TO 1-1A-1 NAVAIR 01-1A-1 - Tinker Air Force Base

TO 1-1A-1

NAVAIR 01-1A-1

TECHNICAL MANUAL

ENGINEERING HANDBOOK SERIES FOR AIRCRAFT

REPAIR

GENERAL MANUAL FOR STRUCTURAL REPAIR

(ATOS)

THIS MANUAL SUPERSEDES AF TO 1-1A-1 AND NAVAIR 01-1A-1, DATED 1 APRIL 2015.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. HQ AFMC PA Case Number 070201. Submit

recommended changes or problems with this technical order to 558 CBSS/GBHA, Bldg 3001/1AC1108B, Tinker AFB OK 73145-3041.

Published under authority of the Secretary of the Air Force

15 JANUARY 2016

TO 1-1A-1

NAVAIR 01-1A-1

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer

margins of the page. Changes to illustrations are indicated by shaded or screened areas,

or by miniature pointing hands.

Dates of issue for original and changed pages are:

Original . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . . 15 January 2016

TOTAL NUMBER OF PAGES IN THIS MANUAL IS 160, CONSISTING OF THE FOLLOWING:

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USAF

T.O. 1-1A-1

TABLE OF CONTENTS

Chapter

1

3.1

3.2

SAFETY SUMMARY...............................................vii

3.3

3.3.1

3.3.2

3.3.3

3.4

3.5

A DESCRIPTION OF THE MAIN ELEMENTS IN AIRCRAFT STRUCTURE .............1-1

1.6

1.6.1

1.6.2

1.7

1.7.1

1.7.2

1.8

Principal Structural Units ...........................1-1

Fuselage ......................................................1-1

Engine Mounts............................................1-1

Nacelle ........................................................1-1

Wings ..........................................................1-1

Stabilizers....................................................1-1

Control Surfaces .........................................1-1

Landing Gear ..............................................1-1

Fuselage ......................................................1-1

General........................................................1-1

Structure......................................................1-1

Engine Mounts............................................1-3

General........................................................1-3

Structure......................................................1-4

Nacelles.......................................................1-4

General........................................................1-4

Structure......................................................1-4

Wings ..........................................................1-4

General........................................................1-4

Structure......................................................1-4

Inspection and Maintenance of

the Wings, Fuselage, and Nacelles.......................................................1-5

Stabilizers....................................................1-6

General........................................................1-6

Structure......................................................1-6

Control Surfaces .........................................1-6

General........................................................1-6

Structure......................................................1-8

Landing Gear ............................................1-10

3.5.1

3.5.2

3.5.3

3.6

3.7

3.8

3.9

3.9.1

3.9.2

3.9.3

3.9.4

3.10

3.11

3.11.1

3.11.2

3.11.3

3.12

3.13

4

Causes of Aircraft Damage........................2-1

Damage Classifications ..............................2-2

Repair Classifications .................................2-5

Investigation of Damage ............................2-6

Nondestructive Inspection ..........................2-6

Nondestructive Inspection (NDI) ...............2-6

Damage Types ............................................2-6

NDI Techniques..........................................2-7

4.2.2

4.2.3

4.2.4

4.2.5

4.2.6

4.2.7

4.2.8

GENERAL WORKING PRACTICE .......................3-1

5

Page

Repair of Aircraft Structures......................3-1

Aluminum Alloy Stressed Skin

Structure .................................................3-1

Aluminum Alloy Sheet Substitutions ........................................................3-1

Explanation of Substitution Table .............3-1

Explanation of Rule 1 ................................3-4

Explanation of Rule 2 ................................3-4

Rivets and Riveting Practice......................3-4

Replacement of Spot Welds and

Worn Laminas........................................3-5

General........................................................3-5

Removal of Spot Welds .............................3-5

Spot Weld Failures .....................................3-6

Fasteners .....................................................3-9

Extracting Broken Screws..........................3-9

Advanced Composite Repair....................3-10

Tubing Repair ...........................................3-11

General......................................................3-11

Identification of Tubing Systems.............3-11

Tubing Damage ........................................3-12

Repairs ......................................................3-12

Repair of Threaded Installations..............3-12

Stop-Drilling Cracks in Sheet

Material (Low- and MediumStress Areas) ........................................3-13

