1 6.

1 Aircraft Materials — Ferrous 02 05

1.1 6.1 Identification of Ferrous Metals. 2 05
2 6.2 Aircraft Materials — Non-Ferrous 2 06
2.1 6.2 Identification of Non-Ferrous metals. 2 03
2.2 6.2 Testing of Non Ferrous Metal. 2 03
3 6.3 Aircraft Materials - Composite &
2 08
Non- Metallic.
3.1 6.3 Familiarization of Composite. 2 02
3.2 6.3 Identification of Plastic & Rubber parts. 2 02
3.3 6.3 Identification of woods, Fabrics &
2 04
Dopes used on A/C
4 6.4 Corrosion. 2 05
4.1 6.4 Familiarization of Corrosion removal &
3 05
Protection.
5 6.5 Fasteners. 2 40
5.1 6.5.1 Thread cutting practices (External &
2
internal). 05
5.2 6.5.1 Identification of various threads. 2 05
5.3 6.5.2 Identification of different types of bolt. 2 02
5.4 6.5.2 Identification of Different types of pins. 2 02
5.5 6.5.2 Identification of Different types of
2 02
screws.
5.6 6.5.2 Torque wrench familiarization. 2 02
5.7 6.5.3 Locking devices. 2 06
5.8 6.5.3 Use of locking devices. 2 02
5.9 6.5.3 Safety wire locking. 2 05
5.10 6.5.4 Aircraft rivets. 1 04
5.11 6.5.4 Familiarization of different types of
Rivets and its identification ,Installation 1 05
of different types of rivets.
6 6.6 Pipes and Unions. 2 04
6.1 6.6 Identification of pipes, connector and
2 02
unions.
6.2 6.6 Tube forming process and Plumbing
2 02
assemblies.
7 6.7 Springs. 2 02
7.1 6.7 Familiarization of springs. 2 02
8 6.8 Bearings. 02 02
8.1 6.8 Familiarization of bearings used on
2 02
aircrafts.
9 6.9 Transmissions. 2 04
9.1 6.9 Identification of different types of Gears. 2 02
9.2 6.9 Familiarization of belts, pulley, chain
2 02
and sprockets.
10 6.10 Control Cables 2 04
10.1 6.10 Familiarization of control cable and their
2 02
assembly.
10.2 6.10 Swaging of cable and Splicing. 2 02

Total Hrs 80
CONTENTS
1. TERMS AND DEFINITIONS 01
2. AIRCRAFT MATERIAL : FERROUS 04
3. NON FERROUS METALS AND IT’S ALLOYS 26
4. NICKELALLOYS 43
5. MAGNESIUM ALLOYS 53
6. MECHANICALTESTING OF METALS 78
7. PLASTICS 95
8. TRANSPARENT MATERIALS 103
9. NATURALAND SYNTHETIC RUBBERS 108
10. ADVANCED COMPOSITE MATERIALS 112
11. METHODS OF CURING OF COMPOSITES 129
12. TYPE OF DAMAGES OF COMPOSITE AND THE METHODS OF
INSPECTION 135
13. CORROSION 145
14. FASTENERS 150
15. KNOWLEDGE OFVARIOUS TYPES OFTHREADS, USED IN BRITISH
AND 154
AMERICAN SYSTEM
16. THREAD FORMS 159
17. BOLTS AND SCREWS OF BRITISH MANUFACTURE 170
18. AIRCRAFT NUTS 205
19. AIRCRAFT SCREWS 230
20. LOCKING DEVICES (AIRCRAFTWASHERS) 239
21. AIRCRAFT RIVETS 246
22. PIPES AND UNIONS USED IN AIRCRAFTS 275
23. SPRINGS 298
24. BEARINGS 301
25. GEARS, GEAR TRAINS AND BEARINGS 310
26. BELTS AND DRIVES 323
27. CONTROL CABLES 331
28. ELECTRICAL CABLES CONTROL CONNECTORS 339
29. SWAGING 356


