Aircraft Structure Design Principles

INDEX
1. REFERENCES ...................................................................................................... 2
2. INTRODUTION.................................................................................................... 2
3. SHEET PARTS ..................................................................................................... 3
3.1 BEND RADIUS ........................................................................................................................... 3
3.2 LIGHTENING HOLES ................................................................................................................ 4
3.3 TOOLING HOLES ...................................................................................................................... 5
3.4 VARIOUS .................................................................................................................................... 5
4. MACHINED PARTS ............................................................................................ 6
4.1 TOOL RADIUS ................................................................................................................................ 6
4.1.1 Standard ..................................................................................................................................................................... 6
4.1.2 Specials ...................................................................................................................................................................... 7
4.1.3 Spherical tool ............................................................................................................................................................. 8
4.2 THICKNESS-HEIGHT RATIO IN STIFFENERS ...................................................................................... 9
4.2.1 Transitions / Changes in thickness ............................................................................................................................. 9
4.3 CHAMFER................................................................................................................................. 10
4.4 STIFFENERS ENDINGS ............................................................................................................... 11
4.5 MINIMUM MACHINED THICKNESS .................................................................................... 11
4.6 TAPPING ................................................................................................................................... 12
5. JOINS ................................................................................................................... 13
5.1 STEP........................................................................................................................................... 13
5.2 FOR INSTALLATION ...................................................................................................................... 13
5.2.1 Drilling diameter ...................................................................................................................................................... 13
5.2.2 Other requirements .................................................................................................................................................. 18
5.3 EDGE DISTANCES .................................................................................................................. 20
5.3.1 New parts ................................................................................................................................................................. 20
5.3.2 Parts reused existing holes ....................................................................................................................................... 20
5.4 RIVET STEP .................................................................................................................................. 21
5.5 TYPICAL VALUES FOR EDGE AND STEP DISTANCES .................................................... 21
5.6 SHIMS ........................................................................................................................................ 22
5.7 CLEARANCES ............................................................................................................................... 22
5.8 RIVETS REPLACEMENT ................................................................................................................. 22
6. TOLERANCES ................................................................................................... 23
6.1 METALLIC PARTS ......................................................................................................................... 23
6.2 COMPOSITE PARTS ....................................................................................................................... 23
6.3 NO MODEL ELEMENTS .................................................................................................................. 24
7. MATERIAS, PROCESSES AND APPLICABLE CODES…….

PROTECTION .............................................................................................................. 25
1. REFERENCES
1. NT-FA-ID-05006: Selection of materials, processes, and corrosion prevention codes applicable
to A330-200-MRTT programme.
2. NT-FA-ANC-05006: Standard parts applicable for EADS-CASA to A330-200 MRTT
2. INTRODUTION
The purpose of this document is to present and summarize the design principles used in the
transformation to a commercial Airbus A330-200 in a tanker aircraft (MRTT)
It is important to remember that change is a repair, it will replace, modify or strengthen parts as
needed. In particular, special attention should be paid to existing riveted, which will determine some
design decisions.
3. SHEET PARTS
In general, bent sheet metal parts used only when the tolerances are not smalls (although the charges
are not very high, if they are fit enough pieces, small tolerances are required.) When the tolerances are
tight or the part must be copied double-curved, bent sheet metal part is not the choice. In that case,
double-curved, it is possible to do like ruled surface.
The preferred material is 2024 aluminum cladding (Clad) and the normal state T3. Preferred
thicknesses are in the following table (to reduce weight without penalizing supplies). Sizes larger than
the standard must be communicated immediately to manufacturing / materials for availability / timing
3.1 BEND RADIUS

The most used bend radius are shown in the I+D-P-212 for aluminum and I+D-P-206 for steel and
titanium, for thickness, treatment and selected material. The typical values for this materials are shown
in the following table:
STATE BEND RADIUS (Minimum) en mm

MATERIAL THK IN
mm 0,3 0,4 0,5 0,63 0,8 1,0 1,2 1,3 1,4 1,5 1,6 1,8
2024 0 0,6 0,6 0,6 0,6 1,0 1,2 1,6 1,8 2,0 2,0 2,0 3,0
2024 Clad T3 T4 1,0 1,0 1,6 2,0 2,5 3 4 4,5 5 5 5 6,0
0 0,8 0,8 0,8 0,80 0,8 1,6 1,6 1,6 - - 2,3 3
7075 Clad
T6 2,3 2,3 3 4 4,8 6,4 - 7,9 - - 10,4 11,2
STATE BEND RADIUS (Minimum) en mm

