread, other left-thread.
Barrel has matching (slot and groove) internal
thread at the end has groove identified left or
right thread and for safe tying.

Left Righ
t

Groove
CONTROL CABLES
CONTROL CABLES
CONTROL CABLES
CONTROL CABLES
CONTROL CABLES

Pull for inspection

CONTROL CABLES
 CONTROL CABLES
Safety wire (wire wrapping); single wrapping.
 CONTROL CABLES
Safety wire (wire wrapping); double wrapping.
CONTROL CABLES
CONTROL CABLES
PUSH-PULL TUBE LINKAGE
PUSH-PULL TUBE LINKAGE
PUSH-PULL TUBE LINKAGE
PUSH-PULL TUBE LINKAGE
PUSH-PULL TUBE LINKAGE
 PUSH-PULL TUBE LINKAGE
Used as linkage in various types of mechanically operated
permits the transfer of either compression or tension stress
consists of:
Hollow aluminum alloy or steel tube
Adjustable end fitting
Check nut at either end.
The check-nuts secure the end fittings after the tube
assembly has been adjusted.
 SAFETY METHODS
The process securing of fasteners so that they do not work
loose due to vibration most widely used methods are :
Safety wire,
Pin (Cotter pins),
Lock washers,
Nuts
 SAFETY METHODS
Methods of safe tying:
Pins are used in shear applications and for safe
tying.
Types of pins used:
Taper pin,
Flathead pin,
Cotter pin
Roll pin.
 SAFETY METHODS
Plain and threaded taper pins (AN385 and AN386) are used in
joints which carry shear loads and where absence of play is
essential.
The plain taper pin is drilled and usually safetied with wire.
The threaded taper pin is used with a taper pin washer
(AN975) and shear nutStationary
(safetied with a cotter pin or safety
clip) or self-locking nut.member

Plain
Taper Pin

Moveable
member
 SAFETY METHODS
Plain and threaded taper pins (AN385 and AN386) used in
joint carry shear loads, threaded taper pin is used with taper-
pin washer (AN975) and shear nut (safe tied with cotter pin or
self-locking nut).
 SAFETY METHODS
Flathead pin (Clevis pin MS20392) is used with tie rod
terminals and in secondary control s which are not subject to
continuous operation, installed with the head up.
 SAFETY METHODS
Cotter Pin
AN380 cadmium-plated, low carbon steel is used for safe
tying bolts, nuts, other pins.
AN381 corrosion resistant steel cotter pin used in non
magnetic location where material is required or resists
corrosion.
 SAFETY METHODS
Cotter Pin safe tying.
Installation should fit into the hole, with very little side play.
 SAFETY METHODS
Cotter Pin safe tying.
Prong bent over the bolt end should not extend beyond the
bolt diameter.
Prong bent down should not rest against the surface washer.
 SAFETY METHODS
Cotter Pin safe tying.
Warp the prongs should not extend outward from the
sides of the nut.
Prong should be bent over a reasonable radius.
Tapping lightly with a mallet is the best method.
 SAFETY METHODS
Roll Pin
Pressed-fit pin with chamfered ends, tubular shape and is
slotted the full length of the tube.
Inserted with hand tools and is compressed as it driven into
place.
 SAFETY METHODS
Methods of safe tying:
Safety wire is method of safe tying most positive and
satisfactory which cannot be safe tied by any other
practical means wiring together two or more units in such a
manner that any tendency of one to loosen is counteracted
by the tightening.
There are methods:
Single wire or
Double-twist.
 SAFETY METHODS
Double-twist the most common of safety wiring.
Single-wire method may be used in a closely spaced and in
places that are extremely difficult to reach.
The number of nuts, bolts or screws that may be safety wired
maximum three a group in series used by double-twist
method (depend on application).
 SAFETY METHODS
Parts being safety-wired should be torque (recommended
value) and holes aligned before attempting safe tying.
The force applied to the wire is in tightening direction.
The wire is arranged never be loose of tightened, loop should
tends to down.

Loop
SAFETY METHODS
SAFETY METHODS
SAFETY METHODS
 SAFETY METHODS
General safety wiring rules.
Must be the new (one time used) each application.
Loop around the head should stay down (not tend to come
up over the bolt head).
Twist should be tight without over twisting.
Not under such tension that normal handling vibration will
break the wire
A pigtail of - inch (3-6 twist), must be bent to prevent
injury the personal.
 SAFETY METHODS
Snaprings - is a ring of metal, either round or flat in cross
section have springlike action will hold the snapring firmly
seated in a groove.
There are:
External types are designed to fit in a groove around the
outside of a shaft or cylinder.
The internal types fit in a groove inside a cylinder, and are
never safetied.
 SAFETY METHODS
A special type of pliers is designed to install each type of
snapring. Snaprings can be reused as long as they retain their
shape and springlike action.
 APPRAISAL SELF TEST

Magnesium alloy structures have what

designation
5056.
2017.
1100.
 APPRAISAL SELF TEST

Whattypeofrivet should you use when space is

limited
Solid type.
Pull type. .
Flat type.
 APPRAISAL SELF TEST

What fasteners has a shear and tensile strength

Turnlock.
Lock-bolt.
Airloc.
 APPRAISAL SELF TEST

Two types of Airloc receptacles

Fixed and flying.
Fixed and set.
Fixed and floating.
 APPRAISAL SELF TEST

If flat-head pin used in terminal, besecuredwith

what device
Self-locking nut.
Safety wire.
Cotter pin.
 APPRAISAL SELF TEST

Allen wrench is required to tighten or loosen

which what type of bolts
Countersunk-head.
Hex head.
Eye.
 APPRAISAL SELF TEST

Nuts are divided into

Ferrous and nonferrous.
Metal insert and fiber insert.
Self-1ocking and nonself- locking.
 APPRAISAL SELF TEST

Which of anall-metalself- lockingnut

An elastic stop nut.
A flexloc nut.
An internal-wrenching nut.
 APPRAISAL SELF TEST

Which types of nuts are designed to be used

cotter pins
Check nuts.
Plate nuts.
Castlenuts.
 APPRAISAL SELF TEST

When an assembly is frequently removed, what

nuts should be used
Wing nuts.
Shear nuts.
Spring nuts.
 APPRAISAL SELF TEST

What types of screws are most commonlyused

Self-tapping,Phillips,and commonscrews.
Brazier-head,round-head,and
commonscrews.
Machine, structural, and self-
tappingscrews.
 APPRAISAL SELF TEST

A 7 x 19 cable has what total number of wires

133.
19.
17.
 APPRAISAL SELF TEST

Terminal fittings are attached to the ends of

cables by
Swaging.
Splicing.
Soldering.
 APPRAISAL SELF TEST

Whatisthepreferredmethod for
safetyingturnbuckles
Double-wire.
Clip-locking.
Wire-wrapping.
 APPRAISAL SELF TEST

Mild steel rivets are used for riveting

Nickel steel parts.
Magnesium part.
Steel parts.
 APPRAISAL SELF TEST

An AN clevis bolt used

For tension and shear load.
External tension loads are applied.
Shear load applications.
 APPRAISAL SELF TEST

The NAS 144 25, the number 25 means

Grip in sixteenth.
Diameter in sixteenth.
Series number.
 APPRAISAL SELF TEST

Ability of a metal to stretch or bend without

breaking
Toughness.
Strength.
Ductility.