TABLE OF CONTENTS
Part-66 Module 6. Materials and Hardware (......................... Appendix I
- Basic Knowledge Requirements..............................................19
6.1A aircraft materials – ferrous ..........................................21
Introduction to Properties of
Metals .....................................................21
Explanation of Terms..........................................................................21
Ferrous Aircraft Metals ................................................22
Characteristics and Selection
Factors .........................................................................22
Stress Factors ....................................................................23
Identification of
Ferrous ........................................................................................24
Nomenclature and Chemical Compositions of Steels ..............................
Characteristics, and Uses of Alloyed Steels......27
Heat Treatment or Ferrous Metals ....................................................28
Behavior of Steel during Heating and Cooling ...................29
Hardening.................................................................................29
Hardening Precautions.......................................................30
Tempering ..................................................................30
Annealing.............................................................................31
Normalizing ..........................................................................31
Casehardening....................................................................32
Carburizing ..................................................................33
Application of Alloy teels........................................................33
6.1B aircraft materials – ferrous ........................................35
Testing of Ferrous Materials for Hardness, Tensile Strength, Fatigue
Strength and Impact Resistance.....35
Tensile Testing...............................................................35
Tensile Stress (Strength)..........................................35
Strain ............................................................................35
Load/Extension
Diagrams.................................................................................Tensile
Test Machine...................................................................37
Fatigue.........................................................37
Fatigue Testing ..............................................................................38
Fatigue
Failure......................................................................................39
Vibration.............................................................40
Fatigue Nature....................................................40
6.2A Aircraft Materials – Non-ferrous...........................................43
Aluminium and Aluminium .............................................................43
Category B1 according Part-66 Appendix 1 Module 6 Materials and
Hardware
CONTENTS
1 INTRODUCTION ......................................................................................... 1-1
2 PROPERTIES OF METALS ........................................................................ 2-1
2.1 BRITTLENESS .......................................................................................... 2-1
2.2 CONDUCTIVITY ........................................................................................ 2-1
2.3 DUCTILITY ................................................................................................ 2-1
2.4 ELASTICITY .............................................................................................. 2-1
2.5 HARDNESS ............................................................................................... 2-1
2.6 MALLEABILITY.......................................................................................... 2-1
2.7 PLASTICITY .............................................................................................. 2-1
2.8 TENACITY ................................................................................................. 2-1
2.9 TOUGHNESS ............................................................................................ 2-2
2.10 STRENGTH ............................................................................................... 2-2
2.10.1 Tensile Strength ........................................................................... 2-2
2.10.2 Yield Strength .............................................................................. 2-2
2.10.3 Shear Strength ............................................................................. 2-2
2.10.4 Bearing Strength .......................................................................... 2-2
3 TESTING OF MATERIALS ......................................................................... 3-1
3.1 TENSILE TESTING ................................................................................... 3-1
3.1.1 Tensile Strength ........................................................................... 3-1
3.2 LOAD/EXTENSION DIAGRAMS ............................................................... 3-4
3.2.1 Ductility ........................................................................................ 3-7
3.2.2 Proof Stress ................................................................................. 3-7
3.3 STIFFNESS ............................................................................................... 3-9
3.4 TENSILE TESTING OF PLASTICS ........................................................... 3-9
3.5 COMPRESSION TEST ............................................................................ 3-10
3.6 HARDNESS TESTING ............................................................................ 3-10
3.6.1 Brinell Test ................................................................................. 3-10
3.6.2 Vickers Test ............................................................................... 3-11
3.6.3 Rockwell Test ............................................................................. 3-11
3.6.4 Hardness Testing on Aircraft ...................................................... 3-12
3.7 IMPACT TESTING ................................................................................... 3-13
3.8 OTHER FORMS OF MATERIAL TESTING ............................................. 3-14
3.8.1 Creep ......................................................................................... 3-14
3.8.2 Creep in Metals .......................................................................... 3-14
3.8.3 Effect of Stress and Temperature on Creep ............................... 3-15
3.8.4 The Effect of Grain Size on Creep .............................................. 3-16
3.8.5 Creep in Plastics ........................................................................ 3-16
3.8.6 Fatigue ....................................................................................... 3-16
3.8.7 Fatigue Testing .......................................................................... 3-17
3.9 S-N CURVES .......................................................................................... 3-18
3.10 CAUSES OF FATIGUE FAILURE ............................................................ 3-20
3.11 VIBRATION ............................................................................................. 3-20
EASA Part 66 - Materials and Hardware.doc Issue 1 - 21 March, 2013 Page 2