MATERIAL THK IN
mm 2,0 2,3 2,5 3,0 3,2 3,5 4 4,8 5 6 6,4 9,5 12,7
0 3,0 4 4 5 5 5,6 7,2 9,5 10 12 16 35 64

2024
2024 Clad T3 T4 8 9 10 12 12 12,7 17 21,4 25 30 32 48 -
0 3 4 4,8 - 5,6 - 7,9 9,6 - - 22,9 35 63,5
7075 Clad
T6 12,7 14,2 16,8 - 21,3 - 27 35 - - 50,8 - -
In general, the used bend radius should be the minimums, unless the cargos will be small and the bend
radius standard should be used.
If it bend in 0 state, and it will be processed to final state (T4 or T6), it is necessary to explain this like:
2024-0  2024T42
7075-0  7075T62
3.2 LIGHTENING HOLES
To lightening and provide access while it gives rigidity to the piece, lightening holes are used
according to CAN 16070. The edge of the lightening hole will, if it is possible, on the side of the flap
of the piece. The preferred type is BT, whose dimensions listed in the CAN are:
Designación A aprox. C aprox. E mín. H aprox. R ± 1mm

BT20 20 17 9 3 3
BT25 25 22 9 3 3
BT30 30 26 9,5 4,5 4
BT35 35 32 10 4,5 4
BT40 40 36 10 5 5
BT42 42 39 10 5,5 5
BT50 50 46 10 5,5 6
BT60 60 56 10 6 7
BT70 70 65 10,5 6,5 7
BT80 80 75 11 7 8
BT90 90 84 11,5 7,5 8
BT100 100 94 12 8 8
BT120 120 112 13 9 8
BT140 140 131 14 10 8
BT160 160 150 15 11 8
BT180 180 169 16 12 8
The minimum distances to edges, some folded, some lightening, etc. are also included in the CAN
16070
According to the material and treatment, thickness and maximum sizes are:
Diametro
Material Estado Espesor
max Min Max
W 2,5 20 180
2024 O 2,5 20 180
T42 1,6 20 180
W 2,5 30 180
2024
O 2,5 30 180
Clad
T4 1,6 30 180
7075 W 2,5 30 180
Clad O 2,5 30 180
3.3 TOOLING HOLES
To hold the piece in useful during complex bending operations (piecework, lightening, or flanges
snare a curved shape), often are required tooling holes
The standard diameter is 6.1 mm. The minimum number of drills to use a piece is two, but depending
on the size might be needed more. In any case, the distance between them should be as large as
possible. His position must be agreed with manufacturing.
3.4 VARIOUS
Cutout radius: The best cutout radius are 8 mm (4mm if it not possible 8mm).
Minimum length flap. The minimum length required to bend a flap is defined in the standard
DIN9003, if in a particular case appear not to use 2.5 times the bending radius. This minimum distance
must be respected in all areas near the tip radius.
NT-FA-ASO-05-087 Edic./Issue A Pág. 6
4. MACHINED PARTS
4.1 TOOL RADIUS
4.1.1 Standard
Como compromiso adecuado entre velocidad de avance, profundidades habituales de mecanizado y obtención
de detalles con vida en fatiga aceptable y peso no penalizado, la herramienta típica es:
diameter = 16 mm. Cutter radius = 4 mm

To avoid stalls during the machining tool, the modeling radio parts must be greater than the tool.
Therefore:
Drafting radius = 9 mm. Cutter radius= 4 mm
D/2+1
R
ØD
R
Tipical tool:
D = 16, R = 4
4.1.2 Specials
4.1.3 Spherical tool
In general, it is prefer the use of cylindrical tools. The spherical tools increase the costs, but it can be
used in special cases.
The most used are:
R4
R5
R6
In the next pictures it can be seen in which cases can be used spherical tool, and which is the
alternative with cylindrical.
Alternative solution with

cylindrical tool
Cylindrical tool Spherical tool

USUAL USE EXCEPCIONAL USE
4.2 THICKNESS-HEIGHT RATIO IN STIFFENERS

The following table lists the maximum height of stiffeners depending on the thickness and length.
h t R E
25 1,5 10 150
36 1,8 16 180
42 2,0 20 200
60 2,5 20 250
75 3,0 20 300
96 4,0 25 450
120 6,0 25 450
These values are met if the cutter diameter D satisfies:

 For Aluminum D ≥ h / 3
 To Titanium & Steel D ≥ h / 2
4.2.1 Transitions / Changes in thickness

Thickness transitions in the direction of the load must be done gently to avoid problems of fatigue.
The value to use as a baseline to confirm with fatigue, 70%
t1
t2
t3
Recommended value 0.7
t2≈ 0.7 t1
t3≈ 0.7 t2 ~ 0.4 t1
To make a piecework in a machined part (see figure below) are recommended in the following table
values (thickness zone ≈ 7 x depth of piecework). It will seek to install a rivet in the area of additional
thickness to withstand torque produced by the misalignment of loads.
S 0,6 0,8 1,0 1,2 1,6 2,0 2,5 3,2 4,0 5,0
M
X 4,2 5,6 7 8,4 11,2 14 17,5 22,4 28 35
4.3 CHAMFER
To attach machined parts, the preferred method is to chamfer the inner part. The chamfer is 1 mm
greater than the radius of machining the part on which it rests (R1 +1). The inner radius R2 should be
large enough to keep the throat, causing the thickness of the thin wing, ie, w ≥ min. (t1, t2)
Gap for sealant. Parts were designed, leaving a gap of 0.2 mm between the pieces. This gap is due to
the thickness of sealant applied to the assembly between the bearing faces of the pieces.
4.4 STIFFENERS ENDINGS

Stiffeners that end not attached to another wing or stiffener, should be cut at an angle to improve the
discharge. When the load is tension, the angle that produces the best allowable fatigue is 15 º. If
compression, cutting two planes 15 and 30 º is recommended
1
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5
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4.5 MINIMUM MACHINED THICKNESS

The minimum thickness depends on the material, the size of the area to be machined, the support on
the table and technology. The minimum values are
Tecnology Conventional High speed

One face Two faces One face Two faces
Material
Aluminium 1,2 1,5 0,7 0,8
Titanium - steel 1,5 1,7 - -
4.6 TAPPING
In exceptional cases, with the consent of fatigue can be used tappings to allow the seat of the head of
bolts or rivets.
If you make will be made according to the following diagrams.
By request of fatigue, the tapping fillet radius will be 2.5 mm.

5. JOINS
5.1 STEP
The typical step of riveting will be between 5 and 8 D (D = diameter of rivet)
For joints staggered, the distances between rivets also apply.
For sealing, at least one staggered riveted joint must be used
5.2 FOR INSTALLATION
5.2.1 Drilling diameter

It will be identified and it will be used drill diameters and adjustments from CAN40027 for fixed
joints:
Hi-Loks
Typical drills (like I+D-P-117)

AA
Drills with more tightening than AA (strong requirement for fatigue)

A
Solid rivets
Drills presure limit ( like I+D-L-113)

FF
Drills with greater ease than FF (without pressure limit)

F
For removable elements, are used preferably screws of 4.8 mm. The holes are as follows (see
CAN16030 for drill rivet nut installation):
2D
5D**, 8D*
D+1
D is the maximum diameter needed for bolt, according with CAN16030. For not anchor nuts it will be
used the LOCK NUTS column. The diameter for anchor nuts only is necessary to apply in the part
where nut is riveted, in the other(s) join part(s) the diameter will be LOCK NUTS column.
Anchor nuts will be modeled with nominal diameter and measured with tolerances +/- 0,1; for not
anchor nuts will be modeled with minimum diameter and measured with tolerances – 0,0 / +0,1.
ANCHOR NUTS IN PRIMARY STRUCTURE, ACCORDING WITH CAN16030

Hole Min edge Min hole Min radius
Bolt diameter
diameter (D) distance(mm.) distance(mm.) distance (mm.)
inch mm mm. 2D 5D D+1
.1120 2,84 3,3 -3,5 7 18 5
.1380 3,50 4,0 - 4,2 8 21 6
.1640 4,17 4,7 - 4,9 10 25 6
.1900 4,83 5,3 - 5,5 11 28 7
.2500 6,35 6,8 - 7,0 14 35 8
.3125 7,94 8,4 - 8,6 17 43 10
.3750 9,52 10,0 - 10,2 20 51 12
.4375 11,11 11,6 - 11,8 24 59 13
.5000 12,70 13,2 - 13,4 27 67 15
ANCHOR NUTS IN SECUNDARY STRUCTURE, ACCORDING WITH CAN16030

