AMT – 100 Aircra, Material, Processes & Hardware Chapter 5
advertisement
AMT–100 Aircra,Material,Processes& Hardware Chapter5 MetalProper<es • Hardness-Thepropertyofamaterialthat enablesittoresistpenetra<on,wearorcuDng ac<ons. • Strength–Theabilityofamaterialtoresist deforma<on(beingdeformed) • Malleability-Thecharacteris<cofamaterial thatallowsittobestretchedorshapebybea<ng ofahammerorpassingthroughrollerswithout breaking. MetalProper<es • Duc<lity-Thepropertywhichallowsmetaltobe permanentlydrawn,bent,ortwistedinto variousshapeswithoutbreaking. • Elas<city-Thecapabilityofamaterialtobe stretched(deforma<on)andtorecoverit'ssize andshapea,erit'sdeforma<on.Thepointat whichpermanentdeforma<onoccursisthe yieldpoint. • Toughness-Thepropertyofthemetalwhich allowsittobedeformedwithoutbreaking.The oppositeofbriPleness. MetalProper<es • BriPleness-Thepropertyofamaterialtobreak whenbentordeformed.Itistheresistanceto changeintherela<veposi<onofthemolecules inthematerial. • Conduc<vity-Theabilityofamaterialto transferheatorelectricity • ThermalExpansion–Thecontrac<onand expansionofmaterialastheresultofhea<ngor cooling. FerrousMetals • Ferrousmetalisonethatcontainsiron • Pureironistooso,foraircra,use ! Addcarbontoironandyougetsteel • SAE-SocietyofAutomo<veEngineers • SAEfour-digitnumberingsystemforiden<fying steel Firstdigit:basicalloyingelement ! Seconddigit:thepercentageofthebasicelementin thealloy ! Thirdandfourthdigits:percentageofcarboninthe alloyin1/100ofapercent ! FerrousMetals • Example:SAE1020-steelthatislow-carbon steelthatcontains0.20%carbon • Maximumamountofcarbonisjustover1% ! Morecarbon,harderandmorebriPle • 1XXX–Carbonsteel ! SAE1010to1030 • 0.10to0.30%carbon • So, • Canbesurfacehardened FerrousMetals • 1XXX–Carbonsteel SAE1030to1050–medium-carbonsteels ! SA1050andgreater–high-carbonsteel ! • 2XXX–Nickel ! SAE2330steelisusedforaircra,bolts,cable terminals,keys,clevises,andpins. • 3xxx-Nickel-chromiumsteel FerrousMetals • 41xx-Chrome-molybdenumsteel ! 4130verycommoninaircra,parts • 6xxxChrome-vanadiumsteel ! Commonfortools • • • • • CRES CorrosionResistantsteel Stainlesssteel 10+%ofchromium 200thru400series Usuallynon-magne<c AluminumAlloys • Aluminumalloyfour-digitiden<fica<onsystem: Firstdigit-Alloytype ! Seconddigit-Modifica<onofalloy ! Thirdandfourthdigits-Purityofaluminum ! • 1100–purealuminum • 2XXX–Copperischiefalloy Strongbutcorrodeseasily ! 2117–rivets,2024–sheetmetal ! Can’tweld ! AluminumAlloys • Cladaluminum(Alcad)–averythinlayerofpure aluminumappliedtothesurfaceofsheet aluminum ! Protectagainstcorrosion • Purealuminumcreatesaluminumoxidewhenexposed • Aluminumoxideisawhitefilm • Protectstheremainingaluminum • Isaninsulator Easytoscratch ! Slightlylessstrengththananuncladsheetofthe samethickness ! • • • • MagnesiumAlloys Light&Strong Highlysuscep<bletocorrosion Tendencytocrack Burns Usedry-powderfireex<nguisher ! Don’tusewater ! • • • • Titanium Highstrength Corrosionresistant Lightweight Needspecialtoolstowork,machineorweld • • • • PureCopper Goodconduc<vity–heatandelectricity Corrosionresistant BecomesbriPlewhenworkhardened Alloys Beryllium ! Zinc–makesbrass ! Tin–makesbronze ! Aluminum ! Manganese ! Nickel • Usedforhighstrengthandhightemperature applica<ons • Monel • Inconel IronCrystallineForm IronCrystallineForm MetalHeatTreatment • Steelhasacrystallinestructure • Thearrangementofatomsinsteel’scrystalline structuredeterminethesteel’shardness • Theprocessesofhea<ngandcoolingareusedto controlnatureofthestructure • Thesamehea<ngandcoolingprocessescanbe usedtocontrolhowthealloyingelements changethesteel’sstructure MetalHeatTreatment • Cri<calTemperature–Thetemperatureatwhich theinternalstructuretakesacrystallineform ! Lowerthanmel<ngpoint • Tocontrolthesteel’shardness,thesteelisraised toabovethecri<caltemperatureandthan cooledtolockinthecrystallinestructure • Thefasterthesteeliscooled Themoredensethecrystallinestructure ! Themorehard(harder) ! ThemorebriPle ! MetalHeatTreatment • Thecoolingprocessiscallquenching • Quenchingliquidsandrates Brine(water&salt)–veryfast ! Water–fast ! Oil–slow ! • Canstartaflashfire Polymerandwater–precisioncontrol ! Salts–precisioncontrol ! • Producesmoreconsistentresultsbetweeninteriorand surface • Highspeedquenchingcancausecracking MetalHeatTreatment • Normalizing Forging,working,rolling,machiningandweldingcan leavestressesinametalstructure ! Normalizingrelievesthestresses ! Heattoabovecri<caltemperatureandthencooled slowlyinair ! MetalHeatTreatment • Annealing Producesafine-grain,so,,duc<lemetalwithout internalstressesorstrains ! Canproducetheloweststrengthsteel ! Heatabovecri<caltemperatureandletitsit(soakat thattemperature ! Slowlycooledinatemperaturecontrolledfurnace ! SteelTemperatureRanges Temperaturerangesforheattrea<ngsteelalloys. MetalHeatTreatment • Tempering-Aformofheattreatmentinwhich someofthehardnessandbriPlenessisremoved fromametalthathasbeenhardenedbyheat treatment Temperingtemperaturesarelowerthanthecri<cal temperature ! Temperingproceduresincludeaspecific temperatureand<me ! MetalHeatTreatment Temperingtemperaturesforvarioussteelalloystoobtaintheindicatedtensilestrength. ToolTempering Temperingofsmalltoolsbyobservingthecoloroftheoxidesthatformwhenthesteelisheated. CaseHardening • Casehardening-Atypeofmetalheattreatment inwhichthesurfaceofthemetalishardened andmadebriPlewhilethecoreofthematerial remainsstrongandtough Usuallydonewithlowercarbonsteel ! Thehardenshellisverythin ! • 0.01”to0.06” ! Thehardeningprocesscanbeappliedtoonlyspecific partsofanobject CaseHardening • Nitriding-Amethodofcasehardeningsteelby hea<ngitinanatmosphereofammonia.The nitrogenintheammoniareactswiththesurface ofthesteeltoformextremelyhardnitrides Doesn’tchangethedimensionofthepart ! Causeslessdistor<onthanothertypesofcase hardening ! CaseHardening • Carburizing-Casehardeningprocessinwhich addi<onalcarbonisinfusedintothesurfaceofa low-carbonsteel. Surfaceisheatedandthenexposedtocarbon 2 ! CarboncancomefromCO ,sootorcoke 2 ! CanbemadeinafurnacefilledwithCO ! ColdWorking • Plas<cDeforma<on-Amaterialundergoing non-reversiblechangesofshapeinresponseto appliedforces • ColdWorking-Thestrengtheningofametalby plas<cdeforma<onatlowtemperatures Alsocalledworkhardeningorstrainhardening ! Coldrollingisaformofcoldworking ! • Wrought-beatenoutorshapedbyhammering Forging • Forging–Theprocessbywhichmetalisheated andisshapedbyplas<cdeforma<onbysuitable applyingcompressiveforce Usuallydonewithpowerhammerorpress ! Refinescrystalgrainstructure ! • Improvesstrength,duc<lityandtoughness • Canorientdirec<onofgrainflowtothatoftheprinciple stressesencounteredinactualuse • Video1 • Video2 • Video3 Cas<ng • Cas<ng–formingbymel<ngthemetaland pouringintoamoldofthedesiredshape • Video1,Video2 • Lesscontrolovergrainandcoolingprocess • LowerstrengthandmorebriPlethanforged products Extrusion • Extrusion–forcingametalthroughanopening inadie,thuscausingthemetaltotaketheshape ofthedie • Video HeatTrea<ngAluminumAlloys • CalledSolu<onHeatTrea<ng • Mustbequenchedimmediatelyinwater ! Createssmallcrystals • ThesmallerthecrystalsthebePer • Quenchasfastaspossible ! Delayinquenchingcausesthecrea<onoflarger crystals • Largercrystalscauseintergranularcorrosion ! Intergranularcorrosion-Corrosionthatformsalongthegrain boundariesinapieceofmetal. IntergranularCorrosion Intergranularcorrosioncanstartonthesurfaceandprogress throughthemetal,followingthegrainboundaries. IntergranularCorrosion IntergranularCorrosion HeatTrea<ngAluminumAlloys • Aluminumdoesn’treachfullstrength immediatelya,erquenching • Thealuminumhardenswithage Called“aging”or“agehardening” ! Canhappeninminutes,hours,daysoryears ! Remember“icebox”rivets(D&DD) ! Ar<ficiallyAgeHardeningAluminum • CalledPrecipita<onHeatTreatment • Acceleratetheprocessofagehardening • Heldatatemperature,muchlowerthanthat usedforsolu<onheattreatment,forupto24 hoursandthenremovedfromtheovenand allowedtocooledins<llair • Increasesthestrengthandhardness • Reducesduc<lity • Makeshardertobendandform AluminumTreatment • Annealingisusedtoso,enaluminum ! Usedtoso,enaluminumwhenworkingor “pounding”metalintoshape • AluminumisNOTnormalized ! Onlysteel • Onceclad,sheetmetalisnotheattreated ! Thepurealuminumlayerwillcontaminateinner layer AluminumAlloyTemperDesigna<ons • Temper-hardened • F–Fresh/rawaluminum ! Nevercoldworked,heattreated,orannealed • O–Annealed • T–Heattreated/hardened • H–Work/strainharden AluminumAlloyTemperDesigna<ons Temperdesigna<onsofaluminumalloys. HardnessTes<ng • Twomethods: Rockwell ! Brinell ! • Rockwell Measuresthehardnessofametalbymeasuringthe depthofpenetra<onofaspecialpenetratorundera specifiedload ! So,metalsuseahardenedsteelball ! Hardmetalsuseadiamondcone ! Fourscales:AthruD ! • BandCthemostcommon RockwellTes<ng • Video RockwellTes<ng BrinellHardnessTes<ng • Hardnessofthematerialismeasuredbythe diameteroftheimpressionmadebya10-mmdiameterhardenedsteelballforcedintothe materialbyahydrauliccylinder BrinellHardnessTes<ng Figure 7-9. A.Brinellhardnesstester. B.MicroscopicviewofimpressionmadebyaBrinelltester. • • • • Wood Onceaverypopularmaterial Lightandstrong Hasproblemswithwaterdecay Becarefulwhichglueisusedforrepair Theglueusedtomanufacturetheaircra,mayno longerbeacceptable ! AC43-1BrecommendsResorcinoladhesive (resorcinol-formaldehyderesin) ! AC43-1Balsorecommendsepoxybutdoesn’t indicatewhichone ! Plas<cs • Thermoplas<cresins So,enedbyheatandhardenedwhencooled ! Usedforwindshieldsandsidewindows ! Celluloseacetate ! • Yellowswithage • Dissolveswithacetone ! Acrylicresins • Tradename-Plexiglas,Lucite,andPerspex Plas<cs • ThermoseDngResins Willnotso,enwhenitisheated,anditwillcharand burnbeforeitmelts ! Plas<ctrim ! Epoxy ! • CoPon Fabric Decayseasily ! Usedforrestora<onprojects ! • PolyesterhasreplacedcoPon ! TradenameDacronorCeconite • Severalcoveringsystemsavailabletoreplace nitrate/butyrate(dope) ! NeedanSTCtoapply Composites • Fabricsheldtogetherwithglue ! Strengthprovidedbyfabricnotglue • Usetheminimumamountofglue • Glues ! Epoxy • Twopartresins • Mixra<oiscri<cal ! Polyesters • Mixwithacatalyst • Mixra<oislesscri<cal • Notasstrongepoxy • Fabrics ! Composites Fiberglass • Strongandlight • Non-conduc<ve • Rela<velyinexpensive ! Kevlar • Strongandstretches • Non-conduc<ve Composites • Fabrics ! Carbon • Verystrong ! Strongerthanfiberglass • Conduc<ve ! Radioinstalla<onmoredifficult • Cancausecorrosionproblemswithmetals • CanbebriPle • Expensive • Theindustryiss<lldevelopingmethodstorepair damage • Agingproper<esares<llunknown Rubber • Natural–fromtrees • Synthe<c • Notallrubbersareequal Matchtherubbertotheapplica<on ! RTFM ! Aircra,Hardware • AsanA&P,youmustinsurethatanaircra, containsonlythehardwarespecifiedbythethe aircra,manufacturer • Na<onalhardwarestandards AN–AirForce-Navy ! MS-MilitaryStandard ! NAS-Na<onalAerospaceStandards ! • Standards ! ThreadFit UnifiedStandard–3classes • A–screworexternalthread • B–nutsorinternalthread ! American(Na<onal)Standard–4classes • Class-1-fitisaloosefit.Usedforeasytoremove applica<on • Class-2-fitisafreefit.Itisusedforsomemachinescrews. • Class-3-fitisamediumfit.Itisusedforalmostall standardaircra,bolts. • Class-4fitisaclosefit,thatrequiresawrenchtoturnthe nutontothebolt. FastenerTorque • Followthemanufacturer’srecommenda<ons ! OrAC43-13-1BTable7-1 • Unlessotherwisespecified,torquevaluesfor <ghteningaircra,fastenersarespecifiedwith threadsingoodcondi<onandtheymustbe cleananddry ! Iflubrica<onisspecified,usetheexactlubrica<on calledforandtheexactamount • Methods: ! FastenerTorque Torquewrench • Remembertoaddthetorquerequiredtoturnaloose fastener ! Nut-rota<onmethod • Tightenedun<lfastenerissnug,thenturnedaspecific numberofturnsor“faces” ! Bolt-stretchmethod • Tightenedun<lthefastenerisstretchedaspecified amount TorqueRa<os • 1in-oz=28.35gram-in • 1in-lbs=16in-oz • 1foot-lbs=12in-lbs Aircra,BoltIden<fica<on Aircra,boltiden<fica<on. • • • • BoltMarkings Crossorasterisk-nickelsteel Singledash-corrosion-resistantsteel(CRES)bolt Twodashes-aluminumalloy Trianglesurroundingthecrossorasterisk-closetolerancebolt ! Hasnogripcoa<ng AN3thruAN20 • Hexheadboltfortensionorshear • Grip–por<onwithnothread ! • • • • • Shouldbethesamelengthasthethicknessofthe materialbeingfastenedwiththebolt Shank–Includesthethreadedpor<on Chamfer-taperedend Length-boPomoftheheadtothechamfer Finethread–UNF-3A NewstandardisNASM3thruNASM20 AN3thruAN20 • Example:AN4H6 StandardBolt ! AN4–1/4”diameter ! H-steelwithholeinhead ! 6–3/4”long ! NoA-holeinshank ! AN3thruAN20 • AN(Diameter)(Material)(HeadHole)(Length) (ShankHole) • AN • Diameter-3thru20-in1/16’s-3/16through1 1/4(20/16) • Material “-”NickelSteel2330(SilverisCadmium1,Goldis Cadmium2) ! “C”–CRES ! “DD”–Aluminum ! • H-holeinhead AN3thruAN20 • Lengthin1/8’s 3thru7–3/8thru7/8 ! No8or9 ! 