Crack inspection .......................................3-13

Crack evaluation .......................................3-13

Crack repair and treatment.......................3-14

Blending Scratches ...................................3-14

Typical Repair Examples .........................3-14

MATERIALS AND THEIR IDENTIFICATION ...............................................................4-1

4.1

4.2

4.2.1

DAMAGE ASSESSMENT ......................................2-1

2.1

2.2

2.3

2.4

2.5

2.5.1

2.5.2

2.6

3

Chapter

INTRODUCTION........................................................ v

1.1

1.1.1

1.1.2

1.1.3

1.1.4

1.1.5

1.1.6

1.1.7

1.2

1.2.1

1.2.2

1.3

1.3.1

1.3.2

1.4

1.4.1

1.4.2

1.5

1.5.1

1.5.2

1.5.3

2

Page

Material Specifications ...............................4-1

Terminology................................................4-1

Terms for the Study and Use of

Materials.................................................4-1

Steel.............................................................4-4

Aluminum ...................................................4-8

Titanium....................................................4-11

Magnesium................................................4-16

Advanced Composites ..............................4-17

Transparent Plastics..................................4-18

Safety Glass ..............................................4-19

FASTENERS ............................................................5-1

5.1

5.2

5.3

General........................................................5-1

Threaded Fasteners .....................................5-1

Rivets ..........................................................5-4

i

T.O. 1-1A-1

6

WELDING ................................................................6-1

7

ADHESIVES AND BONDING ...............................7-1

7.1

7.2

7.2.1

7.2.2

7.3

7.3.1

7.3.2

7.4

7.4.1

7.4.2

7.4.3

7.4.4

7.4.5

7.5

7.5.1

7.5.2

7.5.3

7.6

Table

7-3

7.7

7.8

7.9

7.10

7.10.1

7.10.2

7.10.3

7.10.4

7.11

8

METAL WORKING ................................................8-1

8.1

8.2

8.3

8.4

8.5

8.6

8.7

8.8

8.9

8.10

8.11

8.12

8.13

8.14

8.15

8.16

ii

General........................................................7-1

Advantages and Disadvantages of

Adhesive Bonding .................................7-1

Advantages..................................................7-1

Disadvantages .............................................7-1

Classification of Adhesive Materials ..........................................................7-2

Functional Classification ............................7-2

Type Classification .....................................7-2

Types of Adhesive-Bonded Joints .............7-4

Lap Joints....................................................7-4

Joggle Lap Joints........................................7-4

Beveled Lap Joints .....................................7-4

Butt Joints ...................................................7-4

Strap Joints .................................................7-4

Design Considerations................................7-4

Stresses........................................................7-4

Compatibility ..............................................7-6

Fabrication ..................................................7-6

Surface Preparation.....................................7-6

Surface Preparation Treatments

for Adhesive Bonding (Tank

Immersion) .............................................7-7

Selection of Adhesive.................................7-8

Curing of Adhesive Bonds.........................7-8

Adhesive Primer Selection .........................7-8

Debonding of Honeycomb with

Dry Ice .................................................7-10

Insulated enclosure ...................................7-10

Packing......................................................7-10

Removal Procedure...................................7-10

Dry Ice Substitute.....................................7-10

Additional Information .............................7-11

General Shop Practices...............................8-1

Sheet Metal Forming..................................8-1

Forming Terminology.................................8-1

Flat Pattern Development...........................8-1

Bend Allowance .........................................8-1

Setback........................................................8-1

Minimum Sheet Metal Bend Radii ...........................................................8-4

Flat Pattern Layout Procedures..................8-4

Bend Line ...................................................8-4

Forming Operations....................................8-4

Box Pan or Cornice Brake Machine Forming ......................................8-10