Bolt diameter
.1120 2,84 4,4 – 4,6 9 23 6
.1380 3,50 5,0 – 5,2 10 26 7
.1640 4,17 5,7 – 5,9 12 30 7
.1900 4,83 6,4 – 6,6 13 33 8
.2500 6,35 7,9 – 8,1 16 41 10
.3125 7,94 9,5 – 9,7 19 49 11
.3750 9,52 11,0 – 11,2 22 56 13
.4375 11,11 12,6 – 12,8 26 64 14
.5000 12,70 14,2 – 14,4 29 72 16
NOT ANCHOR NUTS, ACCORDING WITH CAN16030

Bolt diameter
.1120 2,84 3,0 – 3,1 6 16 5
.1380 3,50 3,7 – 3,8 8 19 5
.1640 4,17 4,3 – 4,4 9 22 6
.1900 4,83 5,0 – 5,1 10 26 7
.2500 6,35 6,5 – 6,6 13 33 8
.3125 7,94 8,1 – 8,2 16 41 10
.3750 9,52 9,7 – 9,8 20 49 11
.4375 11,11 11,3 – 11,4 23 57 13
.5000 12,70 12,9 – 13,0 26 65 14
Countersink the minimum thickness, according to the following tables:
FASTENER TYPE
Fastener DAN6 DAN8 NAS1097 NAS1581
Diam. H t H t H t H t
4 1,041 1,6 1,778 2,7 0,945 1,4
4,8 1,194 1,8 2,045 3,1 1,168 1,8 1,25 1,9
6,4 1,549 2,3 2,743 4,1 1,524 2,3 1,6 2,4
8 1,727 2,6 3,429 5,1 1,79 2,7
9,6 1,981 3,0 4,115 6,2 2,07 3,1
11,1 2,461 3,7 4,813 7,2 2,55 3,8
12,7 2,713 4,1 5,486 8,2 2,83 4,2
FASTENER TYPE
Fastener ASNA0077 NASM 20426
Diam. H t H t
4 1,4 2,1 1,402 2,1
4,8 1,78 2,7 1,785 2,7
6,4 2,44 3,7 2,422 3,6
8 2,703 4,1
9,6 3,417 5,1
11,1
12,7
FASTENER Fastener
TYPE Diam. H t
NAS1153 4,8 2,04 3,1
NAS1154 6,4 2,703 4,1
H ≤ 2/3 t
Min 0,5 mm
H t
“Knife edge”
5.2.2 Other requirements

 Distance to the nearest wall: The rivet head should not be on the radio. It should also
be checked in the piece to which it binds. Typical values indicated in the diagram below.
Taking into account the provision for the case of reusing existing holes (paragraph 5.3.2
below)
Max. of (Inst. Req; R+D+2; Rhead + 1)
1 min
D
 Check installation possibilities, especially for blind rivets.
NO OK OK
 Check access hi-lok/hi-lite Installation
In general, to allow the pass from the pilot holes to final diameter and the installation
of the Hi-Loks with automatic tool, it should be left a free space. For Hi-Lok installation
should be left on the side where it will go the collar, a clearance of 10 mm radius (not
taking into account the radius of the piece) and 50 mm in height for automatic
installation or 30 mm in height for manual installation. Should be left free access to
one of the two sides of the junction (on the side of pilot if exists) for drilling.
20
50 mm automatic
30 mm manual
 The relation between the diameter of the rivet and junction thickness should be between 2.5
(for solid rivets in single shear) and 4 (for bolts in double shear)
D t
Solid rivets t/D  2,5.

