References:

1. Module 6 Materials and Hardware

2. Module 7 Maintenance Practices
3. Module 11A
4. MOE
5. CAD 8204
6. CAD 8206
7. CAAIP

Assessment Topic of Discussion:

1. Material Handling

1.1 Apply correct procedures: Material storage and handling

a) Reference documents for storage of aeronautical parts

Material Safety Data Sheet (MSDS)

- provide procedures for storage and handling, transportation, physical and chemical
properties, first aid procedures
- prepared by supplier or manufacturer of material

Civil Aircraft Inspection Procedure (CAIP)

- referred under airworthiness procedure
- subtopic BL/1-7: Storage condition for aeronautical supply
- newly published manual is Civil Aircraft Airworthiness Information & Procedure (CAAIP)
- under chapter D: engineering practices and procedures
- leaflet D-40: Storage condition for aeronautical supply

AC43.13
- Advisory Circular that exist under the FAA

Civil Aircraft Airworthiness Information & Procedure (CAAIP)

b) Knowledge on 'Shelf Life'

What is ‘Shelf Life’

- a period of time that a material may be stored and remain usable, fit for consumption
- upon expiry, parts must be removed from store for checking or overhaul as instructed by
the manufacturer

Example of item with shelf life:

- o-rings, sealant, tyre, battery, oxygen cylinder
c) Storage of typical aircraft spares

Aircraft battery
- lead acid battery should be stored in fully charged condition
- storage area should be cool, dry and well ventilated
- ni-cad battery can be stored for long period without damage in any state of charge
- storage area should be clean and dry

Rubbery material
- storage temperature should be between 10-21’C
- should not be exposed directly to sunlight
- isolate from oxygen by packing in airtight container using french chalk
- exposure to air containing ozone should be avoided to prevent permanent damage in
shape and dimension
- avoid contact with copper/brass/iron/steel/any compound of manganese
- if deterioration of seals in suspected, stretch seals to 20% of internal diameter, if any
cracks appear under 10x magnification, seals must be rejected

Tyres
- stored vertically in special racks embodying support tube (so tyre is supported from two
points)
- ⅔ of tyre should be above the support tube and ⅓ should be below
- turn to a new position every 2-3 months

Sheet metal
- should be stored on edge in racks to prevent bending
- must be kept clear from floor to prevent contamination from floor cleaning solvent that
may cause corrosion, bend the edge and might cause scratch
- flat stacking is not recommended because it will slid on stack (unless using suction pad)
- during transit, case should be closed to avoid dust/dirt

Pipeline
- blanks should be installed at both ends
- rags and cloth should not be used as blanks
- rigid pipeline must be supported during storage to prevent distortion
- flexible pipeline should be wrap (sealed in plastic and stored in darkened room) and
vertically suspended
- in hot climate area, pipeline should be stored in cool places, high temperature may
accelerate hardening of outer cover
- store in unstressed condition

Electrical cable
- must be stored horizontally
 - if stored vertically, lower cable may be crushed

d) Storage of flammable materials

- isolate from main store

- all fire safety/precaution must be provided in the area
- flammable material must be kept in special storage box/cabinet away building

e) Protective materials for storage purposes

Vapour Phase Inhibitor

- method of protection against corrosion
- used for stored articles made from ferrous metal

Dessicants
- silica gel & activated alumina
- absorb moisture in packaging container
- avoid corrosion
- colour changes from blue to pink

Protective oil, fluid, compound

- temporary protection on metal
- wrapping in non absorbent material (polythene/waxed paper)

Protective case/plastic

f) Handling of ESDS components

- wear wrist strap

- do not touch pin/ESDS component
- always put ESDS component in anti-static bag
- do work inside a humidity controlled room
- all ESDS component must be stored on a grounded rack/inside dissipative storage

1.2 Identification of a range of materials

a) Knowledge on Ferrous / Non-ferrous materials

What is ferrous materials?

- any material that have iron as their base is a ferrous material
- the most common alloy of iron is steel (iron+carbon)

What is non-ferrous materials?