3.12 FATIGUE METALLURGY ........................................................................ 3-21

3.13 FATIGUE PROMOTERS ......................................................................... 3-22
3.13.1 Design ........................................................................................ 3-22
3.13.2 Manufacture ............................................................................... 3-23
3.13.3 Environment ............................................................................... 3-23
3.14 FATIGUE PREVENTERS ........................................................................ 3-23
3.14.1 Cold Expansion (Broaching) ....................................................... 3-24
3.15 DO'S AND DONT'S – PREVENTING FATIGUE FAILURES .................... 3-25
3.16 STRUCTURAL HEALTH MONITORING (SHM) ....................................... 3-25
3.16.1 Fatigue Meters ........................................................................... 3-25
3.16.2 Strain Gauges ............................................................................ 3-25
3.16.3 Fatigue Fuses ............................................................................ 3-25
3.16.4 Intelligent Skins Development .................................................... 3-25
4 AIRCRAFT MATERIALS - FERROUS ........................................................ 4-1
4.1 IRON ......................................................................................................... 4-1
4.1.1 Cast Iron ...................................................................................... 4-1
4.1.2 Nodular Cast Iron ......................................................................... 4-1
4.2 STEEL ....................................................................................................... 4-1
4.2.1 Classification of Steels ................................................................. 4-2
4.2.2 Metallurgical Structure of Steel ..................................................... 4-3
4.2.3 Structure and Properties – Slow-Cooled Steels............................ 4-3
4.2.4 Effects of Cooling Rates on Steels ............................................... 4-4
4.3 HEAT-TREATMENT OF CARBON STEELS .............................................. 4-4
4.3.1 Associated Problems - Hardening Process .................................. 4-5
4.3.2 Tempering .................................................................................... 4-6
4.3.3 Annealing ..................................................................................... 4-6
4.3.4 Normalising .................................................................................. 4-6
4.4 SURFACE HARDENING OF STEELS ....................................................... 4-7
4.4.1 Carburising................................................................................... 4-7
4.4.2 Nitriding ........................................................................................ 4-8
4.4.3 Flame/Induction Hardening .......................................................... 4-8
4.4.4 Other Surface Hardening Techniques .......................................... 4-8
4.5 ALLOYING ELEMENTS IN STEEL ............................................................ 4-9
4.6 CARBON ................................................................................................... 4-9
4.6.1 Low-Carbon Steel ........................................................................ 4-9
4.6.2 Medium-Carbon Steel .................................................................. 4-9
4.6.3 High-Carbon Steel ........................................................................ 4-9
4.7 SULPHUR ................................................................................................. 4-9
4.8 SILICON .................................................................................................... 4-9
4.9 PHOSPHORUS ....................................................................................... 4-10
4.10 NICKEL ................................................................................................... 4-10
4.10.1 Nickel Alloys ............................................................................... 4-10
4.11 CHROMIUM (CHROME) ......................................................................... 4-11
4.11.1 Nickel-Chrome Steel and its Alloys ............................................ 4-11
4.12 COBALT .................................................................................................. 4-11
4.13 VANADIUM .............................................................................................. 4-12
EASA Part 66 - Materials and Hardware.doc Issue 1 - 21 March, 2013 Page 3

4.14 MANGANESE .......................................................................................... 4-12

4.15 MOLYBDENUM ....................................................................................... 4-12
4.16 CHROME AND MOLYBDENUM .............................................................. 4-12
4.17 TUNGSTEN ............................................................................................. 4-13
4.18 MARAGING STEELS............................................................................... 4-13
5 AIRCRAFT MATERIALS - NON-FERROUS ............................................... 5-1
5.1 PURE METALS ......................................................................................... 5-1
5.1.1 Pure Aluminium ............................................................................ 5-1
5.1.2 Pure Copper ................................................................................. 5-2
5.1.3 Pure Magnesium .......................................................................... 5-2
5.1.4 Pure Titanium ............................................................................... 5-2
5.2 ALUMINIUM ALLOYS ................................................................................ 5-3
5.3 IDENTIFICATION OF ELEMENTS IN ALUMINIUM ALLOYS .................... 5-3
5.4 CLAD MATERIALS .................................................................................... 5-5
5.5 HEAT-TREATMENT OF ALUMINIUM ALLOYS ......................................... 5-5
5.5.1 Solution Treatment ....................................................................... 5-6
5.5.2 Age-Hardening ............................................................................. 5-7
5.5.3 Annealing ..................................................................................... 5-7
5.5.4 Precipitation Treatment ................................................................ 5-8
5.6 IDENTIFICATION OF HEAT-TREATED ALUMINIUM ALLOYS................. 5-9
5.7 MARKING OF ALUMINIUM ALLOY SHEETS .......................................... 5-10
5.8 CAST ALUMINIUM ALLOYS ................................................................... 5-11
5.9 MAGNESIUM ALLOYS ............................................................................ 5-11
5.10 COPPER ALLOYS ................................................................................... 5-12
5.11 TITANIUM ALLOYS ................................................................................. 5-13
5.12 WORKING WITH TITANIUM AND TITANIUM ALLOYS ........................... 5-13
5.12.1 Drilling Titanium ......................................................................... 5-14
6 METHODS USED IN SHAPING METALS .................................................. 6-1
6.1 CASTING ................................................................................................... 6-1
6.1.1 Sand-Casting ............................................................................... 6-1
6.1.2 Advantages/Disadvantages of Sand-Casting ............................... 6-3
6.1.3 Typical Casting Defects................................................................ 6-3
6.1.4 Shell-Moulding ............................................................................. 6-3
6.1.5 Centrifugal-Casting ...................................................................... 6-3
6.1.6 Die-Casting .................................................................................. 6-4
6.1.7 Investment-Casting (Lost Wax) .................................................... 6-4
6.2 FORGING .................................................................................................. 6-5
6.2.1 Drop-Stamping ............................................................................. 6-6
6.2.2 Hot-Pressing ................................................................................ 6-6
6.2.3 Upsetting ...................................................................................... 6-6
6.3 ROLLING ................................................................................................... 6-7
6.4 DRAWING ................................................................................................. 6-7
6.5 DEEP DRAWING/PRESSING ................................................................... 6-7
6.6 PRESSING ................................................................................................ 6-7
6.7 STRETCH-FORMING ................................................................................ 6-7
EASA Part 66 - Materials and Hardware.doc Issue 1 - 21 March, 2013 Page 4

