Standard Aircraft Handbook for Mechanics and Technicians

621 Pages·2016·18.08 MB·English

by  Reithmaier L.

Standard Aircraft Handbook for Mechanics and
Technicians
ABOUT THE EDITORS

Larry Reithmaier, a retired aerospace engineer, helped design and develop jet
fighter and bomber aircraft and NASA spacecraft. He has a degree in mechanical
engineering and holds the following FAA certificates: Commericial/Instrument
Pilot, Flight/Ground Instructor, and Airframe and Powerplant (A&P) Mechanic.
The author of several technical books on aviation, Mr. Reithmaier has also
written the Aviation and Space Dictionary, Mach I and Beyond, the Private
Pilot’s Guide, and the Instrument Pilot’s Guide.
Ronald Sterkenburg started teaching at Purdue University in 1999 after a 20-
year career in the U.S. Navy. He is the author or co-author of 10 books and more
than 60 articles in national and international journals and conference
proceedings. The focus of Dr. Sterkenburg’s research is the repair of metallic
and composite aircraft structures. He is a certificated Airframe and Powerplant
(A&P) Mechanic, holds an Inspection Authorization (IA), and is a Designated
Mechanic Examiner (DME).
Standard Aircraft Handbook for
Mechanics and Technicians
Edited by Larry Reithmaier and Ronald
Sterkenburg
Seventh Edition

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Contents

Preface
Acknowledgments

Chapter 1. Introduction

Fuselage Structure
Location Numbering Systems
Wing Structure
Empennage or Tail Assembly
Chapter 2. Tools and How to Use Them

Safety Considerations
General-Purpose Hand Tools
Hammers
Screwdrivers
Pliers
Punches
Wrenches
Metal-Cutting Tools
Hand snips
Hacksaws
Chisels
Files
Drilling and countersinking
Reamers
Layout and Measuring Tools
Rules
Combination sets
Scriber
Dividers and calipers
Slide calipers
Taps and Dies
Shop Equipment
Holding devices
Squaring shears
Throatless shears
Bar folder
Sheet-metal brake
Slip roll former
Grinders
Rotary punch
Chapter 3. Materials and Fabricating

Aluminum and Aluminum Alloys
Alloy and temper designations
Cast and wrought aluminum alloy designation system
Aluminum
Aluminum alloys
Temper designation system
Characteristics of Aluminum Alloys
Nonheat-treatable alloys
Heat-treatable alloys
Clad alloys
Annealing characteristics
Typical uses of aluminum and its alloys
Heat treatment of aluminum alloys
Identification of aluminum
Handling Aluminum
Forming Aluminum Alloys
Forming at the factory
Blanking
Bending
Press-Brake Forming
Stretch Forming
Hydro Press Forming
Roll Forming
Flexible-Die Forming
Machining
Drilling
Turret Lathes and Screw Machines
Milling
Routing
Forging
Casting
Chemical Milling
Making Straight-Line Bends
Bend allowance
Brake or sight line
J chart for calculating bend allowance
Making Layouts
Relief holes
Miscellaneous shop equipment and procedures
Magnesium and Magnesium Alloys
Heat treatment of magnesium alloys
Titanium and Titanium Alloys
Titanium designations
Corrosion characteristics
Treatment of titanium
Working with Titanium
Machining of titanium
Milling
Turning
Drilling
Tapping
Grinding
Sawing
Cleaning after machining
Shop-forming titanium
Stress relief
Ferrous Aircraft Metals
Identification
Types, characteristics, and uses of alloyed steels
Heat treatment of ferrous metals
Chapter 4. Drilling and Countersinking

Rivet Hole Preparation
Rivet hole location
Drills
Drill sharpening
Drill points
Drilling equipment
Drilling Operations
Chucking the drill
Drilling holes
Drill stops and drill bushings
Using an extension drill
Drilling aluminum and aluminum alloys
Drilling titanium and titanium alloys
Drilling stainless steel
Deburring
Countersinking
Types of countersinking cutters
Countersinking holes
Minimum countersinking depth
Form countersinking (dimpling)
100° combination predimple and countersink method
Hole preparation for form countersinking
Shaving Flush Head Fasteners
Reamers
Chapter 5. Riveting

Solid-Shank Rivets
Material
Rivet types and identification
Riveting Practice
Edge distance
Rivet length
Rivet spacing
Hole preparation
Use of clecos
Driving solid-shank rivets
Rivet sets
Bucking bars
Riveting procedure
Blind bucking
Tapping code
Hand Riveting
Rivet Squeezers
Inspection after riveting
Rivet Removal
NACA Method of Double Flush Riveting
Blind Rivets
Mechanical locked-stem self-plugging rivets
Removal of mechanically locked blind rivets
Sheet-Metal Repair
Damage removal
Repair material thickness
Rivet selection
Rivet spacing and edge distance
Repair approval
Typical sheet-metal repairs
Patches
Flush Patch
Chapter 6. Bolts and Threaded Fasteners

Aircraft Bolts
General-purpose bolts
Close-Tolerance Bolts
Classification of Threads
Identification and coding
Aircraft Nuts
Self-locking nuts to 250°F
High-temperature self-locking nuts
Miscellaneous nut types
Aircraft Washers
Plain washers
Lock washers
Installation of Nuts and Bolts
Torque tables
Cotter pin hole line-up
Safetying of nuts, bolts, and screws
Cotter Pin Safetying
Installation: Bolts, Washers, Nuts, and Cotter Pins
Miscellaneous Threaded Fasteners
Screws