Hi-Loks y structural bolts t/D  4*
* In areas of high load transfer stress department should be consult by the convenience of used
steel hi-loks.
CONTOURING CRITERIA
Ø Fastener Maximum thickness to join Maximum thickness to join
inch mm. HI-LOKS Y BOLTS RIVETS
3/32 2,38 10 6
4/32 3,2 13 8
5/32 3,96 16 10
3/16 4,82 19 12
7/32 5,56 22 14
1/4 6,35 25 16
5/16 7,94 32 20
7/16 9,52 38 24
1/2 11,11 44 28
5.3 EDGE DISTANCES
5.3.1 New parts

Typical values:
 Metal, all directions: 2D+1mm
 Composites: Perpendicular to principal load or compression: 2.5D+1mm

Parallel to principal load: 3D + 1mm
5.3.2 Parts reused existing holes

When it is reusing existing holes, the distances to edge should be considered sufficient additional
margin to see the original assembly tolerances. The actual position of the drilling could oscillate a few
mm from the original theoretical position.
When reusing existing holes shall be increased by 2mm to-edge distances typical. The impact on
weight, should be analyzed case by case basis
D+4 2D+4
5.4 RIVET STEP

General values for structural joints:
Min: 4D
Max: 8D
Optimum step for structural joints:
Metal: 5D
Composites:
Fibra Alto Módulo: 4,5D
Fibra alta resistencia: 5D
For non-structural joints, the maximum is used to 10D
For removable joints, the typical step is 10D
5.5 TYPICAL VALUES FOR EDGE AND STEP DISTANCES
EDGE DISTANCE
EDGE DISTANCE
METAL COMPOSITE FASTENER PITCH (P)
METAL COMPOSITE FASTENER PITCH (P)
Fastener Std Shear/Comp. Tension Minimum Nominal Maximum
Std Shear/Comp. Tension Nominal
Dia. dFastener Det +=1d des==22,5
et = des = 2 d D 1+ 1des =d2,5
et = 3 D + 1 ( 4D MetalMinimum
(4D) Composite (4,5D) Ma
Dia. es D + D+1 det = )3 D + 1 ( 4D ) Metal (4D) ( 6D )
Composite (4,5D) (
4 4 9 9 11 1113 16
13 16 16 1816 24 18
4,8 4,8 11 11 13 1315,5 19,2
15,5 19 19,2 2219 28,8 22 2
6,4 6,4 14 14 17 1720,5 25,6
20,5 26 25,6 2926 38,4 29 3
8 8 17 17 21 2125 32
25 32 32 3632 48 36
9,6 9,6 20 20 25 2530 30
38,4 38 38,4 4438 57,6 44 5
des
des
det
det
5.6 SHIMS
For easer installation or to take into account manufacturing tolerances and assembly, in some places it
is necessary to consider the use of shims. The application to this program are:
 Liquid shim allowed to 0.5 mm

 Solid shim allowed to 1.0mm (standard solid shim LN29557-3.0255.32Axx, XX thickness)
Shim aplication rule: I+D-P-061
5.7 CLEARANCES
In the absence of other documents that define specific values for an installation, the following values
are used for parts to be designed with security clearances or distances:
 Between joint parts but with relative movement between them: 6.5mm (1/4”)
 Between non-joint parts but with relative movement between them : 13 mm (1/2”)
 Between non-joint parts, relative movement between them and possible vibration: 25mm (1”)
5.8 RIVETS REPLACEMENT
The criteria for the replacement of rivets or other fasteners are:
 Solid rivet replaced by solid rivet: Use the same diameter

 Solid rivets replaced by hi-lok: Use oversized hi-lok
 Hi-lok replaced by Hi-lok: Use oversized hi-lok
6. TOLERANCES
6.1 METALLIC PARTS
The typical values for machining parts are following as shown. In the drawings wil be indicated (always with the
manufacturing agreement) those values that are required for assembly
BORE AND NERVE THICKNESS  0,15
LENGHTS 30 mm  l  0,2
30 < l  100  0,3
100 < l  500  0,5
500 < l  1000 1
1000 < l < 2000  1,2
ANGLES 30    1º
31 <   120  0,5º
120 <   315º  0.25º
ACCORDING RADIUS + 1,0

- 0,5
DEPTH RADIUS  0,5
ROUND OF EDGES R = 0,3 + 0,2

-0
FLATNESS  0,5 / 100 mm. Max. 1.0mm
PARALLELISM  0,3 / 100 mm. Max. 1.0mm

SQUARENESS
RIGHTNESS  0.1 / 100 mm. Max. 1.0mm
6.2 COMPOSITE PARTS

Tolerances in manufacturing parts depends of manufacturing methodology, material and the number of plies.
Typical values are:
Thickness tolerance (CASA values)