 - any material that does not have a significant amount of iron in its chemical composition
(generally 1%)
- common non-ferrous materials are aluminium, copper and nickel

Description of iron:
- soft, malleable and ductile in its pure state
- silvery white in colour and is quite heavy
- readily combines with oxygen to form iron oxide (rust)
- cast iron is made by pouring molten iron into a mould
- have few usage but is used in engine (piston rings) as its porosity and wear
characteristic allow it to hold lubricant film

Steel
- iron + carbon

Stainless Steel
- iron + chromium (18%) + nickel (8%)
- high corrosion resistant and strength
- well suited for high temperature application

Molybdenum
- very high wear resistant and fatigue strength
- chrome-molybdenum (chrome-moly) is the most common on aircraft
- SAE 4130 (1% moly 0.3% carbon) makes landing gear structure and engine mount

Aluminium
- anodized form
- silver in colour, lighter than steel

Copper
- colour is between red to brown
- unalloyed state is soft and ductile
- copper + tin = bronze
- copper + zinc = brass

Nickel
- tough, able to perform at high and low temperature
- corrosion resistant
- used in tanks/hot section/combustion chamber

b) Identification of Ferrous / Non-ferrous materials

Identification of ferrous
- may form rust
 - attracted to magnet

Identification of non-ferrous materials

- will not form rust (iron oxide) due to lack of iron content
- is not magnetic
- corrosion may be white powdery (aluminium), green (copper), white powder (titanium)

Nickel alloy (monel)

Nickel alloy (inconel)

- 1 drop of cupric chloride & hydrochloric acid solution to the metal and allowing it to
remain for 2 minutes
- shiny spot = inconel, copper
- colour spot = stainless steel

Titanium
- used for fuselage, engine shroud, firewall
- to identify, do spark test for white spark (yellow spark for stainless steel)

c) Common alloying elements of aluminium e.g. 2024

2024 aluminium alloy

- Copper is the main alloying element
- High strength to weight ratio and good fatigue resistance
- Have poor corrosion resistance, solved by cladding with aluminium
- Commonly found in wing and fuselage

Wrought aluminium alloy designation system:

1xxx
- 99% aluminium content or more
- can be work hardened

2xxx
- aluminium + copper
- also known as duralumin
- can be precipitation hardened to strength comparable to steel

3xxx
- aluminium + manganese
- can be work hardened

4xxx
- aluminium + silicon
5xxx
- aluminium + magnesium
- high corrosion resistant

6xxx
- aluminium + magnesium + silicon
- general purpose aluminium alloy

7xxx
- aluminium + zinc
- can be precipitation hardened
- highest strength of any aluminium alloy
- increasingly used in modern aircraft

8xxx - other element

9xxx - unused series

d) Heat treatment identification of sheet metal

O
- annealed temper of wrought alloy

F
- fabricated condition for wrought alloy
- cast for casting alloy

T2
- annealed temper of casting alloy

T3
- solution heat treated followed by strain hardening

T4
- solution heat treated followed by natural aging at room temperature

T5
- artificially age at an elevated temperature

T6
- solution heat treat followed by artificially aging

T7
- solution heat treat followed by stabilization
T8
- solution heat treat followed by strain hardening then artificial aging

T9
- solution heat treated followed by artificial aging then strain hardening

According to British standard 1470-1477 (Non Heat Treatable Alloy)

O
- material in annealed condition

M
- material in as manufactured condition

OO
- annealed and lightly drawn

T
- solution heat treated

W
- solution heat treated and require precipitation treatment

WP
- solution and precipitation heat treated

WD
- drawn after solution heat treatment

P
- precipitation heat treated only

A
- annealed

N-sol
- heat treated without requiring precipitation

e) Precautions when using certain materials

- know what material you are working with

- be aware of potential hazard
- refer MSDS / CSDS ( Chemical Safety Data Sheet)
f) Protection treatment on materials

Cladding
- a thin layer of pure aluminium to make material more corrosion resistant

Anodizing
- electrolytic process to produce oxide film to obtain corrosion resistance properties and
abrasion resistance to aluminium & aluminium alloy
- the 3 types are: sulphuric acid process, chromic acid process, hard anodizing process

Cadmium plating
- an electro chemical process which deposits a layer of cadmium on the surface of the
parts to protect against corrosion
- for copper base material and for reduction of contact corrosion for less noble material

Chromate treatment (magnesium alloy)

- provide a temporary protective and initial treatment prior to surface sealing, painting
- phosphating on steel

g) Allowable repairs on materials

AMM

Structural Repair Manual (SRM)

