DOCUMENT RESUME ED 097 517 Aircraft Sheet Metal General .

DOCUMENT RESUMEED 097 517TITLEINSTITUTIONPUB DATENOTEEDRS PRICEDESCRIPTORSIDENTIFIERSCE 002 287Aircraft Sheet Metal General Repairs; Sheet MetalWork 3: 9857.01.Dade County Public Schools, Miami, Fla.Apr 7318p.; An Authorized Course of Instruction for theQuinmester ProgramMF- 0.75 HC- 1.50 PLUS POSTAGE*Aviation Mechanics; Behavioral Objective; CourseContent; Course Descriptions; *Curriculum Guides;Grade 12; Job Skills; *Metal Working Occupations;Secondary Grades; *Sheet Metal Work; Shop Curriculum;Skill Development; *Trade and Industrial Education;Vocational Education; Welding.*Quinmester ProgramABSTRACTThe outline will serve as a guide to the high schoolstudent interested in the field of sheet metal work. Intended for the12th grade level, the course is orgftnized into three instructionalblocks: (1) general repairs, (2) line maintenance, (3) brazing andsoldering, followed by a posttest. The advanced course is 135 hoursin length and offers instruction in sheet metal techniques inmanufacturing and repairing miscellaneous parts for aircraft and shopequipment. A bibliography lists basic and supplementary referencematerials and films. A posttest sample concludes the coursedescription. (MW)

BEST COPY AVAILABLEU S DEPARTMENT OF HEALTH.EDUCATION I WELFARENATIONAL INSTITUTE OFEDUCATIONtry,' DOCUMENI HAS BEEN REPRODUCED E *A( tt y As RECEIVED F ROMTHE PERSON OR ORGANIZATIONA Nc, I I PO1E11501 VIE* OR OPINIONSstArE0 DO NOI NE( ESSARic Y REPRESIN? 0; I 'CIA). N.I IONAL 1E45111ot 01FOUCAliON POSI ION OR POI. YAUTHORIZED COURSE OF INSTRUCTION FOR THE61''doCourse OutlineSHEET METAL WORK 3 - 9857(Aircraft Sheet Metal General Repairs)Department 48 - Quin 9857.017'74raODIVISION OF INSTRUCTION.1973

DADE COUNTY PUBLIC SCH'OOLS1 4 5 0NORTHEAST SECOND AVENUEMIAMI,FLORIDA33132Course OutlineSHEET METAL WORK 3 - 9857(Aircraft Sheet Metal General Repairs)Department 48 - nuin 9857.01county office ofVCCATIONAL AND ADULT OUCATION

THE SCHOOL BOARD OF DADE COUNTYMr. G. Holmes Braddock, ChairmanMr. William H. Turner, Vice-ChairmanMrs. Ethel BeckhamMrs. Crutcher HarrisonMrs. Phyllis MillerMr. Robert RenickDr. Ben SheppariDr. E. L. Whigham, Superintendent of SchoolsDade County Public SchoolsMiami, Florida 33132April, 1973Published by the School Board of Dade County

Course Description9857State CategoryNumber48County Dept.Number9857.01Aircraft Sheet Metal General RepairsCounty CourseCourse TitleNumber.This is an advanced quinmester course in sheet metal techniques in manufacturingand repairing miscellaneous parts for aircraft and shop equipment. Use of brazingand soldering equipment will be included. This is a three quinmester credit course.Indicators of Success:Prior to entry into this course, the student will displaymastery of the skills indicated in 9855.01.Clock Hours:135

PREFACEThe following quinmester course outline will serveas a guide to thehigh school student who wishes to pursue the field of sheet metal work.This is a first quinmester course for the twe.fth grade.This course outline consists of four blocks of instruction which aresubdivided into several units each.The course is 135 hours in length.Prior to entry into this course the student must display masteryof the skills indicated in Quin 9855.01.Great emphasis will be placed on the use of visual aids, mock-ups,cutaways, transparencies, films, instructional sheets and manipulativeshop practice.This outline was developed through the cooperative efforts of theinstructional and supervisory personnel, the Quinmester Advisory Committee,and the Vocational Curriculum Materials Service, and has been approved.bythe Dade County Vocational Curriculum Committee.

