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LAB MANUAL
AE 1306
Aircraft Structures Repair Lab
AE 1306 Aircraft Structures Repair Lab
List of Experiments
(As per the Anna University syllabus - Regulation 2004)
Introduction
Terms involved in riveting
Aircraft structural members are designed to perform a specific function. The prime
objective of aircraft is to restore damage parts to their original condition. Very often replacement
is the only way to obtain the original condition. First study the parts carefully so that its purpose
or function is fully understood. Strength may be principle requirement in the repair of certain
structures.
INSPECTION OF DAMAGE
When visually inspecting damages resembles that there may be caused by impact of
foreign objectives. A rough landing gear may be over loaded and causing it to damage the spring.
They would be classified as load damage during inspection considers that this damage extends to
supporting structural members. This will cause a huge damage a shock can extend through a
length hence a close examination for failed rivets and elongated hole is very important.
CLASSIIFICATION OF DAMAGE
After the extent of damage has been found, it should be of one of these categories:
o Negligible damage
o Damage repairable by patching
o Damage repairable by insertion
o Damage requiring replacement of part
NEGLIGIBLE DAMAGE
It is the damage or distortion that may be allowed to exist or corrected by some simple
procedures without placing a restriction on the flight status of airplane. Before classifying
damage as negligible ensure that the damage complies with manufacture specified unit and limit
of negligible damage.
Any damage exceeding negligible limits and that can be required by bridging the damage
of the component with a material piece. Reinforcement member are attached to the damaged
portion of the component to restore e the characteristic and air-worthiness of the aircraft. The
patch materials used are usually same as that of the damaged part but one gauge heavier. In a
patch repair, filter plates of the same gauge may be used for bearing purpose or to return the
damaged part to its original contours. Damage repaired by patching is specified for each member
of air frame
Damage that is extensive enough to penetrate to a major portion of the member but which
is not so extensive as to require requirement is classified as damage repairable by insertion. The
repairs are made by inserting a new-alike section and secure the insertion by splicing the
insertion at each end.
Damage that cannot be repaired by any practical means is classified under this category. The
replacement of an entire part is considered with one or more of the following conditions:
Also short structural members usually must be replaced because repair of such member is
generally impractical.
TERMS INVOLVED IN RIVETING:
PITCH:
The distance between the centres of the adjacent rivets in the same row.
SPACE:
LAND \ MARGIN:
The distance from the edge of the plate to the nearest rivet centre.
ALLOWANCE:
The protruding length of the rivet after the rivet is inserted in the hole of the plate to be
attached. Usually it should be 1.5 -1.75 times the diameter of the rivet.
SPHERE OF INFLUENCE:
The area in which the closed rivets maintains the plates in close proximity.
LAP JOINT BY RIVETING
AIM:
To carry out the repair on an aircraft metallic skin by making a lap joint.
REQUIREMENT:
MATERIAL:
TOOLS:
DIMENSIONS
Land or margin = 10 mm
Pitch = 15 mm
Space = 20 mm
Hole diameter = 3.2 mm
Tolerance = ± 0.02 mm
Allowance = 4.5 mm
PROCEDURE
RESULT:
Thus a repair on the aircraft metallic skin by making a lap joint is done.
BUTT JOINT BY RIVETING
AIM:
To carry out the repair on an aircraft metallic skin by making a butt joint of single strap
type.
REQUIREMENT:
MATERIAL:
TOOLS:
DIMENSIONS:
Land or margin= 5 mm
Pitch = 10 mm
Space = 20 mm
Hole diameter = 3.2 mm
Tolerance = ± 0.02 mm
Allowance = 4.5 mm
PROCEDURE
RESULT:
Thus a repair on the aircraft metallic skin by making a single strap butt joint is carried out
successfully.
BUTT JOINT BY TIG WELDING
AIM:
To carry out the repair by TIG welding on damaged aluminium sheets of an aircraft
through butt joint.
REQUIRMENTS:
MATERIALS:
EQUIPMENTS:
PROCEDURE:
RESULT:
AIM:
REQUIRMENT:
MATERIAL:
TOOLS:
MAN POWER:
1 Technician
1 Supervisor
PROCEDURE:
RESULT:
AIM:
To renew a damaged pipe length in an aircraft with necessary flaring and end fitting to
prevent leakage.
REQUIREMENTS:
TOOLS:
Smooth file
Filter square
Steel rule
Hack saw
MATERIAL:
Aluminium pipe
Nipple and nut
EQUIPMENT:
Bench wise
Hand flaring tools
PROCEDURE:
RESULT:
Thus the damaged pipe is renewed with necessary flaring to prevent damage of leakage.
MAKING A CHANNEL SECTION BY HAND FORMING
AIM:
REQUIRMENT:
MATERIALS:
Aluminium sheet
EQUIPMENT:
DIMENSION:
PROCEDURE:
RESULT:
AIM:
To design a T joint by MIG welding for the required dimension of aluminium as material.
REQUIRMENTS:
MATERIAL:
Aluminium sheet of 75 x 60 x 3 mm
Aluminium sheet of 75 x 50 x 3 mm
TOOLS:
Scale
L – Square
File
MIG –welding unit
PROCEDURE:
RESULT:
Thus the given aluminium material is made into T joint using MIG welding unit.
BENDING OF ALUMINIUM TUBE
AIM
To carry out a bending of aluminium tube with the help of bending machine
REQUIREMENTS
MATERIAL
Aluminium pipe
Filler material
TOOLS
PROCEDURE
RESULT:
Thus the pipe bending carried out successfully as per the requirements.
BENDING OF ALUMINIUM TUBE