Aviation Mechanic Handbook

Contents

introduction ............................................................................................................ iii Section 1: General information .............................................................................1 1.1

Fraction, Decimal, and Metric Equivalents..............................................................................3

1.2

Conversions.......................................................................................................................... .4

1.3

Aircraft Nomenclature .......................................................................................................... 13 Axes of an Airplane.........................................................................................................13 Forces Acting on an Aircraft in Flight..............................................................................13 Types of Aircraft Structure ..............................................................................................14 Truss .........................................................................................................................14 Monocoque ...............................................................................................................14 Semimonocoque ........................................................................................................15

1.4

ATA-100 System of Identification......................................................................................... .16

1.5

Aircraft Nationality Identification.............................................................................................21

1.6

Title 14 of the Code of Federal Regulations......................................................................... .24

1.7

Standard Taxi Signals...........................................................................................................27

1.8

Cylinder Color Code Identifiers ............................................................................................ 28

Section 2: Physical and Chemical .......................................................................29 Periodic Table of Elements ................................................................................................. 30

2 .1

Temperature Conversion ......................................................................................................... ..31

2.2

ICAO Standard Atmosphere ..................................................................................................... ...37

Absolute Temperature .................................................................................................. 36

2.3

Distribution of Electrons in the

2.4

Density of Various Solids and Liquids ............................................................................. ..41

Chemical Elements .........................................................................................................38

Density of Various Gases ........................................................................................ ..41 2.5 2.6

Hydraulic Relationships.......................................................................................................... ..42 Quantity of Liquid in a Drum ................................................................................................. ..44

Estimating Quantity of Liquid in a Standard 55-Gallon Drum ..........................................................44

V

Section 3: Mathematics

45

3.1

Measurement Systems The International System of Units (SI) The Metric System U.S. - Metric Conversion Length Weight Volume

47 47 48 48 48 48 49

3.2

Mathematical Constants

50

3.3

Mathematical Symbols

51

3.4

Squares, Square Roots, Cubes, Cube Roots of Numbers

52

3.5

Diameter, Circumference and Area of a Circle

55

3.6

Geometric Formulas Triangle Square Rectangle Parallelogram Trapezoid Regular Pentagon Regular Hexagon Regular Octagon Circle Ellipse Sphere Cube Rectangular Solid Cone Cylinder

58 58 58 58 58 58 59 59 59 59 59 60 60 60 60 60

3.7

Trigonometric Functions

61

3.8

Powers of Ten

65

3.9

Number Systems 68 Binary Equivalent of Decimal 68 Octal Equivalent of Decimal 68 Binary Equivalent of Octal 68 Hexadecimal Number System 68 Binary Coded Decimal Equivalent of Decimal 69 The Gray Code 69 American Standard Code for Information Interchange (ASCII) ... 69 Special Control Functions Used in ASCII: 71

vi

Section 4: Aircraft Drawings

73

4.1

Types of Aircraft Drawings Sketches Detail Drawings Assembly Drawings Installation Drawings Sectional Drawings Cutaway Drawing Exploded-View Drawing Schematic Diagram Block Diagram Repair Drawings Wiring Diagrams Pictorial Diagrams Orthographic Projections

75 75 75 75 75 75 75 75 76 76 76 76 76 76

4.2

Meaning of Lines

77

4.3

Material Symbols

78

4.4

Location Identification Fuselage Stations Water Lines Butt Lines Wing and Horizontal Stabilizer Stations

79 79 79 79 79

Section 5: Aircraft Electrical Systems

81

5.1

Electrical Symbols

83

5.2

Alternating Current Terms and Values

91

5.3

Ohm's Law Relationships

92

5.4

Electrical Formulas Formulas Involving Resistance Formulas Involving Capacitance Formulas Involving Inductance Formulas Involving Both Capacitance and Inductance Resonant Frequency Total Reactance Impedance

94 94 95 97 100 100 100 100

5.5

Electrical System Installation Selection of Wire Size Notes on Wire Installation Switch Derating Factors Wire and Circuit Protectors MS Electrical Connectors Resistor Color Code Aircraft Storage Batteries Lead-Acid Batteries Nickel-Cadmium Batteries

101 101 106 108 109 110 114 116 116 117

Section 6: Aircraft Materials

119

6.1

Composition of Wrought Aluminum Alloys

121

6.2

Four-Digit Designation System for Wrought Aluminum Alloys

122

6.3

Mechanical Properties of Aluminum Alloys

123

6.4

Temper Designations for Aluminum Alloys Heat-Treatable Alloys

124 124

6.5

Temperatures for Heat Treatment of Aluminum Alloys

125

6.6

Bearing Strength (in pounds) of Aluminum Alloy Sheet

126

6.7

Shear Strength of Aluminum Alloy Rivets 127 Single-Shear Strength (in pounds) of Aluminum-Alloy Rivets ... 127 Double-Shear Strength (in pounds) of Aluminum-Alloy Rivets .. 127