6.8 RUBBER-PAD FORMING ......................................................................... 6-7

6.9 EXTRUDING ............................................................................................. 6-8
6.9.1 Impact-Extrusion .......................................................................... 6-8
6.10 SINTERING ............................................................................................... 6-8
6.11 SPINNING ................................................................................................. 6-9
6.12 CHEMICAL MILLING ................................................................................. 6-9
6.13 ELECTRO-CHEMICAL MACHINING ......................................................... 6-9
6.14 ELECTRO-DISCHARGE MACHINING E.D.M. ........................................ 6-10
6.15 CONVENTIONAL MACHINING ............................................................... 6-11
6.16 SUPERPLASTIC FORMING .................................................................... 6-12
7 AIRCRAFT MATERIALS - COMPOSITE AND NON-METALLIC ................ 7-1
7.1 PLASTICS ................................................................................................. 7-1
7.1.1 Thermoplastic Materials ............................................................... 7-2
7.1.2 Thermosetting Materials ............................................................... 7-3
7.1.3 Resins .......................................................................................... 7-4
7.1.4 Elastomers ................................................................................... 7-6
7.2 PRIMARY ADVANTAGES OF PLASTICS ................................................. 7-7
7.3 PRIMARY DISADVANTAGES OF PLASTICS ........................................... 7-7
7.4 PLASTIC MANUFACTURING PROCESSES ............................................. 7-8
7.5 COMPOSITE MATERIALS ........................................................................ 7-9
7.5.1 Glass Fibre Reinforced Plastic (GFRP) ........................................ 7-9
7.5.2 Carbon Fibre Reinforced Plastic (CFRP) .................................... 7-10
7.5.3 Aramid Fibre Reinforced Plastic (AFRP) .................................... 7-11
7.5.4 General Information ................................................................... 7-11
7.5.5 Laminated, Sandwich and Monolithic Structures ........................ 7-12
7.6 NON-METALLIC COMPONENTS ............................................................ 7-13
7.6.1 Seals .......................................................................................... 7-13
8 DETECTING DEFECTS IN COMPOSITE MATERIALS.............................. 8-1
8.1 CAUSES OF DAMAGE .............................................................................. 8-1
8.2 TYPES OF DAMAGE................................................................................. 8-1
8.3 INSPECTION METHODS .......................................................................... 8-3
8.3.1 Visual Inspection .......................................................................... 8-3
8.3.2 Ring or Percussion Test ............................................................... 8-3
8.3.3 Ultrasonic Inspection .................................................................... 8-3
8.3.4 Radiography ................................................................................. 8-3
8.4 ASSESSMENT OF DAMAGE .................................................................... 8-4
9 BASIC COMPOSITE REPAIRS .................................................................. 9-1
9.1 REPAIR OF A SIMPLE COMPOSITE PANEL ........................................... 9-2
9.2 REPAIR OF A SANDWICH PANEL ........................................................... 9-3
9.3 GLASS FIBRE REINFORCED COMPOSITE REPAIRS ............................ 9-5
9.4 TYPES OF GLASS REINFORCEMENT .................................................... 9-5
9.4.1 Uni-Directional Cloth .................................................................... 9-5
9.4.2 Bi-directional Cloth ....................................................................... 9-6
9.4.3 Chopped Strand Mat .................................................................... 9-6
9.4.4 Resin ............................................................................................ 9-6
EASA Part 66 - Materials and Hardware.doc Issue 1 - 21 March, 2013 Page 5