TABLE OF CONTENTSwith Suggested Hourly BreakdownPagePREFACEGOAT SSPECIFIC BLOCK AL REPAIRS (60 Hours)Repairing Miscellaneous PartsManufacturing and Repairing Shop.EquipmentMaking Modification on AircraftLINE MAINTENANCE (60 Hours)Making Repairs as NeededInterpreting SpecificationsBRAZING AND SOLDERING (15 Hours)Brazing Steel PartsSilver SolderingSoft Soldering11111222QUINMESTER POST-TESTAPPENDIX:QUINMESTER POST-TEST SAMPLE5

GOALSThe student must be able to demonstrate:1.The skills and knowledge necessary to do aircraft sheet metal generalrepairs.2.Ability to manufacture and repair shop equipment.3.Ability to perform line maintenance aircraft general repairs.4.Ability to refer to federal aviation administration publication andinterpret their meanings.5.Skills used for sheet metal repairs.6.Ability to do simple brazing and soldering operations.iii

SPECIFIC BLOCK OBJECTIVESBLOCK I - GENERAL REPAIRSThe student must be able to:1.2.Demonstrate the ability to make general repairs on the aircraft.Exhibit the ability required in manufacturing and repairing shopequipment.3.Exhibit the ability required ih making modification in aircraftand interpret specifications for modiftcations.BLOCK II - LINE MAINTENANCEThe student must be able to:1.2.Exhibit the ability to do general repairs on the line maintenanceaircrafts and equipMents.Exhibit the skills and knowledge to interpret specification setforth by the F.A.A. and the aircraft manufacture.BLOCK III - BRAZING AND SOLDERINGThe student must be able to:1.2.3.Demonstrate the ability to do simple brazing operations.Demonstrate the ability to do simple soldering operations.State the hazards of brazing and soldering.BLOCK IV - QUINMESTER POST-TESTThe student must be able to:1.Satisfactorily complete the quinmester post-test.iv

Course OutlineSHEET METAL WORK 39857(Aircraft Sheet Metal General Repairs)Department 48 - Quin 9857.01I.GENERAL REPAIRSA.Repairing Miscellaneous Parts1.2.3.4.5.6.7.8.9.10.11.12.B.DoorsHatchesWash roomDeckingSeatsHingesDoor hatchesGalleyBrackets and fixturesCowlingFirewallInstrument panelManufacturing and Repairing Shop Equipment1.Making metal containersa.Waste cansh.Parts pansc.Parts wash pand.Tank2.Making metal utility itemsa.b.c.d.e.C.FunnelsTool kit boxesHose cartsLadder and stepsAir ductsMaking Modification on Aircraft1.Interpreting federal publication and specification2.Interpreting manufacturer's manuals and specificationLINE MAINTENANCEA.B.Making Repairs as Needed1.Repairing flight controls2.Repairing air frame damage3. Repairing Nacelles and cowling4.Repairing hulls, tanks iud floatsInterpreting Specifications1.Complying with F.A.A. requirements2.Complying with manufacturer's recommendations and specifications.1

III.IV.BRAZING AND SOLDERINGA.Brazing Steel Parts1.Preparation of material for brazing2.Function and application of flux3.Special techniques used in brazing4.Use of brazing in aircraft repairsB.Silver Soldering1.Preparation of parts for silver soldering2.Function and application of flux3.Special techniques used in silver soldering4.Use of silver in aircraft partsC.Soft Soldering1.Soldering copper2.Tinning the copper3.Types of soft solder4.Soldering techniques5.Post soldering treatmentQUINMESTER POST-TEST-2-