1”andabove–firstdigit–inches,second–1/8’s ! • 'A'isnoshankhole,Nothingisholeinshank AN3thruAN20 • Example:AN4H6 StandardBolt ! AN4–4/16”-1/4”diameter ! H-steelwithholeinhead ! 6–6/8”-¾”long ! NoA-holeinshank ! • TestExamples: AN5-7 ! AN14C7A ! AN16H10 ! AN7DD7A ! BoltInstalla<on • Whenpossible Installheadfacingforward or Installheadfacingup ! Lesslikelytofallout ! • AN3isreallyaNO.10-32screwsize ! Closeto3/16” BoltInstalla<on–AC43-13-1B • Overtheyears,somefastenersspecifica<ons havebeenchanged.Forthisreason,itis recommendedwhenmakingrepairstoan aircra,,whoseoriginalhardwareisbeing replaced,thatyoumustfirstmeasurethebolt beforeordering,ratherthanrelyingontheparts manualforiden<fica<on. • Themaximumcombinedheightofwashersthat shouldbeusedis1/8inch.Thislimitstheuseof washersnecessarytocompensateforgrip,upto thenextstandardgripsize. BoltInstalla<on–AC43-13-1B • Allboltinstalla<onswhichinvolveself-lockingor plainnutsshouldhaveatleastonethreadofthe boltprotrudingthroughthenut. • Lockorsafetyallboltsand/ornuts,exceptselflockingnuts.DonotreusecoPerpinsorsafety wire. ClevisBolt Aclevisboltisdesignedtotakeshearloadsonly,and shouldneverbeusedwhereatensileloadisimposed. AN21thruAN37 • Clevisbolt • Forshearloadsonly • Normallyinstalledsothattheyarelooseand freetorotate • Whenrota<onispossible,ashearcastlenut shouldbeinstalledandacoPerpinshouldbe usedtosecurethenuttothebolt. • Whenaclevisboltisusedtosecureafork-end cableterminal,thenutshouldbe<ghtenedun<l itissnug,buttheremustbenostrainonthe fork. AN21thruAN37 • Steelonly • Usesiden<fiernumbersimilartoAN3thruAN20 • Diameter AN21–NO.6-40screwsize ! AN22–NO.8-32screwsize ! AN23–NO.10-32screwsize ! NoAN36 ! AN24thru37 ! • (AN#-20)X1/16 ! e.g.AN24–(24–20)X1/16=4/16=1/4" AN21thruAN37 • Materialisalways“-” ! Steel • Lengthin1/16” ! Nospecialdesigna<onforover15/16” • Add'A'totheendfornoshankhole.Nothingis holeinshank DrilledHeadBolts • AN73thruAN81–DrilledHeadBolts ! Threadtype&material • “-”–Steelwithfinethread • “A-”–Steelwithcoarsethread ! Diameterin1/16” • AN#-70 ! e.g.AN75–70=5/16 Lengthis1/8” ! Noshankholeandno“A”used ! DrilledHeadBolts • AN73thruAN81–DrilledHeadBolts e.g.AN75-10is5/16”diameter,steel,finethread&1 1/4”(10/8)long ! e.g.AN75A-10is5/16”diameter,steel,coarsethread &11/4”(10/8)long ! DrilledHeadBolts • SupersededbyNASM20073&NASM20074 NASM20073issteelwithfinethread ! NASM20074issteelwithcoarsethread ! Bothuse–dd-llforsizing ! • ddistwodigitdiameterin1/16” • llistwodigitlengthin1/8” e.g.NASM20073-05-10issteel,finethread,5/16” diameter&11/4”(10/8)long ! e.g.NASM20074-05-10issteel,coarsethread,5/16” diameter&11/4”(10/8)long ! DrilledHeadBolts • Finethreadfornutsorsteelparts • Coarsethreadforaluminumormagnesium cas<ngs CloseToleranceBolts • AN173thruAN186 • Noexternalcoat ! Protectedbyoilorgrease • Steelonly • NumberingsystemthesameasAN3thruAN20 exceptsubtract170fromAN# ! e.g.AN175–170=5or5/16diameter • HeadMarkings–triangle,trianglewithacross inside,trianglewithasteriskinside Nuts Commonlyusednon-self-lockingaircra,nuts. Nuts • AN310–CastleNut&AN320–ShearCastleNut NowcalledNASM310&NASM320 ! Material ! • “-”–Steel • D–Aluminum • C–CRES Diameterin1/16”–finethread ! AN320areusedforshearapplica<onsonly ! TorquetominimumseDng.Ifshankholedoesn’t lineup,torqueuptomaximumseDng ! • Changewashersifshankholedoesn’tlineup • AN315–PlainNut Nuts NowcalledNASM315 ! Material ! • “-”–Steel • D–Aluminum • C–CRES Diameterin1/16”–finethread ! “R”isrighthandthread,“L”isle,handthread ! • RmaybeomiPed ! e.g.AN315-8RorAN315-8 • AN316–CheckNut Nuts NowcalledNASM316 ! Material ! • “-”–Steel • C–CRES Diameterin1/16”–finethread ! “R”isrighthandthread,“L”isle,handthread ! • RmaybeomiPed e.g.AN316-8RorAN316-8 ! Usetolockothernuts ! Nuts • AN365–SelfLockingNut NowcalledMS20365 ! Material ! • “-”–Steel • D–Aluminum • B–Brass ! Diameter&TPI–ddPordP • dorddisdiameterin1/16” • PisTPI(coarsethreadfor#4thru#8screwsizes) • e.g.624is3/8-24 • Screwsizes440,632,832&1032 Nuts • AN365–SelfLockingNut ! Insertmaterial • A-non-metallic–lowtemperatureapplica<ons • C–metallic–hightemperatureapplica<on • Nodesigna<on–EitheranAorCcanbeused Theinserthasasec<onthathasnothreads,thisis whatlocksthebolt ! Selflockingnutsshouldnotbeusedwithfasteners thatrotate ! Ifyoucanturnaselflockingnutwithyourhand,itis wornout. ! Nuts • AN363(MS20363)–Hightemperatureself locking • AN364(MS20364)–Thin(shear)selflocking • AN356(MS27151)–PalNut Nutmadeoutofpressedsheetmetal ! TrademarkPalnut™ ! AN356andMS27151isdifferentnumberingsystem ! Nuts • AN350–Wingnuts • MS21078,MS21080,MS21081areluganchor nut • MS21079isachannelnut TinnermanSpeedNut PlainWashers • AN960–Plainwasher ! NowcalledNAS1149 • AN970-PlainWasherLargeArea ! NowcalledNASM970 • Availableinavarietyofmaterialsandcoa<ng ! Usecorrectmaterialandcoa<ngpreventcorrosion problems • Availableisstandardandlight(thin)thicknesses ! Lightwashercanbeusedtoadjustcastlenut posi<on PlainWashers • Providesasmoothbearingsurface • Protectssurfacefromgalling&corrosion ! Mustbeusedwhenusingalockingwashers • Shouldbeusedundereveryboltheadandnut • Whenusinglockwasher,theordershouldbe: Ma<ngsurface ! Plainwasher ! Lockwasher ! Nut ! LockWashers LockWashers • AN935–Splitlockingwasher NowcalledMS35338 ! Steel ! AN935hasdifferentthicknesses,MS35338doesn’t ! • AN936–Starwasher TypeA–internalteeth ! TypeB–externalteeth ! Availableinsteelandbronze ! WhenNottouseaLockWasher • Withfastenerstoprimaryorsecondarystructure • Withfastenersonanypartoftheaircra,where failuremightresultindamageordangertothe aircra,orpersonnel • Wherefailurewouldpermittheopeningofa jointtotheairflow. • Wherethescrewissubjecttofrequentremoval WhenNottouseaLockWasher • Wherethewashersareexposedtotheairflow • Wherethewashersaresubjecttocorrosive condi<ons • Theaboverulesaregoodguidelineswhennotto uselocknuts CoPerPins AN380–SteelcoPerpin AN381–CREScoPerpin NowcalledMS24665 Checkdatasheetfordashnumberingsystem Diametershouldbethelargestsizetofitinto fastener’shole • Topreventinjuryduringanda,erpin installa<on,theendofthecoPerpincanbe rolledandtucked. • • • • • CoPerPins • Don’treusecoPerpins • Don’tuseautomo<veorhardwarestorecoPer pins CoPerPins–43.13-1B • Types: Screws Structural ! Machinescrews ! Self-tapping ! • Structuralscrew Muchlikestandardboltbutwithscrewhead ! Fineandcoarsethread ! • Machinescrews Usuallynogrip ! Steel,CRESorbrass ! Nousedforprimarystructure ! Screws • Countersunk/flatheadmachinedandstructural screwuse100°countersink • Fillisterheadscrewsmayhaveasafetywirehole ScrewHeads FillisterHead ScrewHeads ScrewHeads WasherHeadScrews • • • • • SelfTappingScrews AlsocalledPKorParkerKalonscrews 82°countersunk Usedforsheetmetalandinspec<onpanel UsedwithTinnermannuts Non-structural SelfTappingScrews DzusFastener Dzus™Fastener Dzus™Fastener Dzus™Fastener Dzus™Fastener • Lengthspecifiedin1/100(0.01)inchincrements • Diameterspecifiedin1/16inchincrements • Headmarkingsarebodydiameter,typeofhead, andlengthofthefastener • Reten<ongrommet/collarcommonlycome loose CamLockFastener CamlockFastener Camlockfastener:explodedview. AirlocFastener BlindRivets • Canbeinstallfromoneside ! Installedwith“puller”tool • PopRivet Poprivetinstalla<on ! Usedforno-structuralworkonly ! Hollowa,erinstalla<on ! BlindRivets • “CherryRivets” Notyourhardwarestorerivets ! Widevariety–CherryLock,CherryMax,Huck-Clinch, HuckMax,Olympic-Loc ! CherryMaxAnima<on ! CherryMaxcanreplaceasolidrivetofthesamesize diameter ! • Somemechanicsareconcernedabouttherivetsvibra<ng loose InstallCherryMaxRivet ! Hardtoremove ! • Airframebook(FAA-H-8083-31)page4-49 CherryRivetRemoval Hi-Shear™ Hi-Shear™ Hi-Shear™ Hi-Lok™ • Installa<onVideo • Canbeinstalledwithstandardtools HuckLockbolt™ HuckLockbolt™ Rivnut™ Good for thin sheet metal applications Rivnut™ CherryRivetlessNutplate • Installa<onanima<on Aircra,ControlCable Aircra,ControlCable Aircra,ControlCable CablePulley CableFairleads Aircra,ControlCable • CableMaterial CRES ! Galvanizedsteel ! • Olderstyle • Typesofcable: Nonflexible ! Flexible ! Extraflexible ! Aircra,ControlCable Aircra,ControlCable • CableSize: 1/32”through1/2” ! Primarycontrolcablesmustbe1/8”orlarger ! Trimtabactuatorcablescanbelessthan1/8” ! • Nonflexiblecable 1X7–7individualwires ! 1X19–19individualwires ! Forstraightrunsonly ! Can’tpassoverapulley ! Aircra,ControlCable • FlexibleCable ! Core • Centersec<on • 7wires • Straight ! Outerstrands • 6strands • Eachstrandhas7wires • Spiraledaroundthecore ! Call7X7 • 7strands/corewith7wireseach Aircra,ControlCable • FlexibleCable Usedforenginecontrolsortrimtabcontrols ! Canbeusedwithapulley ! • Extra-flexibleCable 7standswith19wireseach ! Cableispreformed ! • Willnotspringoutwhencut ! Usedforprimaryflightcontrols • Cablesareinspectedforbrokenwiresbyrunning aclothalongthecable ! Abrokenwirewillsnagthecloth ControlCableTerminals ControlCableTerminals A.AN664Singleshankballend. B.AN663Doubleshankballend. C. AN666Threadedcableterminal. D.AN667Forkendcableterminal. E. AN668Eyeendcableterminal. Aircra,ControlCable ControlCableTerminals • Terminalsareswagedon ! Squeezedontothecable • Swagedconnec<onis100%(full)ofcable strength • Cablesaretestwitha“go-no-go”gage ! Theterminalmustbe“squeezed”enoughtofit throughthegage • Aspotofpaintisappliedtocable/terminalseam toprovideaninspec<onmark ! Ifthepaintisdamaged,thecablehasslipped • Replacethecable SwageTools TerminalGage A. Gagingaswaged-oncontrolcableterminalto determinethatithasbeenproperlyswaged. B.Typicalterminalgage. Nicopress A.Installa<onofNicopress-typesleevesonacontrolcable. B.TypicalNicopressgage. Nicopress Nicopress • Cableiswrappedaroundasteelthimble • Acoppersleeveisswagedoverthecable ! Threecrimps • First-center • Second–nexttothimble • Third–farend ! 