9.5 POT LIFE................................................................................................... 9-7

9.6 CURING .................................................................................................... 9-7
9.7 GEL COAT ................................................................................................ 9-8
9.8 STORAGE OF GFRP MATERIALS ........................................................... 9-8
9.8.1 Storing Resin ............................................................................... 9-8
9.8.2 Storing Hardener .......................................................................... 9-8
9.8.3 Storing Fabrics ............................................................................. 9-8
9.9 PREPARATION FOR REPAIR .................................................................. 9-9
9.9.1 Surface Preparation ................................................................... 9-11
9.10 TECHNIQUES OF LAMINATING GLASS FIBRE ..................................... 9-11
9.11 PRE-WETTING GLASS FIBRE ............................................................... 9-12
10 ADHESIVES AND SEALANTS ................................................................. 10-1
10.1 THE MECHANICS OF BONDING ............................................................ 10-1
10.1.1 Stresses on a Bonded Joint ....................................................... 10-1
10.1.2 Advantages of Adhesives ........................................................... 10-3
10.1.3 Disadvantages of Adhesives ...................................................... 10-3
10.1.4 Strength of Adhesives ................................................................ 10-4
10.2 GROUPS AND FORMS OF ADHESIVES ................................................ 10-4
10.2.1 Flexible Adhesives ..................................................................... 10-4
10.2.2 Structural Adhesives .................................................................. 10-4
10.2.3 Adhesive Forms ......................................................................... 10-4
10.3 ADHESIVES IN USE ............................................................................... 10-5
10.3.1 Surface Preparation ................................................................... 10-5
10.3.2 Final Assembly ........................................................................... 10-5
10.3.3 Typical (Abbreviated) Process .................................................... 10-6
10.4 SEALING COMPOUNDS ......................................................................... 10-6
10.4.1 One-Part Sealants ...................................................................... 10-7
10.4.2 Two-Part Sealants ...................................................................... 10-7
10.4.3 Sealant Curing ........................................................................... 10-7
11 CORROSION ............................................................................................ 11-1
11.1 CHEMICAL (OXIDATION) CORROSION................................................. 11-1
11.1.1 Effect of Oxide Thickness ........................................................... 11-2
11.1.2 Effect of Temperature ................................................................ 11-3
11.1.3 Effect of Alloying ........................................................................ 11-4
11.2 ELECTROCHEMICAL (GALVANIC) CORROSION ................................. 11-5
11.2.1 The Galvanic Cell ....................................................................... 11-5
11.2.2 Factors Affecting the Rate of Corrosion in a Galvanic Cell. ........ 11-6
11.3 TYPES OF CORROSION ........................................................................ 11-8
11.3.1 Surface Corrosion ...................................................................... 11-8
11.3.2 Dissimilar Metal Corrosion ......................................................... 11-8
11.3.3 Intergranular Corrosion .............................................................. 11-9
11.3.4 Exfoliation Corrosion .................................................................11-10
11.3.5 Stress Corrosion .......................................................................11-10
11.3.6 Fretting Corrosion .....................................................................11-11
11.3.7 Crevice Corrosion .....................................................................11-11
11.3.8 Filiform Corrosion ......................................................................11-11
11.3.9 Pitting Corrosion .......................................................................11-12
EASA Part 66 - Materials and Hardware.doc Issue 1 - 21 March, 2013 Page 6

11.3.10 Corrosion Fatigue......................................................................11-13

11.3.11 Microbiological Contamination...................................................11-13
11.3.12 Hydrogen Embrittlement of Steels .............................................11-13
11.4 FACTORS AFFECTING CORROSION ...................................................11-14
11.4.1 Climatic .....................................................................................11-14
11.4.2 Size and Type of Metal .............................................................11-14
11.4.3 Corrosive Agents.......................................................................11-14
11.5 COMMON METALS AND CORROSION PRODUCTS ............................11-15
11.5.1 Iron and Steel ............................................................................11-15
11.5.2 Aluminium Alloys .......................................................................11-15
11.5.3 Magnesium Alloys .....................................................................11-16
11.5.4 Titanium ....................................................................................11-16
11.5.5 Copper Alloys ............................................................................11-16
11.5.6 Cadmium and Zinc ....................................................................11-16
11.5.7 Nickel and Chromium ................................................................11-17
11.6 CORROSION REMOVAL .......................................................................11-17
11.6.1 Cleaning and Paint Removal. ....................................................11-17
11.6.2 Corrosion of Ferrous Metals ......................................................11-18
11.6.3 High-Stressed Steel Components .............................................11-18
11.6.4 Aluminium and Aluminium Alloys ..............................................11-18
11.6.5 Alclad ........................................................................................11-19
11.6.6 Magnesium Alloys .....................................................................11-19
11.6.7 Acid Spillage .............................................................................11-20
11.6.8 Alkali Spillage ............................................................................11-20
11.6.9 Mercury Spillage .......................................................................11-21
11.7 PERMANENT ANTI-CORROSION TREATMENTS ................................11-22
11.7.1 Electro-Plating ...........................................................................11-22
11.7.2 Sprayed Metal Coatings ............................................................11-22
11.7.3 Cladding ....................................................................................11-22
11.7.4 Surface Conversion Coatings ....................................................11-23
11.8 LOCATIONS OF CORROSION IN AIRCRAFT .......................................11-23
11.8.1 Exhaust Areas ...........................................................................11-23
11.8.2 Engine Intakes and Cooling Air Vents .......................................11-23
11.8.3 Landing Gear ............................................................................11-24
11.8.4 Bilge and Water Entrapment Areas ...........................................11-24
11.8.5 Recesses in Flaps and Hinges ..................................................11-24
11.8.6 Magnesium Alloy Skins .............................................................11-24
11.8.7 Aluminium Alloy Skins ...............................................................11-24
11.8.8 Spot-Welded Skins and Sandwich Constructions......................11-25
11.8.9 Electrical Equipment .................................................................11-25
11.8.10 Miscellaneous Items ..................................................................11-25
12 AIRCRAFT FASTENERS .......................................................................... 12-1
12.1 TEMPORARY JOINTS ............................................................................ 12-1
12.2 PERMANENT JOINTS ............................................................................. 12-1
12.3 FLEXIBLE JOINTS .................................................................................. 12-1
12.4 SCREW THREADS ................................................................................. 12-2
12.4.1 The Inclined Plane and the Helix ................................................ 12-2
12.5 SCREW THREAD TERMINOLOGY ......................................................... 12-4
EASA Part 66 - Materials and Hardware.doc Issue 1 - 21 March, 2013 Page 7