BIBLIOGRAPHY(Aircraft Sheet Metal General Repairs)Basic Reference:NoneSupplementary References:1.Aero Publishers.Maintenance and Repair of Aerospace Vehicles.3rd ed.New York: McGraw-Hill Book Company, Inc., 1963.Pp. 320.2.Airframe Mechanic Written Exam Guide.Fort Worth, Texas:School of Aeronautics, 1968. Pp. 63.3.Alcoa Aluminum Handbook.1959.Pp. 222.4.Boggess, Edward.Aircraft Sheet Metal Work.Publishing Company, 1941. Pp. 117.5.Forming Manual.Salt Lake City:Education, 1942.Pp. 298.6.Frazer, Russell.Practical Aircraft Sheet Metal Work.McGraw-Hill Book Company, Inc., 1942.Pp. 193.7.Giachino, J. U.Aircraft Sheet Heti.) Work.The Manual Arts Press, 1942. Pp. 123.8.Leavell, Stuart, and Bungay, Stanley.Standard Aircraft Handbook.Los Angeles:Aero Publishers, Inc., 1952.Pp. 159.9.Lemaster, Clarence Allen. Aircraft Sheet Metal Work.nerican Technical Society, 1944.Pp. 117.Pittsburg.:ktmeAluminum Company of America,PitmanNew York:Utah State Board of VocationalNew York:Peoria, Illinois:Chicago:10.Nista, Albert H.Aircraft Riveting.Company, Inc., 1942. Pp. 160.11.Norcross, Girl.How To Do Aircraft Sheet Metal, New York:McGraw-Hill Book Company, Inc., 1942. Pp. 228.12.Northrup Institute of Technology.Aircraft Maintenance and Repair.New York:McGraw-Hill Rook Company, Inc., 1955.Pp. 444.13,Overby, Charles A.Aircraft and Missile Oesikn Maintenance Handbook.New York:The Macmillan Company, 1960.Lp. 320.14.Rice, Ralph.Aero Mechanics Ouestionnaire,Publishers, Inc., 1955. Pp. 238.-3-New York:McGraw-Hill BookLos Angeles:Aero

15.Template Layout.Pp. 306.16.United States Department of Air Force.Air Frame Maintenance.Air Force Manual 52-11. Washington, D.C.:United StatesGovernment Printing office, 1964.Pp. 314.17.United States Naval Air Technical Training Command. AircraftStructural Maintenance Nau ers 10308B. Washington, D.C.:United States Government Printing Office, 1969.Pp. 414.Glendale, California:Aero Publishers, 1942.Films:1.Airframe MechanicJam Handy.2.Airplane Structures.The.16 mm.16 mm.10 min.45 ing PBY.16 mm.Corporation.4.Forming Aluminum.5.How To Rivet Aluminum.45 min.16 mm.B/W.20 min.16 mm.-4-1943.B/W.20 min.Consolidated Aircraft1966.B/W.Alcoa.1942.Alcoa.

Quinmester Post-Test Sample5

QUINMESTER POST-TESTNameDateBEST COPY AVAILABLEScoreMultiple Choice Test ItemsEach statement needs a word, a figure, or a phrase to make it correct.Only one of the choices listed is correct. Place the number of the choiceyou make in the space provided at the right edge of the sheet.1.2.Aircraft metal work is usually called sheet metal work.What isthe difference between sheet and plate?(1)Sheet can be formedby hand and plate cannot, (2)Composition of metal, (3) Dependsonly on where it is used, (4) Thickness only)Fuel tanks should be constructed capable of withstanding aninternal pressure of:(1)3-1/2 psl, (2)5 psl, (3) 2-1/2 psl,(4)15 psl.)3.In bending sheet metal it is important that, if possible, it is tobe bent:(1)180 to the grain, (2) across the grain, (3) 45 to the grain, (4) parallel to the grain.4.A sheet metal technician is to repair a damaged aircraft spar,he must do the work in accordance with the instructions containedin the:(1)repair manual for the applicable spar, (2) manufacturer's structural handbook, (3) structural repair manual forthe applicable aircraft, (4)general structural repair manual.5.If you discover a crack in the web of a bulkhead, you should usethe same type repair as you would use:(1)on fully stressedskin, (2) on lightening hule repairs, (3)on staingers andlongerons, (4)if the web were buckled.6.(The heads on a former rib serve what purpose?the rib, (2) They reinforce the flange, (3)rigid, (4) they stiffen the web.qhich of the following is an advantage of the use of a former ribrather than a truss or reinforced rib?(1)It is lighter,(2)It is stronger, (3)It.does not require lightening holes,(4)It is more adaptable for use in larger aircraft.8.The term brazing includes all but which of the following processes?(1)Bronze welding, (2) Hard soldering, (3) Silver soldering,(4)Stainless steel welding9.For brazing a joint in metal with a melting point of 1, 870 F, youshould not use brazing alloy of graze?(1)A, (2) B, (3)C,1))(1)They lightenThey keep the flange7.(4)()