6.8

SAE Classification of Steel

128

6.9

Strength of Steel Related to its Hardness

129

6.10

Color of Steel for Various Temperatures

130

6.11

Color of Oxides on Steel at Various Tempering Temperatures

131

Non-Heat-Treatable Alloys

124

Section 7: Tools for Aircraft Maintenance

133

7.1

135 135 135 135 136 136 136 136 136 136

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Measuring and Layout Tools Steel Rule Hook Rule Combination Set Vernier Calipers Dividers Outside Calipers Inside Calipers Hermaphrodite Calipers Scriber

How to Read the Vernier Scale Micrometer Caliper Dial Indicator Feeler Gages Small-Hole Gages Telescoping Gages

137 138 140 140 140 140

7.2

Holding Tools Vises Bench Vise Drill Press Vise Pliers Combination/Slip Joint Pliers Water Pump Pliers Vise-Grip® Pliers Needle-Nose Pliers

141 141 141 141 141 141 142 142 142

7.3

Safety Wiring Tools Diagonal Cutting Pliers Duckbill Pliers Safety Wire Twisting Tool

143 143 143 143

7.4

Bending and Forming Tools Tools for Making Straight Bends and Curves Cornice Brake Box Brake Press Brake Slip Roll Former Forming Compound Curves in Sheet Metal English Wheel

144 144 144 144 144 145 145 145

7.5

Cutting Tools Shears Throatless Shears Squaring Shears Scroll Shears Hand Shears Tin Snips Compound Shears Saws Band Saw Hacksaw W o o d Saws Crosscut Saw Ripsaw Compass, or Keyhole Saw Backsaw

145 145 145 146 146 146 146 147 147 147 148 148 148 148 148 149

ix

Chisels Flat Chisel Cape Chisel Diamond Point Chisel Round Nose Chisel Files

149 149 149 149 149 150

7.6

Hole Cutting Tools Twist Drills Twist Drill Sizes Drill Gage Twist Drill Sharpening Drill Point Gage Large Hole Cutters Hole Saws Fly Cutter Countersink Reamers Drills for Wood and Composite Materials Auger Bits Forstner Bits Flat Wood-Boring Bits Brad-Point Drills Spade Drill

151 151 151 154 154 155 156 156 156 156 157 157 157 158 158 158 158

7.7

Threads and Threading Tools Unified and American Standard Thread Form Thread-Cutting Tools Body and Tap Drill Sizes Taps Screw Pitch Gage

159 159 159 160 160 161

7.8

Torque and Torque Wrenches Click-Type Torque Wrench Deflecting-Beam Torque Wrench Torque Conversions Recommended Torque Values

162 162 162 164 164

7.9

Pounding Tools Carpenter's Claw Hammer Ball Peen Hammer Metalworking Hammers Straight Peen and Cross Peen Hammers Body, or Planishing Hammer Mallets and Soft-Face Hammers Sledge Hammers

166 166 166 166 166 166 167 167

7.10

Punches.................................................................................................................................167 Prick Punch.................................................................................................................. 167 Center Punch .............................................................................................................. 167 Drift, or Starting Punch................................................................................................ 167 Pin Punch ................................................................................................................... 168 Transfer Punch.............................................................................................................168 Automatic Center Punch ..............................................................................................168

7.11

Wrenches .......................................................................................................................... 169 Open End Wrench .......................................................................................................169 Adjustable Open End Wrench ................................................................................169 Ratcheting Open End Wrench................................................................................ 169 Box End Wrench.......................................................................................................... 170 Ratcheting Box Wrench ......................................................................................... 170 Combination Wrench ................................................................................................... 170 Flare Nut Wrench ........................................................................................................ 170 Socket Wrenches ........................................................................................................ 171 Socket Wrench Handles......................................................................................... 171 Hand Impact Tool .................................................................................................. 171 Typical Socket Wrenches....................................................................................... 172 Extension and Adapters......................................................................................... 172 Allen Wrenches ........................................................................................................... 172

7.12

Screwdrivers ....................................................................................................................... .173 Slot Screwdrivers ........................................................................................................ 173 Offset Screwdriver....................................................................................................... 173 Recessed-Head Screwdrivers .....................................................................................173 Screw Heads for Special Structural Screws.................................................................174

S e c t i o n 8 : A i r c r a f t H a r d w a r e ...................................................................................... ..1 7 5 8.1

Standards.............................................................................................................................177

8.2

Threaded Fasteners .............................................................................................................177 Bolts ............................................................................................................ .......................177 Hex-Head Bolts...................................................................................................... 178 Flush-Head Bolts ................................................................................................... 179 Drilled-Head Bolts.................................................................................................. 179 Twelve-Point, Washer-Head Bolts ......................................................................... 179 Internal Wrenching Bolts ....................................................................................... 179 Clevis Bolts ............................................................................................................ 180 Eye Bolts ............................................................................................................... 180 B o l t Installation......................................................................................................... 180 Bolt Fits....................................................................................................................... 181

xi

Screws Aircraft Screw Heads Set Screws Self-Tapping Sheet-Metal Screws Nuts Nonlocking Nuts Self-Locking Nuts Low-temperature locking nuts High-temperature locking nuts Wing Nuts Anchor Nuts Channel Nuts Pressed-Steel Nuts Instrument Nuts Rivnuts Threaded Fastener Safetying Locking Washers Cotter Pins Safety Wire and Safety Wire Twisting

