IC381 Appreciation of Aircraft

Manufacturing Processes/
P72 Aircraft Maintenance
Practices II
for HKAR-66 Cat. B1.1
Aeroplane/Turbine

TM5043
Sheet Metal Trade Practices
PPT01
Introduction to Sheet Metal and
Fasteners

File Name: IC381_P72_SMTP_PPT01

Publication No.:
Rev. No.: 0
Rev. Date: 23 July 2020
Assessment
> 100% Continuous Assessment
• Workshop Assignment = 40%
• Quiz =20%
• Report = 40%
Aluminium alloys
>Aluminium alloys are the most widely used
nonferrous metal in aircraft construction
>Aluminum is light weight metal, but it does not
have sufficient strength to be used as structure
material so that it alloyed with other metal, such
as copper, is much stronger.
Aluminium alloys
The alloy is identified by a four-digit numbers
Frist digit: alloy type
Second digit: modification of alloy
Third and fourth digit: purity of aluminium
99 % (minimum) pure Aluminium 1xxx
Copper 2xxx
Manganese 3xxx
Silicon 4xxx
Magnesium 5xxx
Magnesium & Silicon 6xxx
Zinc 7xxx
Other 8xxx
Aircraft Structural Aluminium
2024-T3
 This is the most common of the the high-
strength aluminum alloys. It has excellent
fatigue resistance.
 Typical uses for 2024-T3 aluminum sheet are
aircraft skins, cowls, aircraft structures, and
also for repair and restoration because of its
shiny finish.
 Ultimate strength is 62000 PSI with a shearing
strength of 40000 PSI.
Aircraft Structural Aluminium
6061-T6
 This alloy has a very good corrosion resistance and
finishing ability.
 The strength level of 6061-T6 aluminum sheet is
about that of mild steel.
 6061-T6 aluminum sheet can be fabricated by most
of the commonly used techniques.
 Typical uses are aircraft landing mats, truck bodies
and frames, structural components and more.
Ultimate strength is 45000 PSI with a shearing
strength of 30000 PSI.
Aircraft Structural Aluminium
7075
> Aircraft manufacturers use high-strength alloys to
strengthen aluminum aircraft structures.
> 7075 has Copper (1.6%), Magnesium (2.5%) and
zinc (5.6%) added for ultimate strength
> 7075 has the best machinability and it will result in a
very nice finish.
> Ultimate strength is 33000 PSI (-0) and 82000 PSI (-
T6) with a shearing strength of 22000 PSI (-0) and
49000 PSI (-T6).
Aircraft Structural Aluminium
Temper designation
>Most common temper designations found are T3
and T6.
>T3 is solution heat-treated and cold-worked by
the flattening process.
>T6 is solution heat-treated and artificially aged.
Aluminum - Advantages
1. Predictable strength which is certified by the manufacturer of
the metal and which is recorded with each batch.
2. The metal conductivity enables a single wire electrical system
to be used which saves weight and complexity.
3. The metal conductivity maximizes antenna reception and
transmission.
4. Recognized lightning strike properties and protection.
5. Minimal UV degradation from sunlight.
6. Controllable moisture problems such as corrosion.
7. Will transmit loads and can bend without failure.
8. Smoothness of construction is pre-determined; no extensive
sanding or filling is required.
9. Paint chips do not materially effect the integrity of the
underlying aluminum
Aluminum- Disadvantages
1. Form blocks must be built to hydro-form the metal in a
soft state which then has to be heat-treated to gain its
strength back.
2. Due to the setup of the hydro-form process, there is a
high per unit part cost unless large batches are
produced at one time.
3. Thin aluminum, as used in general aviation aircraft,
cannot be compound curved and still carry structural
loads, thereby increasing drag in some areas if
improperly engineered.
4. It is almost impossible to build laminar flow wings with
the skin thickness used in general aviation aircraft.
Forming Process
Forming, which tends to change the shape or
contour of a flat sheet or extruded shape, is
accomplished by either stretching or shrinking
the material in a certain area to produce curves,
flanges, and various irregular shapes.
Stretching
Stretching metal is achieved by hammering or
rolling metal under pressure.
Shrinking
Shrinking metal is much
more difficult than
stretching it. During the
shrinking process, metal
is forced or compressed
into a smaller area.
Crimping
Crimping is folding,
pleating, or corrugating a
piece of sheet metal in a
way that shortens it or
turning down a flange on
a seam.
Aircraft Fasteners
>On average, for example, 2.4 million (2,400,000)
fasteners are used to for assemble a Boeing 787
aircraft
>22% are structural bolts (mostly titanium) and the
rest is rivets
>Types of Fasteners in Aircraft Industry and their
Features:
• Aircraft Bolts
• Aircraft Nuts & Washers
• Aircraft Rivets
Types of aircraft fasteners

> Permanent Fastening

• Rivets
> Temporary Fastening
• Bolts
• Studs
• Screws
Aircraft Fastener Standard

>Most aircraft hardware is manufactured per

government standards
>The three most common aircraft fastener
standards used are:
• AN = Air Force/Navy
• NAS = National Aerospace Standards
• MS = Military Standards
AN Number Breakdown
> For Example : AN3DD5A
• AN means the bolt is manufactured according to Air
Force-Navy specs.
• “3” indicates the diameter of the bolt shank is in
sixteenths of and inch (3/16”)
• “DD” indicates the material is 2024
• “5” indicates the length in eighths of an inch (5/8”)
• “A” means the shank of the bolt is undrilled (no letter
here means a drilled shank)
Thread Standards
Aircraft, bolts, nuts, screws and studs are
manufactured to the many, different, International
Standards and in a variety of different thread forms,
as can be seen in the table
Quick-Release Fasteners
>Special fasteners have been
designed to hold fairings,
cowlings and inspection
panels in position and to
allow their rapid removal
and replacement during
servicing.
Quick-Release Fasteners
Dzus Fastener
>DZUS fasteners are
available in two types. A
light-duty type is used on
box -covers, access
hole covers, and
lightweight fairings. The
heavy-duty type is used
on cowling and heavy
fairings.
Friction Lock Rivets
>These are generally
fabricated in two parts,
consisting of a rivet head
with a hollow shank and a
stem that extends through
the hollow shank.
Special Fasteners
>Hi-Lok/Hi-Tigue Fasteners
Special Fasteners

>Hi-Shear Fasteners
END