Alabama
Department of
Postsecondary Education
Representing Alabama’s Public Two-Year College System
AMT 111
Aircraft Sheetmetal Structures
Plan Of Instruction
Effective Date: 2004
Version Number: Base Document
This course may be taught in its entirety in career/technical education degree
programs, non-degree programs, and Training for Business and Industry
programs. Individual instructional modules may be taught in customized
training, adult education work-based project learner activities, and short-term
training.
COURSE DESCRIPTION: This course introduces aircraft sheetmetal repairs.
Emphasis is placed on the use of proper procedures, tools, and materials to complete
sheetmetal repairs. Upon completion, students should be able to install conventional
rivets; form, layout, and bend sheetmetal; install special rivets and fasteners; and
inspect and repair sheetmetal structures. CORE
CONTACT/CREDIT HOURS (applicable if entire course is taught in a career/technical education
degree or non-degree program)
Theory Contact/Credit Hours
Lab Contact/Credit Hours
Total Contact/Credit Hours
3/3 hours
6/2 hours
9/5 hours
40 hours (1:1)
100 hours (3:1)
140 hours
NOTE: Colleges may schedule lab hours as manipulative (3:1) or experimental (2:1). Adjustments in contact hours
must be made accordingly.
PREREQUISITE COURSES (applicable if entire course is taught in a career/technical education
degree or non-degree program)
AMT 100, AMT 101, AMT 102 or equivalent
CO-REQUISITE COURSES (applicable if entire course is taught in a career/technical education
degree or non-degree program)
Determined by college unless stated otherwise.
Alabama College System
Aircraft Sheetmetal Structures
AMT 111
INDUSTRY COMPETENCIES
SHEETMETAL REPAIRS
Utilize the fundamentals of aircraft sheetmetal tools and equipment
Install conventional rivets
App. C, Sec ID, Item 15, Level 3
Form, layout and bend sheetmetal
App. C, Sec ID, Item 16, Level 3
Install special rivets and fasteners
App. C, Sec ID, Item 10, Level 2
Inspect and repair sheetmetal structures
App. C, Sec ID, Item 14, Level 3
Inspect and repair bonded honeycomb and laminated structures
App. C, Sec ID Item 11 & 12, Level 2
Inspect and repair plastic structures
App. C, Sec ID Item 12, Level 2
Inspect, check, service and repair windows, doors and interior finishing
App. C, Sec. ID Item 13, Level 2
COURSE OBJECTIVES
The cognitive objective of this course is for each student to comprehend foundational
knowledge needed to perform stated entry-level industry competencies.
The performance objective of this course is for each student to apply foundational
knowledge to problems and exercises encountered in class.
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Aircraft Sheetmetal Structures
AMT 111
INDUSTRY COMPETENCIES/STUDENT PERFORMANCE
Industry Competency
Student Performance Objectives
MODULE A SHEETMETAL REPAIRS
Utilize the fundamentals of Given instruction in this course, aircraft sheetmetal tools,
aircraft sheetmetal tools
sheetmetal equipment, and verbal instructions,
and equipment
demonstrate the proper use of each tool and piece of
equipment while completing the lab requirement outlined
on this course.
Install conventional rivets
App. C, Sec ID, Item 15,
Level 3
Given instruction in this course, sheetmetal tools, general
tools, aircraft coverings and structures, conventional rivets
and verbal instructions, install conventional rivets to
simulated airworthiness specification.
Form, layout and bend
sheetmetal
App. C, Sec ID, Item 16,
Level 3
Given instruction in this course, sheetmetal tools and
equipment, various pieces of sheetmetal, materials, tools,
and verbal instructions, form, layout and bend sheetmetal
to specification.
Install special rivets and
fasteners
App. C, Sec ID, Item 10,
Level 2
Given instruction in this course, sheetmetal tools, general
tools, aircraft coverings and structures, special rivets and
fasteners, verbal instructions, install special rivets to
simulated airworthiness specification
Inspect and repair
sheetmetal structures
App. C, Sec ID, Item 14,
Level 3
Given instruction in this course, sheetmetal tools, general
tools, aircraft sheetmetal coverings and structures, and
verbal instructions, inspect and repair sheetmetal
structures as necessary to simulated airworthiness
specification.