100%ofcablestrength • Testedwitha“go-no-go”gauge Turnbuckles Turnbuckles • Onesideisthreadedle,andothersideis threadedright ! Turningthebarrelwilleitherlengthenorshortenthe turnbuckle • Nomorethanthreethreadscanbeexposedon eitherendofthebarrel • Onini<alinstalla<on,theturnbuckleterminals shouldnotbescrewedinsidetheturnbuckle barrelmorethanfourthreads • SafetyaccordingtoAC43-13-1B Turnbuckles • AC43.13-1B ! SafetyWire Chapter7-Sec<on7 • Safetying ! Chapter7–Sec<on10 • SafetyMethodsforTurnbuckles SafetyWire • Usedtosecure: Drilledheadboltheadsandscrews ! Valvehandles ! Electricaltwist-onconnectors ! Oilfilters ! Emergency&oxygenhandles ! Turnbuckles ! • Whenacastlenutisinstalledonastudthatis screwedintoacas<ng,itshouldbesafe<edwith safetywire. • Materials: SafetyWire Usuallystainlesssteel ! Copper/brass–usedforemergency“breakaway” applica<ons ! • Methods ! SafetyWire Doubletwist • Nomorethan3fasteners ! Singlewire • Closelyspacedorclosed-geometricalpaPernsuchasa triangle,square,rectangle,orcircle • Nomorethan24”long SafetyWire–DoubleTwist SafetyWire–SingleWire SafetyWire SafetyWire SafetyWire • DoubleTwistSize 0.032”diameterwireshouldbeusedonpartsthat haveaholediameterlargerthan.045” ! 0.020“maybeusedonpartshavinganominalhole diameterbetween.045and.062”withaspacing betweenpartsoflessthan2” ! • SingleWireSize ! Largestsizewirethattheholewillaccommodate • Followthemanufacturer’srecommenda<ons SafetyWire Therecommendednumberoftwistsperinchisdeterminedbythediameterofthesafetywire. 6 to 8 twists per inch is typical SafetyWire • Safetywiremustbeinstalledinamannerthat willpreventthetendencyoftheparttoloosen. ! Lookslikeinbackwards“S” • Cleanupsafetywire Cleanupinstalla<onscraps ! Becarefulwhenremovingwire ! • Don’treusewire • Don’tunwireandreinstalls • Don’tknickwire SafetyWire • Reinstallifindoubt • Alwayscurltheendtopreventexposureto sharpends • 4to6twistsontheend • Outsidewireshouldgoaroundhead ! Iflimitedspace,outsidewirecangooverthetop • AC43-13-1Bisthebestreference ! FollowtheAC’sinstalla<onexamples SafetyWire–Method • Twobolt–AC43-1B Outsidewire–clockwisearoundfirsthead ! Headonetotwo–twistclockwise ! Outerwire–counter-clockwisearoundsecondhead ! Twistendcounter-clockwise ! Curlend ! SafetyWire • Threebolt–AC43-1B Outsidewire–clockwisearoundfirsthead ! Headonetotwo–twistclockwise ! Outerwire–counter-clockwisearoundsecondhead ! Headtwotothree–twistcounter-clockwise ! Outerwire–counter-clockwisearoundthirdhead ! Twistendcounter-clockwise ! Curlend ! SafetyWire • Threebolt–alternatemethod Outsidewire–clockwisearoundfirsthead ! Headonetotwo–twistclockwise ! Outerwire–counter-clockwisearoundsecondhead ! Headtwotothree–twistcounter-clockwise ! Outerwire–clockwisearoundthirdhead ! Twistendclockwise ! Curlend ! SafetyWire–Turnbuckles SafetyWire–Turnbuckles • Doublewrapmethodspreferred • Endsmusthaveaminimumof4turns • FollowthemethodsshowninAC43-13-1B Figure7-26