Less than 20 ply 20 - 40 ply
UD Tape Prepreg +/- 6% Max of (+/- 5% , +/-0,22)
Fabric Prepreg +/- 7% Max of (+/- 4,5% , +/-0,20)
Glass Fibre Prepreg +/- 7% Max of (+/- 6% , +/-0,14)
6.3 NO MODEL ELEMENTS

Primer and paint, tedlar, adhesives, bronze net and fiberglass patch are not modeled in CATIA but should be
considered for the calculation / determination of the gaps between parts.
For the clearance calculation, following values are used:
 Primer: N/A
 Paint: N/A
 Sealant: 0,2 mm
 Fiberglass (for ply): 0,1 mm
 Tedlar, bronze net and adhesives: 0,3 mm
7. MATERIAS, PROCESSES AND APPLICABLE CODES…….

PROTECTION
SEMI-
EADS-CASA FINISHED AIRBUS MATERIAL
MATERIAL DESCRIPTION
DESIGNATION PRODUCT SPECIFICATION
STANDARD
ANTICORROSIVE PROTECTIONS (See 2.2.1)
CORROSION INHIBITING
Z11.502 --- AIMS09-08-001Gr.2 COMPOUND
CORROSION INHIBITING
Z11.505 --- AIMS09-08-003 COMPOUND
PRIMERS AND TOP COATS (See 2.2.2)
Z12.113 --- AIMS04-04-004 FUEL TANK COATING

NON CORROSION INHIBITING
Z12.129 --- AIMS04-04-002 PRIMER
Z12.132 --- AIMS04-04-002 PRIMER FOR ANTIEROSION PAINT
Z12.201 --- --- EPOXY FILLER
Z12.210 --- --- EPOXY FILLER
Z12.211 --- AIMS04-04-011 POLYURETHANE PORE-FILLER

INTERNAL PAINT SYSTEM (TOP
Z12.380 --- AIMS04-04-003 COAT)
Z12.402 --- AIMS04-04-009 VARNISH FOR TOUCH-UP
Z12.412 --- AIMS04-04-023 U.V. RESISTANT VARNISH
Z12.512 --- AIMS04-04-024 ANTISLIP PAINT
Z12.520 --- AIMS04-04-007 ABRASION RESISTANT PAINT

SEALANT BEAD PROTECTION
Z12.524 --- AIMS04-04-010 PAINT
PLASTIC MATERIALS (See 2.2.3)
Z14.501 LN9298 WL-5.1129.10 PTFE MOLDED (SHEETS)
Z14.502 --- AMS3652 PTFE SKIVED (FOILS)

L-P-1040B TYPE II, GRADE B, POLYVINYL FLUORIDE FILM
Z14.510 --- CLASS 1 (GREY)
L-P-1040B TYPE II, GRADES B POLYVINYL FLUORIDE FILM

Z14.512 ---
AND C, CLASS 1 (WHITE)
SEMI-
EADS-CASA FINISHED AIRBUS MATERIAL
DESIGNATION PRODUCT SPECIFICATION
STANDARD
RESIN AND ADHESIVE MATERIALS (See 2.2.4)
Z15.101 --- MMM-A-121 ELASTOMERIC ADHESIVE (NEOPRENE)
Z15.104 --- MIL-C-4003 ELASTOMERIC ADHESIVE (NITRILE)
Z15.201 --- I+D-N-200 EPOXY ADHESIVE
Z15.209 --- DAN1284-01 EPOXY ADHESIVE
Z15.301 --- I+D-N-200 SILICONE ADHESIVE
Z15.415 ABS5337 AIMS10-02-003 CORE SPLICING ADHESIVE

EPOXY FILM ADHESIVE (300 g/m2, 115 ± 5°C
Z15.429 --- I+D-N-200 CURE)
Z15.601 --- A-A-3097 TYPE I CL.2 CYANOACRYLIC ADHESIVE
Z15.915 --- I+D-N-200 BONDING PRIMER
Z18.115 --- I+D-N-200 EPOXY CORE FILLER (LOW VISCOSITY)
Z18.144 --- I+D-N-200 EPOXY CORE FILLER (R.T. CURING)
Z18.179 --- DAN1206-01 EPOXY CORE FILLER (HOT CURING)