181 182 183 183 184 184 185 185 186 186 186 187 187 188 188 189 189 189 190

8.3

Washers

193

8.4

Special Rivets Blind Rivets Friction-Lock Rivets Mechanical-Lock Rivets CherryMax Rivets, Olympic-Lok Rivets, Huck Rivets High-Strength Pin Rivets Hi-Shear Rivet Hi-Lok Fasteners Hi-Tigue Fasteners

195 195 196 197 198 198 198 200 201

8.5

Cowling Fasteners

202

8.6

Thread Repair Hardware Helicoil Insert Acres Sleeves

203 203 204

Section 9: Metal Aircraft Fabrication

205

9.1

Sheet Metal Layout and Forming Definitions Layout Procedure Example Forming

207 207 208 208 210

9.2

Minimum Bend Radii for 90° Bends in Aluminum Alloys

211

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S e c t i o n 1 2 : N o n d e s t r u c t i v e I n s p e c t i o n .................................................2 4 5 12.1

Visual Inspection............................................................................................................... ..247 NDI...............................................................................................................................247 Visual Inspection ..........................................................................................................247 Surface Visual Inspection ...................................................................................... ..247 Internal Visual Inspection ........................................................................................247

12.2

Tap Test............................................................................................................................ ..248

12.3

Penetrant Inspection ........................................................................................................ ...249

12.4

Magnetic Particle Inspection ............................................................................................ ...250

12.5

Eddy Current Inspection ......................................................................................................251 How it works ............................................................................................................... .25 1 What it is suited for........................................................................................................252 Method ...................................................................................................................... ...252 Detection of corrosion...................................................................................................252

12.6

Ultrasonic Inspection............................................................................................................253

12.7

Radiography. ..................................................................................................................... ..253 X-Rays..........................................................................................................................253 Gamma Rays ...............................................................................................................254 Inspection—Steps .........................................................................................................254 Considerations .............................................................................................................255 Safety .......................................................................................................................... 255

S e c t i o n 1 3 : A i r c r a f t C o n t r o l S y s t e m s ....................................................2 5 7 13.1

Types of Control Systems....................................................................................................259 Torque Tubes.............................................................................................................. 259 Push-Pull Rods.......................................................................................................... ..259

13.2

Control Cables .....................................................................................................................260

13.3

Control Cable Terminals ......................................................................................................261

13.4

Turnbuckles ..................................................................................................................... ....262 Turnbuckle Safetying ................................................................................................. ..262

13.5

Control Cable Tension ..................................................................................................... ....264

Clip-Locking Turnbuckles .......................................................................................... ..263

S e c t i o n 1 4 : A i r c r a f t F l u i d L i n e s ................................................................2 6 7 14.1

Rigid Fluid Lines............................................................................................................... ..269 Materials recommended for rigid fluid lines.................................................................269

14.2

Flexible Fluid Lines .............................................................................................................271 Types of Flexible Fluid Lines .......................................................................................271

xiv

14.3

Installation of Flexible Hose

273

14.4

Fluid Line Identification

274

Section 15: Oxygen System Servicing

277

15.1

279 279

Oxygen System Servicing Filling Pressure for 1,850 PSI Oxygen Cylinders

Section 16: Aircraft Weight and Balance

281

16.1

Locating the Center of Gravity

283

16.2

Datum Forward of the A i r p l a n e — N o s e Wheel Landing Gear

284

16.3

Datum Aft of the Main Wheels — Nose Wheel Landing Gear

285

16.4

Datum Forward of the Main W h e e l s — T a i l Wheel Landing Gear... 286

16.5

Datum Aft of the Main Wheels — T a i l Wheel Landing Gear

16.6

Location of CG with Respect to the Mean Aerodynamic Chord .... 288

287

Section 17: Composites

291

17.1

Resin S y s t e m s — T y p i c a l Properties

293

17.2

Resin Mix Ratios

294

17.3

Fiber/Resin Ratio Formulas

295

17.4

Reinforcing Fibers

296

17.5

Textile and Fiber Terminology

297

17.6

Yarn Part Numbering Systems

298

17.7

Fabric Weave Styles

299

17.8

Common Weave Style Numbers and Features

301

17.9

Ply Orientation Conventions

302

1 7 . 1 0 Damage R e m o v a l — S c a r f i n g and Stepping

302

1 7 . 1 1 Core Materials

304

1 7 . 1 2 Bleeder Schedules

305

Appendices

307

1: Hydraulic Fittings

309

2: Engines

313

3: Aircraft Lead Acid Battery Theory

315

4: Aircraft Tires

335

Index

347

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xvi