ENABLING OBJECTIVES/KEY INDICATORS
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Identify sheetmetal types
State the purpose of each type of sheetmetal
Identify tools used for aircraft sheetmetal
Explain the purpose and use of each tool used in aircraft sheetmetal
Identify equipment used in aircraft sheetmetal
Explain the purpose and use of equipment used in aircraft sheetmetal
Identify and explain the use of different rivets used in aircraft sheetmetal repair
Describe the stresses rivets are designed to resist
Describe the preparation of sheetmetal for installation of rivets
Determine the correct rivet length and diameter
Describe how to install a high shear rivet
Identify the precautions concerning rivet fit
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Aircraft Sheetmetal Structures
AMT 111
ENABLING OBJECTIVES/KEY INDICATORS (Cont)
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Describe how to install blind-type rivets
Identify and the explain the use of riveting equipment
Describe the process of removing rivets
State the number of rivets to be used in making a structural sheetmetal repair
Describe the handling and installation of rivets that require heat treatment prior to use
Describe forming operations for bending sheetmetal
Describe sheetmetal layout and bending operations
Summarize the process of bending sheetmetal
Identify and explain the use of specialized rivets and fasteners
Explain how to identify and determine correct rivet length and diameter
Summarize the specialized rivet installation procedures
Describe how to determine the condition of stressed skin metal structure that is known to have
been critically loaded
Describe the elements of flight control surface repair
Describe how to repair a hole in a stressed skin metal wing
Describe how to repair structural units built from sheetmetal
Describe how to repair or splice stringers on the lower surface of a stressed skin metal wing
Explain the preparation process for assembly of dissimilar metals
Select and use twist drills
Select and use a hand file for soft meta
Explain how to prepare dissimilar metals for assembly
Determine the type, size and number of rivets used in a structural repair
Explain how to repair sheetmetal flight control surfaces
Explain the loads acting upon a semimonocoque fuselage
Describe the construction characteristics of monocoque and semimonocoque construction
Describe the construction characteristics of cantilever wing structures
Identify the types of loads carried by wing spars
Explain the process of drilling holes in stainless steel
Define bearing failure as related to sheet metal structures
Define shear failure
Explain how to repair a hole in a stressed skin using a single lap sheet splice
Describe how to countersink a hole
Explain how to perform the dimpling process
Explain how to repair or splice stringers on the lower surface of a stressed skin metal wing
Determine the correct rivet layout and spacing for a specified repair
Explain proper riveting techniques
Explain how to stop drill cracks in sheetmetal
Describe how to repair a slightly oversized hole
Describe how to repair shallow scratches in sheetmetal
Determine the condition of a stressed skin metal structure that is known to have been critically
loaded
Explain how to use a reamer
Explain how to prepare sheetmetal for installation of flush rivets
Determine the neutral axis of a bend
Define bend radius
Determine the amount of material required to make a specified bend
Describe how to bend sheetmetal
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Aircraft Sheetmetal Structures
AMT 111
ENABLING OBJECTIVES/KEY INDICATORS (Cont)
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Select and use the correct rivet set for specified rivet head styles
Explain how to select and use bucking bars
Describe how to remove rivets
Determine the condition of a driven rivet head
Describe the circumstances which 2117 rivets may be used to replace 2017 and 2024 rivets
Define rivet tipping
Explain how to handle and install rivets that require heat treatment prior to use
Describe how to adjust and use an air operated riveting gun
Describe the circumstances under which a type “A “ rivet may be used
Describe the mechanical properties of heat-treated rivets
Explain how to make a joggle or offset bend
Describe how to bend sheetmetal that requires the use of a large radius
MODULE B BONDED HONEYCOMB AND LAMINATED STRUCTURES
Inspect and repair bonded
Given the knowledge taught in this course, bonded
honeycomb and laminated honeycomb and laminated structures, general and
structures App. C, Sec ID
specialized tools, and verbal instructions, inspect the
Item 11 & 12, Level 2
honeycomb and laminated structures and repair as
necessary to restore simulated airworthiness.