12.5.1 Screw Thread Forms .................................................................. 12-6

12.5.2 Other Thread Forms ................................................................... 12-8
12.5.3 Classes of Fit ............................................................................. 12-8
12.5.4 Measuring Screw Threads ......................................................... 12-9
12.6 BOLTS ....................................................................................................12-10
12.6.1 British Bolts ...............................................................................12-10
12.6.2 Identification of BS Unified Bolts ...............................................12-10
12.6.3 American Bolts ..........................................................................12-13
12.6.4 Identification of AN Standard Bolts ............................................12-14
12.6.5 Special-to-Type Bolts ................................................................12-16
12.6.6 Metric Bolts ...............................................................................12-17
12.7 NUTS ......................................................................................................12-18
12.7.1 Stiffnuts and Anchor Nuts ..........................................................12-19
12.8 SCREWS ................................................................................................12-22
12.8.1 Machine Screws ........................................................................12-22
12.8.2 Structural Screws ......................................................................12-24
12.8.3 Self-Tapping Screws .................................................................12-24
12.9 STUDS ...................................................................................................12-25
12.9.1 Standard Studs .........................................................................12-26
Waisted Studs ........................................................................................12-26
12.9.3 Stepped Studs ..........................................................................12-27
12.9.4 Shouldered Studs......................................................................12-27
12.10 THREAD INSERTS ................................................................................12-27
12.10.1 Wire Thread Inserts ...................................................................12-27
12.10.2 Thin Wall Inserts .......................................................................12-28
12.11 DOWELS AND PINS ..............................................................................12-29
12.11.1 Dowels ......................................................................................12-29
12.11.2 Roll Pins ....................................................................................12-29
12.11.3 Clevis Pins ................................................................................12-30
12.11.4 Taper Pins.................................................................................12-30
12.12 LOCKING DEVICES ...............................................................................12-
31
12.12.1 Spring Washers ........................................................................12-31
12.12.2 Shake-Proof Washers ...............................................................12-32
12.12.3 Tab Washers .............................................................................12-33
12.12.4 Lock Plates ...............................................................................12-34
12.12.5 Split (Cotter) Pins ......................................................................12-34
12.13 LOCKING WIRE .....................................................................................12-35
12.13.1 Use of Locking Wire with Turnbuckles .......................................12-37
12.13.2 Use of Locking Wire with Locking Tabs. ....................................12-37
12.13.3 Thin Copper Wire ......................................................................12-38
12.14 QUICK-RELEASE FASTENERS ............................................................12-38
12.14.1 Dzus Fasteners .........................................................................12-38
12.14.2 Oddie Fasteners .......................................................................12-39
12.14.3 Camloc Fasteners .....................................................................12-40
12.14.4 Airloc Fasteners ........................................................................12-41
12.14.5 Pip-Pins ....................................................................................12-41
12.14.6 Circlips and Locking Rings ........................................................12-42
12.14.7 Keys and Keyways ....................................................................12-43
EASA Part 66 - Materials and Hardware.doc Issue 1 - 21 March, 2013 Page 8