SEALANTS (See 2.2.5)
Z11.903 --- AIMS04-05-005 TYPE I NON HARDENING JOINTING COMPOUND
Z16.101 --- AIMS04-05-002 INTERFAY FAYING SURFACE SEALANT

Z16.113 MIL-PRF-81733 TYPE II-2 CORROSION INHIBITING COMPOUND
---
Z16.156 AIMS04-05-002 BRUSH INTEGRAL FUEL TANK SEALANT
---
Z16.157 AIMS04-05-002 FILLET INTEGRAL FUEL TANK SEALANT
---
Z16.160 AIMS04-05-006 TYPE A LOW ADHESION SEALANT
---
Z16.161 AIMS04-05-006 TYPE B LOW ADHESION SEALANT
---
MIL-A-46106B GROUP I,
Z16.302 SILICONE SEALANT
--- TYPE I
Z16.912 --- --- ADHESION PROMOTER
HONEYCOMB CORES (See 2.2.6)

Z17.607 I+D-P-176 Class 1, Type 1 ARAMID HONEYCOMB CORE 3.0-1/8
---
Z17.622 I+D-P-176 Class 1, Type 1 ARAMID HONEYCOMB CORE 6.0-3/16
---
SEMI-
AIRBUS MATERIAL FINISHED EADS-CASA
SPECIFICATION PRODUCT DESIGNATION
STANDARD
RESIN AND ADHESIVE MATERIALS (See 2.2.4)

A-A-3097 TYPE I CLASS 2 --- Z15.601 CYANOACRYLIC ADHESIVE
AIMS10-02-003 ABS5337 Z15.415 CORE SPLICE ADHESIVE
DAN1206-01 Z18.179 EPOXY CORE FILLER (HOT CURING)

---
I+D-N-200 Z15.201 EPOXY ADHESIVE
---
---
---
---
I+D-N-200 Z15.301 SILICONE ADHESIVE
---
I+D-N-200 --- Z15.429 EPOXY FILM ADHESIVE (300 g/m2, 115 ± 5°C CURE)
I+D-N-200 Z15.915 BONDING PRIMER
---
I+D-N-200 Z18.115 EPOXY CORE FILLER (LOW VISCOSITY)
---
I+D-N-200 Z18.144 EPOXY CORE FILER (R.T. CURING)
---
MIL-C-4003 Z15.104 ELASTOMERIC ADHESIVE (NITRILE)
---
MMM-A-121 --- Z15.101 ELASTOMERIC ADHESIVE (NEOPRENE)
SEALANTS (See 2.2.5)

Z16.101 FAYING SURFACE SEALANT
AIMS04-05-002 INTERFAY ---
Z16.156 INTEGRAL FUEL TANK SEALANT
AIMS04-05-002 BRUSH ---
Z16.157 INTEGRAL FUEL TANK SEALANT
AIMS04-05-002 FILLET ---
AIMS04-05-005 TYPE I --- Z11.903 NON HARDENING JOINTING COMPOUND
AIMS04-05-006 TYPE A --- Z16.160 LOW ADHESION SEALANT
AIMS04-05-006 TYPE B --- Z16.161 LOW ADHESION SEALANT

MIL-A-46106B GROUP I,
TYPE I --- Z16.302 SILICONE SEALANT
--- --- Z16.912 ADHESION PROMOTER
HONEYCOMB CORES (See 2.2.6)

I+D-P-156 Class 1, Type 1 --- Z17.607 ARAMID HONEYCOMB CORE 3.0-1/8
I+D-P-156 Class 1, Type 1 --- Z17.622 ARAMID HONEYCOMB CORE 6.0-3/16

SEMI-
AIRBUS MATERIAL FINISHED EADS-CASA
SPECIFICATION PRODUCT DESIGNATION
STANDARD
WET LAY-UP MATERIALS (See 2.2.7)

EPOXY RESIN, R.T. CURING, FOR GLASS WET LAY-
AIMS08-02-001 Z18.170
--- UP
AMS-C-9084 T.III C2 Z17.201 GLASS FIBER FABRIC (120 style, 104 g/m2)
---
AMS-C-9084 T.VIII C2 --- Z17.208 GLASS FIBER FABRIC (181 style, 293 g/m2)
EPOXY RESIN, HOT CURING, FOR FILLING AND
I+D-N-200 Z18.142
--- POTTING
PREPREG MATERIALS (See 2.2.8)