ENABLING OBJECTIVES/KEY INDICATORS
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State the reason for using metal sandwich panels in high speed aircraft construction
Describe the construction features of bonded honeycomb structures
Describe the construction features of laminated structures
Explain the damage inspection of bonded honeycomb structures
Explain the damage inspection of laminated structures
Describe the use of metallic ring test to inspect for delamination damage of bonded structures
Evaluate the extent of damage to a bonded structure and determine the type of repair needed
Distinguish between transparent plastic and plate glass enclosures
Describe how to protect plastics during handling of and repair operations
Describe how to remove scratches and surface crazing from plastic enclosures
Explain how to drill a shallow or medium depth holes in plastic materials
Describe the effect of moisture entrapped in honeycomb structures
Explain how to use a router to remove damaged area from honeycomb panels
Explain how to clean honeycomb panels prior to patching
Describe the repair procedures for bonded honeycomb structures
Describe the repair procedures for laminated structures
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Aircraft Sheetmetal Structures
AMT 111
MODULE C PLASTIC STRUCTURES
Inspect and repair plastic
Given the knowledge taught in this course, materials,
structures App. C, Sec ID
tools, plastic structures, and verbal instructions, repair
Item 12, Level 2
plastics the plastic surface to meet simulated
airworthiness specifications.
ENABLING OBJECTIVES/KEY INDICATORS
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Identify different classes of plastics
Describe the features of transparent plastics
Summarize the procedures associated with storage and protection of plastics
Explain how to form plastics
Summarize the installation procedures used with plastics
Explain how to clean plastic window and windshield materials
Explain the inspection procedures and airworthiness requirements for safety belts
Describe the characteristics of acrylic plastic enclosure materials
Explain how to maintain safety belts
Explain how to repair shallow surface scratches in transparent plastic enclosures
Describe how to secure transparent plastic enclosures to the aircraft structure
Describe how to protect transparent plastic enclosure materials during handling and storage
Explain how to clean plastic window and windshield materials
Describe the physical characteristics of transparent plastic enclosures
Explain how to form and shape acrylic plastics
Explain how to repair shallow surface scratches in transparent plastic enclosure
MODULE D WINDOWS, DOORS AND INTERIOR FURNISHINGS
Inspect, check, service,
Given the knowledge taught in this course, an aircraft,
and repair windows, doors
tools and inspection checklists, inspect, service, and
and interior furnishings
repair windows, as required to restore simulated
App. C, Sec. ID Item 13,
airworthiness.
Level 2
Given the knowledge taught in this course, an aircraft,
tools and inspection checklists, inspect, service, and
repair doors as required restoring simulated airworthiness.
Given the knowledge taught in this course, an aircraft,
tools and inspection checklists, inspect, service, and
repair interior furnishings as required restoring simulated
airworthiness.
ENABLING OBJECTIVES/KEY INDICATORS
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Summarize the inspection procedures and airworthiness requirements for safety belts
Summarize the inspection procedures for emergency exits
Explain the inspection procedures and airworthiness requirements for safety belts
Describe the characteristics of acrylic plastic enclosure materials
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Aircraft Sheetmetal Structures
COURSE CONTENT OUTLINE
AMT 111
FAA AUTHORITY 147
SAFETY INSTRUCTION
 General
 Fire Drills
 Severe Weather
 Shop Safety
 Flight Line Safety
MODULE A SHEETMETAL REPAIRS
 Fundamentals of aircraft sheetmetal, tools and equipment
o Aircraft sheetmetal types
o Special tools and equipment for aircraft sheetmetal
NOTE: Practical Exercise I-A to be conducted at this point
App. C, Sec IID, Item 15, Level 3
Installation of conventional rivets
o Identification and selection of rivets
o The stresses that a rivet is designed to resist
o Selection and use of riveting equipment
o Installation of conventional rivets
o Removal of rivets
o Number of rivets to be used in making structural sheetmetal repair
o Handling and installation of rivets that require heat treatment prior to use
NOTE: Practical Exercise I-B to be conducted at this point.
Progressive Examination #1 scheduled for __________________________.
 Form, layout, and bend sheetmetal
App. C, Sec ID, Item 16, Level 3
o Forming operations
o Layout and bending operations
o Bending sheetmetal
NOTE: Practical Exercise I-C to be conducted at this point.
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App. C, Sec ID, Item 10, Level 2
Special rivets and fasteners
o Identification and determining correct rivet length and diameter
o Installation procedures
NOTE: Practical Exercise I-D to be conducted at this point.