12.14.8 Peening .....................................................................................12-44

12.15 GLUE/ADHESIVE BONDED JOINTS .....................................................12-45
12.15.1 Locking by Adhesives ...............................................................12-45
12.15.2 Loctite .......................................................................................12-46
12.15.3 Synthetic Resin Adhesives ........................................................12-46
12.15.4 Testing of Adhesive Joining Techniques ...................................12-46
12.16 METAL-TO-METAL BONDED JOINTS ...................................................12-46
12.16.1 Welding .....................................................................................12-46
12.16.2 Soft Soldering ...........................................................................12-47
12.16.3 Hard Soldering ..........................................................................12-47
13 AIRCRAFT RIVETS .................................................................................. 13-1
13.1 SOLID RIVETS ........................................................................................ 13-1
13.2 RIVET IDENTIFICATION ......................................................................... 13-2
13.2.1 Solid Rivets (British) ................................................................... 13-2
13.2.2 Rivet Identification (British) ......................................................... 13-3
13.2.3 Rivet Material Identification (British) ........................................... 13-3
13.2.4 Solid Rivets (American) .............................................................. 13-5
13.2.5 Rivet Identification (American).................................................... 13-6
13.2.6 Rivet Material Identification (American) ...................................... 13-6
13.3 HEAT-TREATMENT/REFRIGERATION OF SOLID RIVETS ................... 13-7
13.3.1 Heat-Treatment. ......................................................................... 13-8
13.3.2 Refrigeration. ............................................................................. 13-8
13.3.3 Use of Different Types of Rivet Head ......................................... 13-8
13.4 BLIND AND HOLLOW RIVETS ............................................................... 13-9
13.4.1 Friction Lock Rivets ...................................................................13-10
13.4.2 Mechanical Lock Rivets.............................................................13-11
13.4.3 Hollow/Pull-Through Rivets .......................................................13-12
13.4.4 Grip Range................................................................................13-12
13.4.5 Tucker ‘Pop’ Rivets ...................................................................13-13
13.4.6 Avdel Rivets ..............................................................................13-14
13.4.7 Chobert Rivets ..........................................................................13-15
13.4.8 Cherry Rivets ............................................................................13-16
13.5 MISCELLANEOUS FASTENERS ...........................................................13-16
13.5.1 Hi-Lok Fasteners .......................................................................13-16
13.5.2 Hi-Tigue Fasteners ....................................................................13-17
13.5.3 Hi-Shear Fasteners ...................................................................13-18
13.6 SPECIAL PURPOSE FASTENERS ........................................................13-19
13.6.1 Jo-Bolts .....................................................................................13-19
13.6.2 Tubular Rivets. ..........................................................................13-20
13.6.3 Rivnuts ......................................................................................13-21
14 SPRINGS .................................................................................................. 14-1
14.1 FORCES EXERTED ON, AND APPLIED BY, SPRINGS ......................... 14-1
14.2 TYPES OF SPRINGS .............................................................................. 14-1
14.2.1 Flat Springs ................................................................................ 14-1
14.2.2 Leaf Springs ............................................................................... 14-2
14.2.3 Spiral Springs ............................................................................. 14-2
14.2.4 Helical Compression and Tension Springs ................................. 14-2
14.2.5 Helical Torsion Springs .............................................................. 14-2
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14.2.6 Belleville (Coned Disc) Springs .................................................. 14-2