GLASS/PHENOLIC PREPREG (7781 TYPE, 135°C
AIMS05-10-001 ABS5047 Z19.607
CURE)
AIMS05-10-009 ABS5047-01 Z19.605 GLASS/PHENOLIC PREPREG (120 TYPE, 135°C CURE)
I+D-P-250A, Group I --- Z19.101 GLASS/EPOXY PREPREG (181 TYPE, 125°C CURE)
MISCELLANEOUS (See 2.2.9)

A-A-1689, Type I, Class 2 --- Z24.310 VINYL ADHESIVE TAPE
A-A-59163, Type I ABS5334 Z22.127 SELF-ADHERING INSULATION TAPE
A-A-59474, Type I, Class 1 --- Z24.330 PTFE ADHESIVE TAPE
MIL-L-23398 --- Z21.305 SOLID FILM LUBRICANT
--- -- Z24.273 DOUBLE SIDED ADHESIVE TAPE

Aircraft Structure Design Principles

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Aircraft Structure Design Principles

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INDEX

7. MATERIAS, PROCESSES AND APPLICABLE CODES…….

3.1 BEND RADIUS

STATE BEND RADIUS (Minimum) en mm

STATE BEND RADIUS (Minimum) en mm

0 3,0 4 4 5 5 5,6 7,2 9,5 10 12 16 35 64

Designación A aprox. C aprox. E mín. H aprox. R ± 1mm

diameter = 16 mm. Cutter radius = 4 mm

4.1.3 Spherical tool

Alternative solution with

Cylindrical tool Spherical tool

4.2 THICKNESS-HEIGHT RATIO IN STIFFENERS

These values are met if the cutter diameter D satisfies:

4.2.1 Transitions / Changes in thickness

4.4 STIFFENERS ENDINGS

4.5 MINIMUM MACHINED THICKNESS

Tecnology Conventional High speed

If you make will be made according to the following diagrams.

By request of fatigue, the tapping fillet radius will be 2.5 mm.

For joints staggered, the distances between rivets also apply.

For sealing, at least one staggered riveted joint must be used

5.2 FOR INSTALLATION

5.2.1 Drilling diameter

Typical drills (like I+D-P-117)

Drills with more tightening than AA (strong requirement for fatigue)

Drills presure limit ( like I+D-L-113)

Drills with greater ease than FF (without pressure limit)

ANCHOR NUTS IN PRIMARY STRUCTURE, ACCORDING WITH CAN16030

ANCHOR NUTS IN SECUNDARY STRUCTURE, ACCORDING WITH CAN16030

NOT ANCHOR NUTS, ACCORDING WITH CAN16030

Countersink the minimum thickness, according to the following tables:

5.2.2 Other requirements

 Check access hi-lok/hi-lite Installation

Solid rivets t/D  2,5.

5.3 EDGE DISTANCES

5.3.1 New parts

 Metal, all directions: 2D+1mm

 Composites: Perpendicular to principal load or compression: 2.5D+1mm

5.3.2 Parts reused existing holes

5.4 RIVET STEP

Optimum step for structural joints:

For non-structural joints, the maximum is used to 10D

For removable joints, the typical step is 10D

5.5 TYPICAL VALUES FOR EDGE AND STEP DISTANCES

 Liquid shim allowed to 0.5 mm

Shim aplication rule: I+D-P-061

5.8 RIVETS REPLACEMENT

The criteria for the replacement of rivets or other fasteners are:

 Solid rivet replaced by solid rivet: Use the same diameter

BORE AND NERVE THICKNESS  0,15

ACCORDING RADIUS + 1,0

DEPTH RADIUS  0,5

ROUND OF EDGES R = 0,3 + 0,2

FLATNESS  0,5 / 100 mm. Max. 1.0mm

PARALLELISM  0,3 / 100 mm. Max. 1.0mm

RIGHTNESS  0.1 / 100 mm. Max. 1.0mm

6.2 COMPOSITE PARTS

Thickness tolerance (CASA values)

6.3 NO MODEL ELEMENTS

For the clearance calculation, following values are used:

7. MATERIAS, PROCESSES AND APPLICABLE CODES…….

Z12.113 --- AIMS04-04-004 FUEL TANK COATING

Z12.132 --- AIMS04-04-002 PRIMER FOR ANTIEROSION PAINT