Progressive Examination #2 scheduled for __________________________.
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App. C, Sec ID, Item 14, Level 3
Inspection and repair of sheetmetal structures
o Determining the condition of a stressed skin metal structure known to be critically
loaded
o Sheetmetal flight control surface repair
o Repairing a hole in a stressed skin metal wing
o Repairing structural units, such as spars, engine supports, etc., that have been
built from sheetmetal
o Repairing a slightly oversize hole
o Repairing shallow scratches in sheetmetal
o Repairing or slicing stringers on the lower surface of a stressed skin metal wing
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Aircraft Sheetmetal Structures
AMT 111
o Preparing dissimilar metals for assembly
o Constructing a water-tight joint
NOTE: Practical Exercise I-E to be conducted at this point.
Progressive Examination #3 scheduled for __________________________.
MODULE B BONDED HONEYCOMB AND LAMINATED STRUCTURES
App. C, Sec ID, Item 11 & 12,
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Construction features
Level 2
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Damage inspection
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Repair procedures
NOTE: Practical Exercise II to be conducted at this point.
MODULE C PLASTICS
App. C, Sec. ID Item 12, Level 2
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Classification
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Transparent plastics
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Storage and protection
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Forming plastics
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Installation procedures
NOTE: Practical Exercise III to be conducted at this point.
App. C, Sec. ID Item 13, level 2
MODULE D WINDOWS, DOORS, AND INTERIOR
FURNISHINGS
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Inspection procedures and airworthiness requirements for safety belts
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Inspection of emergency exits
NOTE: Practical Exercise IV to be conducted at this point.
Progressive Examination #4 scheduled for __________________________.
FINAL EXAMINATION
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Aircraft Sheetmetal Structures
AMT 111
RECOMMENDED METHODS OF EVALUATION: The table of specifications below
identifies the number of enabling objectives/key indicators per cognitive domain level of
learning (Knowledge, Comprehension, Application) per module. The instructor should
develop 1-3 test questions per Knowledge Level of Learning, 2-4 test questions per
Comprehension Level of Learning, and 5-6 questions per Application Level Learning.
The instructor should use the following test item types for each level of learning:
Knowledge: Alternative Response test items (true/false or yes/no)
Comprehension: Multiple Choice
Application: Multiple Choice, Short Answer Exercises
The instructor should ensure each student meets the performance and standards
published in each criterion objective. See FAA AC 147-3 Certification And Operation Of
Aviation Maintenance Technician Schools Appendix 1for evaluation instrument
guidance and development.
Domain of
Learning/
Content
Module A
Module B
Module C
Module D
Number of
indicators per
level
TABLE OF SPECIFICATIONS
Cognitive Domain
Total
Cognitive
Total
Performance
Knowledge Comprehension Application
4
1
4
1
20
45
14
12
4
75
7
1
8
56
16
16
5
103
5
1
1
3
10
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Aircraft Sheetmetal Structures
AMT 111
RECOMMENDED INSTRUCTIONAL METHODOLOGIES: The table below links the
teaching methods and activities most effective for facilitating student achievement of
learning outcomes published in this plan of instruction.
Cognitive Level
(Thinking)
Knowledge
Descriptive Verbs:
Defines, Lists, States,
Describes, Identifies
Comprehension
Descriptive Verbs:
Describe, Explains,
Summarizes
Goal For Students
Teaching Methods
Knows common terms,
specific facts, methods,
procedures, basic
concepts, principles
Lecture
Computer Based
Instruction
Video
Demonstration
Mnemonics
Examples or Illustrations
Repetition
Summaries
Reviews
Understands facts and
principles
Informal Lecture
Discussion
Demonstration
Participation
Interactive Computer
Based Instruction
1. Teach to the Knowledge
Level
Interprets verbal material
Interprets charts and
graphs
Translates verbal
material to mathematical
formulas
Justifies methods and
procedures
Descriptive Verbs:
Uses, Solves, Operates,
Produces,
Demonstrates, Constructs
Applies concepts and
principles to new
situations
Applies laws and
theories to practical
situations
4. Put students in a new
situation, and the students
solve the new situation
using the concept, principle,
or procedure while
instructor supervises.
