Module 6: Materials and Hardware

6.1Aircraft Materials — Ferrous

• Characteristics, properties and identification of common alloy steels used in aircraft
• Heat treatment and application of alloy steels
• Testing of ferrous materials for hardness, tensile strength, fatigue strength and impact resistance

6.2Aircraft Materials — Non-Ferrous

• Characteristics, properties and identification of common non-ferrous materials used in aircraft
• Heat treatment and application of non-ferrous materials
• Testing of non-ferrous materials for hardness, tensile strength, fatigue strength and impact resistance

6.3Aircraft Materials — Composite and Non-Metallic

6.3.1Composite and Non-Metallic (other than wood and fabric)

• Characteristics, properties and identification of common composite and non-metallic materials used in aircraft
• Sealant and bonding agents
• Detection of defects/deterioration in composite and non-metallic material
• Repair of composite and non-metallic material

6.3.2Wooden Structures

• Construction methods of wooden airframe structures
• Characteristics, properties and types of wood and glue used in aeroplanes
• Preservation and maintenance of wooden structures
• Types of defect in wood material and wooden structures
• Detection of defects in wooden structures and repair

6.3.3Fabric Covering

• Characteristics, properties and types of fabrics used in aeroplanes
• Inspection methods for fabric
• Types of defects in fabric
• Repair of fabric covering

6.4Corrosion

• Chemical fundamentals
• Formation of corrosion, galvanic action, microbiological, stress corrosion
• Types of corrosion and their identification
• Causes of corrosion
• Material types, susceptibility to corrosion

6.5Fasteners

6.5.1Screw Threads

• Screw nomenclature
• Thread forms, dimensions and tolerances for standard threads used in aircraft
• Measuring screw threads

6.5.2Bolts, Studs and Screws

• Bolt types: specifications, identification and marking of aircraft bolts, international standards
• Nuts: self-locking, anchor nuts, standard types
• Machine screws: aircraft specifications
• Studs: types, insertion and removal
• Self-tapping screws, dowels

6.5.3Locking Devices

• Tab washers, lock washers, spring washers, locking plates
• Split pins, pal-nuts (stiff nuts)
• Wire locking
• Quick-release fasteners
• Keys, circlips, cotter pins

6.5.4Aircraft Rivets

• Types of solid and blind rivets
• Specifications and identification
• Heat treatment of rivets

6.6Pipes and Unions

• Identification of, and types of rigid and flexible pipes and their connectors used in aircraft
• Standard unions for aircraft hydraulic, fuel, oil, pneumatic and air system pipes

6.7Springs

• Types of springs, materials, characteristics and applications

6.8Bearings

• Purpose of bearings, loads, material, construction
• Types of bearings and their application

6.9Transmissions

• Gear types and their application
• Gear ratios, reduction and multiplication gear systems, driven and driving gears, idler gears, mesh patterns
• Belts and pulleys, chains and sprockets

6.10Control Cables

• Types of cables
• End fittings, turnbuckles and compensation devices
• Pulleys and cable system components
• Bowden cables
• Aircraft flexible control systems

6.11Electrical Cables and Connectors

• Cable types, construction and characteristics
• High tension and co-axial cables
• Crimping
• Connector types, pins, plugs, sockets, insulators, current and voltage rating, coupling, identification codes