AC43-13
- Advisory Circular containing methods, techniques, practices acceptable to administrator
for inspection and repair when there is no manufacturer repair or maintenance
instruction

2. Disasssemble, Inspect and Assemble an Aircraft Component

2.1 Measure shafts, bores, flanges and adjacent surfaces using a variety of precision measuring
instruments and record dimensions

a) Tools to use for bore and shaft measurement

- inside micrometer
- outside micrometer
- bore gauge
- dial test indicator

Inside micrometer
- used to measure diameter of opening of a hole
Outside micrometer
- used to measure outside diameter of round object, thickness of flat pieces

Bore gauge
- used to measure inside diameter of a hole or cylinder

Dial test micrometer

- used to measure clearance, tolerance or variation in tolerance of machined parts to
ensure accuracy

b) How to 'zero' a micrometer

- Before zeroing a micrometer, ensure that the anvil and spindle measuring surface are
clean and free from defect
- Rotate the thimble until the anvil and spindle are close to each other
- Turn the ratchet slowly until it clicks
- Observe the zero line on the thimble to see whether it lines up with zero line on the
sleeve
- Lock the barrel
- Use the c spanner to manually turn the barrel until the zero line reallign

c) Use of 'C' spanners on micrometer

- to zero a micrometer

d) Vernier reading on micrometer

e) Calibration requirements on precision equipment

- calibrated to ensure the equipment stays within the manufacturer’s limit and spec
requirement
- frequency of calibration depends on usage of equipment and manufacturer’s suggestion
- daily/constant use equipment like torque wrench and micrometer can be calibrated once
a month or quarterly
- seldom use equipment like aircraft weight scale should be calibrated once a year

Calibration tag
- part number and serial number of equipment
- date of calibration and the next due date
- signature/approval number/stamp of certifying staff

Safety precaution
- prior to usage, always check for calibration tag and do visual inspection
 - any discrepancies should render the tool out of use
- return the tool to tool store for recalibration

2.2 Disassemble and assemble an aircraft component IAW (in accordance with) manufacturer's
overhaul manual

a) Knowledge in the use of manual

Aircraft Maintenance Manual

- a manual developed by aircraft manufacturer that provides detailed technical
maintenance instructions for a specific type of aircraft

Structural Repair Manual

- contains procedures for minor repairs on structural damage on an aircraft
- if the repair is not found in the SRM, then a specific Repair Scheme need to be obtain
from the manufacturer

Wiring Diagram Manual

- contains printed wiring diagram that provides precise representation of an aircraft wiring
system

SDS
- familiarise personnel with aircraft system and give sufficient information to understand
how the system operates

Illustrated Tools and Equipment List (ITEL)

- List down tools and equipment that are approved for work on aircraft

AMM Revision
- AMM is kept current through revisions
- every revision will be recorded in the List of Effective Pages (LEP)
- Normal Revision is a complete reissue with differential marking at a specified revision
date
- Temporary Revision is published to introduce information that cannot wait until the next
normal revision. It will stay in effect until a new Normal Revision comes out

Air Transport Association (ATA) 100

- a global standard with regards to engineering manual specification

Standard ATA Chapters

- Aircraft General: ATA 00 to ATA 19
- Aircraft System: ATA 20 to ATA 49
- Aircraft Structure: ATA 50 to ATA 57
- Propeller/Rotor: ATA 60 to ATA 69
 - Power plant: ATA 70 to ATA 89

Chapter/System - Section/Subsystem - Subject/Topic

b) Use of proper tools

c) Special tools requirement

d) Ensuring serviceable and approved replacement components/parts

New component (other than engine and propeller) received should have:
- CAAM Form 1 (CAAM approved manufacturer)
- EASA Form 1 (EASA approved manufacturer)
- FAA 8130 (FAA approved manufacturer)

Raw materials and consumable should have:

- Certificate of Conformity or
- Statement from supplier source

According to AAT MOE, parts without Form 1 may be accepted if the customer have already
ensured that they comply with CAAM requirement

Authorised Release Certificate Form 1

- use to declare airworthiness of a new component/maintenance undertake on component

Certificate of Conformity
- states that part conform to the specs, design, approved instruction etc.
- issued by manufacturer

Bonded Store
- storage area for component and material that have been approved and received with
evidence

Quarantine Store
- storage area for new component and material awaiting inspection and certification
before transferred to bonded store