14.2.7 Torsion-Bar Springs ................................................................... 14-2
14.3 MATERIALS FROM WHICH SPRINGS ARE MANUFACTURED ............ 14-2
14.3.1 Steels used for Cold-Wound Springs.......................................... 14-2
14.3.2 Steels used for Hot-Wound Springs ........................................... 14-3
14.3.3 Steels used for Cold-Rolled, Flat Springs ................................... 14-3
14.3.4 Non-Ferrous Metals used for Springs ......................................... 14-3
14.3.5 Composite Materials used for Springs ........................................ 14-4
14.4 CHARACTERISTICS OF TYPICAL AEROSPACE SPRINGS .................. 14-5
14.5 APPLICATIONS OF SPRINGS IN AIRCRAFT ENGINEERING ............... 14-6
15 PIPES AND UNIONS ................................................................................ 15-1
15.1 RIGID PIPES ........................................................................................... 15-1
15.2 SEMI-RIGID FLUID LINES (TUBES) ....................................................... 15-2
15.2.1 Flared End-Fittings ..................................................................... 15-2
15.2.2 Flare-Less Couplings ................................................................. 15-3
15.3 FLEXIBLE PIPES (HOSES) ..................................................................... 15-4
15.3.1 Low-Pressure Hoses .................................................................. 15-5
15.3.2 Medium-Pressure Hoses ............................................................ 15-5
15.3.3 High-Pressure Hoses ................................................................. 15-6
15.4 UNIONS AND CONNECTORS ................................................................ 15-7
15.4.1 Aircraft General Standards (AGS) .............................................. 15-8
15.4.2 Air Force and Navy (AN) ............................................................ 15-8
15.4.3 Military Standard (MS) ............................................................... 15-8
15.5 QUICK-RELEASE COUPLINGS .............................................................. 15-8
16 BEARINGS ................................................................................................ 16-1
16.1 BALL BEARINGS .................................................................................... 16-2
16.1.1 Radial Bearings .......................................................................... 16-2
16.1.2 Angular-Contact Bearings .......................................................... 16-2
16.1.3 Thrust Bearings .......................................................................... 16-2
16.1.4 Instrument Precision Bearings.................................................... 16-2
16.2 ROLLER BEARINGS ............................................................................... 16-3
16.2.1 Cylindrical Roller Bearings ......................................................... 16-3
16.2.2 Spherical Roller Bearings ........................................................... 16-3
16.2.3 Tapered Roller Bearings ............................................................ 16-3
16.3 BEARING INTERNAL CLEARANCE ....................................................... 16-4
16.3.1 Group 2 (‘One Dot’) Bearings ..................................................... 16-4
16.3.2 Normal Group (‘Two Dot’) Bearings ........................................... 16-4
16.3.3 Group 3 (‘Three Dot’) Bearings .................................................. 16-4
16.3.4 Group 4 (‘Four Dot’) Bearings .................................................... 16-4
16.4 BEARING MAINTENANCE ...................................................................... 16-5
16.4.1 Lubrication ................................................................................. 16-5
16.4.2 Inspection .................................................................................. 16-5
17 TRANSMISSIONS .................................................................................... 17-1
17.1 BELTS AND PULLEYS ............................................................................ 17-1
17.2 GEARS .................................................................................................... 17-3
17.2.1 Gear Trains and Gear Ratios ..................................................... 17-3
17.2.2 Spur Gears................................................................................. 17-4
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17.2.3 Helical Gears ............................................................................. 17-4

17.2.4 Bevel Gears ............................................................................... 17-4
17.2.5 Worm and Wheel Gears ............................................................. 17-4
17.2.6 Planetary (Epicyclic) Reduction Gear Train ................................ 17-5
17.2.7 Spur and Pinion Reduction Gear Train ....................................... 17-6
17.2.8 Accessory Unit Drives ................................................................ 17-6
17.2.9 Meshing Patterns ....................................................................... 17-7
17.3 CHAINS AND SPROCKETS .................................................................... 17-8
17.3.1 Typical Arrangements - Chain Assemblies ................................. 17-9
17.4 MAINTENANCE INSPECTIONS .............................................................17-10
18 CONTROL CABLES.................................................................................. 18-1
18.1 TYPES OF CABLES ................................................................................ 18-1
18.2 CABLE SYSTEM COMPONENTS ........................................................... 18-2
18.2.1 End-Fittings ................................................................................ 18-2
18.2.2 Turnbuckles ............................................................................... 18-3
18.2.3 Cable Tensioning Devices .......................................................... 18-4
18.2.4 Cable Fairleads .......................................................................... 18-5
18.2.5 Pulleys ....................................................................................... 18-6
18.3 FLEXIBLE CONTROL SYSTEMS ............................................................ 18-7
18.3.1 Bowden Cables .......................................................................... 18-7
18.3.2 Teleflex Control Systems ........................................................... 18-9
19 ELECTRICAL CABLES & CONNECTORS ............................................... 19-1
19.1 CABLE SPECIFICATION ......................................................................... 19-1
19.2 CABLE IDENTIFICATION ........................................................................ 19-1
19.3 DATA BUS CABLE .................................................................................. 19-5
19.4 CONDUCTOR MATERIAL & INSULATION ............................................. 19-6
19.5 WIRE SIZE .............................................................................................. 19-7
19.6 WIRE RESISTANCE ............................................................................... 19-8
19.7 CURRENT CARRYING CAPABILITY ...................................................... 19-8
19.8 VOLTAGE DROP ...................................................................................19-10
19.9 WIRE IDENTIFICATION .........................................................................19-11
19.10 WIRE INSTALLATION AND ROUTING ..................................................19-12
19.11 OPEN WIRING .......................................................................................19-12
19.12 WIRE & CABLE CLAMPING ...................................................................19-13
19.13 CONDUIT ...............................................................................................19-
14
19.14 CONNECTORS ......................................................................................19-16
19.15 CRIMPING ..............................................................................................19-
19
19.16 CRIMPING TOOLS .................................................................................19-20
19.17 WIRE SPLICING .....................................................................................19-
21
19.18 BEND RADIUS .......................................................................................19-
22
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