Aircraft Metal Structure

Light Alloy Repair

P10 Write a short report describing the repair theory for a simple light alloy riveted repair carried out to national standard

Contents:
Identification of damage. Use of technical documentations. Selection of materials and Rivets. Tools required. Inspections of repair. Relevant legislations and guide lines.

There are eight major zones for the aircraft. Each major zone is identified by the first digit of a three digits number. The even numbers identify the zones on the right hand side of the aircraft, while odd numbers identify the zones on the left hand side of the aircraft.

The aircraft structure is divided according to the ATA 100 specifications.

Station Numbers:
Buttock line or Butt line (BL) - is a width measurement left or right of, and parallel to, the vertical centre line.
Waterline is the measurement of the height perpendicular from a horizontal plane located below the bottom of the aircraft fuselage.

Aircraft Structure and Maintenance

Section Numbers:
Each major part of the aircraft receives a section number. The fuselage section base number is 10. The fuselage is divided into various sections for manufacturing Reasons.

Aircraft Structure and Section Numbers: Maintenance

Sections

41 - 43 - 46 - 48

Station Numbers:

The station number is the distance in centimetres of a cross-section from a reference point.

Station Numbers:

Technical Documentation:
Aircraft maintenance Manuals (AMM or MM) Aircraft Structural Repair Manual (SRM) Civil Aircraft inspection Procedures (CAIP) and other guidance documents.

How to use an Aircraft Structural Repair Manual (SRM)

Find the location of the damage. water line and station number. Nearest frame number and stringer number. Extent of damage: negligible, repairable or discard. Method of repair.

Determine the Extent of the Damage:

Strip the paint away assuming the aircraft is paint. With the paint removed it could evident that the scratch may have only been in the paint and not in the aircraft. Use Dye Penetrant to confirm the damage, crack or scratch etc.

Determine the Extent of the Damage:

Measure the depth (DTI) width and length vernier calliper. Check with the Structural Repair Manual (SRM) if the damage is allowable or within tolerance. NB a scratch will have to have its sharp edges removed prior to measuring.

Allowable Damage: Example : From B737-300 B737Structural Repair Manual

Determine the Extent of the Damage:

If the damage is allowable or within tolerance according to the Structural Repair Manual (SRM) annotate the Aircraft Technical Log Book damage chart stating. Permanent Repair - Interim Repair - Time-Limited TimeRepair This will prevent the damage being continually being found by other people.

Damage Classification:

All damage must be classified to determine what repair action should be taken. Ultimately, all discrepancies will be placed into one of three categories, negligible damage, non-repairable nondamage or repairable damage.

Negligible Damage:
Negligible damage is damage that can be permitted to exist as is, or corrected by a single cosmetic refinishing procedure with no restrictions on flight operations. This damage may also include some dedelamination, disbonds and voids.

NonNon-repairable Damage:

NonNon-repairable damage exceeds published criteria or limits. (Structural Repair Manual) NonNon-repairable damage may be reclassified as repairable, if the manufacturer prescribes a repair on an individual basis. Normally, non-repairable damage requires the changing nonof components.

Repairable Damage:
Repairable damage is any damage to the skin or structure that cannot be allowed to exist as is without placing performance restrictions on the airframe.

Hail Storm Damage: ail

Replacement of Leading Edge Panel?

Lighting Strike:

It will take more then speedspeed-tape to fix this one.

Bird Strike:

Aerodynamic Smoothness Requirements:

Fuselage limitations on repairs in region of static pressure ports, pitotpitot-static probes, angle of airflow sensors. Wing, ailerons, stabilizers, elevators rudder, flats, leading edge slats, spoilers Nacelle and Pylon

Repairs:
Patch Repair

Insert Repair

Typical Skin Repair:

Restore the structural integrity of the airframe.

Crack Propagation:

It is permitted for some types of crack repair to drill a hole at the end of each end of the crack to prevent it from extending any Further.

Repairs:
Complex repair for a Boeing 737 door aperture crack in the bottom corner. This includes multi external repair plates and the crack is stop drilled.

Metallic Repairs on Aircraft Structure:

Riveting Terminology: Spacing and Edge Distance Rivet spacing, also referred as rivet pitch, is the distance between the rivets in the same row and is measured from the rivet centre to the rivet centre.

Metallic Airframe Structures

Riveting Terminology: A
Edge distance for all rivets, except those with a flush head, should not be less than twice the diameter of the rivet shank or more than four times the diameter of the rivet shank. FlushFlush-head rivets require an edge distance of at least 2 times the diameter.

Metallic Airframe Structures

Riveting Terminology:

B
Rivet pitch, is the distance between the rivets in the same row and is measured from the rivet centre to the rivet centre.

Metallic Airframe Structures

Riveting Terminology: C
Transverse pitch is the distance between the rows of rivets and is measured from the rivet centre to rivet centre.

Metallic Airframe Structures

Riveting Terminology:
The proper length of rivet is an important part of the repair. If the rivet is too long, the formed head will be too large or the rivet may bend or be forced between the sheets being riveted. If the rivet is too short, the formed head will be too small or the riveted material will be damaged. 1 x D+G=L

Where: D = the rivet diameter G = grip (total thickness of material) L = total length of the rivet.

Metallic Airframe Structures

Drilling Rivet Holes:
Standard twist drills are used to drill rivet holes. Note that there is a slight clearance in each case. This prevents binding of the rivet in the hole.

TABLE OF SIZES

Metallic Airframe Structures

Riveting:
Type of rivet; Head shape, material & heat treatment. Rivet strength, length and diameter. How many rivet, spacing and pitch required.

Metallic Airframe Structures

Riveting Tools:
Rivet Forming Tool Rivet Cutters

Rivet Snap Rivet Blocks

Rivet Gun

Metallic Airframe Structures

Riveting Tools:

Pneumatic Rivet Forming Tool

Reports:
Damage classification. Finding limits (structural repair manual SRM). Prepare surface. Rivet selection:-length, diameter & type. selection:Rivets: Pitch, spacing & edge distance. Materials. PPE CAA and Manufacturer Recommendation.

Any Questions

On your FACET ----- File Name: Metallic Structure of Aircraft