Demonstration
Individual Research
Lab Exercises
Case Studies
Experiments
Constructs charts,
graphs, or simple
mechanism
Psychomotor Level
(Doing)
Mechanism
Descriptive Verbs:
Assembles, calibrates,
constructs, measures, fixes,
dismantles, sketches
Learned responses have
become habitual and
can be performed with
some confidence and
proficiency
5. Reteach as required
1. Teach to the Knowledge
Level
2. Teach to the
Comprehension Level
3. Student must identify the
concept, principle, or
procedure and use it to
solve new scenario
Solves mathematical
problems
Demonstrates correct
usage of a method or
procedure
Goal For Students
2. Explains and
demonstrates concept,
principle or procedure
learned
3. Put students in new
situation, and instructor and
students co-solve
employing the indicated
concept, principle, or
procedure.
Estimates future
consequences
Application
Teaching Activities
4. Reteach as required
Teaching Methods
Teaching Activities
Lab Exercises
Case Studies
Experiments
1. Demonstration
2. Observation
3. Feedback
4. Reteach as required
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Aircraft Sheetmetal Structures
Plan of Instruction
(POI)
Industry
Competencies
Course Objectives
Criterion Objectives
Enabling
Objectives/Key
Indicators
Table of
Specifications
Cognitive Domain
Psychomotor Domain
Course Description
Course
Prefix/numbers
Co-requisite Course
Modules
Course Content
Outline
Contact/Credit hours
Prerequisite
Knowledge
Recommended
Methods of Evaluation
AMT 111
Glossary of Terms
A teaching-learning plan which includes student centered
instructional objectives, outlined content, instructional and
evaluation strategies, and other relevant information needed
to guide the development and/or revision of learning
experiences such that students achieve stated educational
outcomes.
Entry-level skills students must acquire during enrollment in
the course.
The overall goal of the course of instruction stated in broad
terms.
The terminal outcome each student is required to meet.
Criterion objectives are directly related to industry
competencies. There will be one or more criterion
objectives published for each industry competency.
The required knowledge and/or skill each student must
acquire in order to have the best chance of achieving the
stated performance in the criterion objective.
Used to ensure adequate sampling of student knowledge as
specified by the enabling and criterion objectives.
The domain of learning typified by thinking and focused on
the development of intellectual capabilities.
The domain of learning typified by performing or doing and
focused on the development of motor skills.
Section Explanation
A broad description of key elements in a given course.
Used to identify courses taught in multiple disciplines.
Course required in conjunction to the specified course often
in the form of a lab
A grouping of interrelated knowledge and skills representing
a sub-element of a course.
A listing of topics for instruction in a particular course
Specifies the recommended contact to credit hours for each
course. Mandates the total credit hours awarded for each
course.
Intellectual capabilities required for handling the academic
rigors of the discipline.
Suggests test item options for measuring student
achievement of enabling objectives. Suggests the number
of test items required to adequately measure student
achievement of enabling objectives. Mandates the
evaluation of criterion objectives.
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Aircraft Sheetmetal Structures
Recommended
Instructional
Methodologies
AMT 111
Suggests the most effective instructional methods for
achieving stated learning levels
Directions for Use
1.
2.
3.
4.
5.
6.
Review the entire document.
Assess the industry competencies specified in the POI keeping in mind that the
stated skills are the target outcomes for the course.
Assess the criterion objectives written for each competency keeping in mind
the objective specifies the behavior each student must exhibit in order to
achieve the competency.
Adjust performance evaluation instruments to ensure each criterion objective is
addressed.
Develop additional performance evaluations as needed
Assess enabling objectives/key indicators specifying student outcomes
Adjust objective evaluations based on the guidance provided in the POI table
of specification to ensure adequate sampling of student learning outcomes.
7.
8.
9.
10.
11.
12.
13.
14.
Evaluate current classroom curriculum and determine if learning experiences
support student achievement of skills identified in criterion objectives. Adjust
as necessary.
Review recommended instructional methodologies for teaching activities
appropriate to specified levels of learning.
Develop appropriate learning experiences for those skills not addressed.
Ensure specified contact hours are enough to cover existing and new learning
experiences developed.
Ensure adequate time exists to evaluate each student on all criterion
objectives.
Adjust course syllabus to reflect changes made.
If necessary, adjust school surveys to reflect changes made.
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