Slip Roll Machine Forming .....................8-10

Hand Forming...........................................8-10

Joggling.....................................................8-24

Working Titanium Alloys ........................8-27

Cutting and Grinding Titanium

Alloys ...................................................8-27

8.17

8.18

8.19

8.20

8.21

8.22

8.23

Drilling and Reaming Titanium

Alloys ...................................................8-27

Dies and Joggle Blocks............................8-27

Forming Titanium Alloys.........................8-27

Cold-Forming Titanium Alloys................8-28

Elevated-Temperature-Forming of

Titanium Alloys ...................................8-28

Titanium Stress-Relieving and

Annealing .............................................8-28

Locating Blind Holes ...............................8-28

9

CABLE REPAIR ......................................................9-1

A

GRIT BLAST SILANE (GBS) PROCESS ............A-1

A.1

A.2

A.3

B

PHOSPHORIC ACID NON-TANK ANODIZE (PANTA) PROCEDURES ....................... B-1

B.1

C

Materials ....................................................A-1

Equipment ..................................................A-1

Process .......................................................A-1

Materials .................................................... B-1

SPECIAL CONSIDERATIONS REGARDING FASTENER HOLES ....................... C-1

C.1

C.2

C.3

C.4

C.5

C.6

C.7

C.8

C.9

C.10

C.11

C.12

C.13

C.14

C.15

C.16

C.17

C.18

C.19

C.20

C.21

C.22

C.23

C.24

C.25

General Process Requirements.................. C-1

Cutting Fluids (Sources)............................ C-1

General Practices to Produce

Quality Holes in Metallic Aircraft Structures...................................... C-1

Drill Motors ............................................... C-2

Cutting Tools ............................................. C-2

Cutting Speeds and Feeds ......................... C-2

Cutting Fluids ............................................ C-2

Hole Quality .............................................. C-3

Cold Working (CW) Of Fastener

Holes; Split Sleeve Method.................. C-3

Process Description ................................... C-3

Engineering Background and Justification ................................................ C-3

Mandrels .................................................... C-4

Nondestructive Inspection ......................... C-4

Lubricants .................................................. C-4

Applied Expansion .................................... C-4

Edge Margin Requirements....................... C-4

Hole Spacing Requirement........................ C-4

Cold Worked Hole Diameter .................... C-4

Post Sizing of Cold Worked

Holes for Fastener Fit........................... C-5

Oversizing .................................................. C-5

Countersinking and Deburring .................. C-5

Rework of Previously Countersunk Holes ............................................ C-5

Hole Diameter vs. Sheet Thickness Ratio.............................................. C-5

Shear Discontinuities................................. C-5

Surface Upset............................................. C-5

T.O. 1-1A-1

INDEX .............................................................. Index 1

LIST OF ILLUSTRATIONS

Number

1-1

1-2

1-3

1-4

1-5

1-6

1-7

2-1

2-2

2-3

2-4

2-5

2-6

2-7

2-8

2-9

2-10

2-11

2-12

2-13

3-1

3-2

3-3

3-4

3-5

3-6

3-7

3-8

3-9

3-10

3-11

3-12

3-13

Title

Page

Principle Structural Units ............................... 1-2

Semimonocoque Fuselage Design.................. 1-3

Aircraft Wing Design ..................................... 1-5

Typical Tail Structures ................................... 1-7

Typical Stabilizer Structures .......................... 1-7

Types of Wing Flaps ...................................... 1-9

Leading Edge Flaps ...................................... 1-10

Negligible Damage ......................................... 2-3

Damage Repairable by Patching .................... 2-4

Damage Repairable by Insertion .................... 2-4

Damage Requiring Replacement .................... 2-5

Typical Borescope .......................................... 2-8

Types of Borescopes....................................... 2-8

Locating Cracks by Radiography ................. 2-10

Eddy Currents Produced in a Conductor

by a Varying Electromagnetic Field ....... 2-11

Path of Eddy Currents Around a Crack....... 2-11

Detecting Flaw with Ultrasonic Inspection Method .............................................. 2-11

Fluorescent Penetrant Action........................ 2-12

Crack in Bar Magnet Attracting Magnetic Particles ........................................... 2-13

Electric Current Creating a Circular

Magnetic Field in a Part .......................... 2-13

Aluminum Alloy Sheet Substitution and

Conversion Table for Commercial

Temper Designations ................................. 3-2

Drill Sizes for Removal of Spot Weld........... 3-5

Method of Shearing Spot Welds for

Riveting ...................................................... 3-6

Locating and Transcribing Tool ..................... 3-6

Spot Weld Shearing Chisel ............................ 3-7

Piloting Drill ................................................... 3-7

Drilling Holes.................................................. 3-7

Removing Spot Welded Skin from

Structure ..................................................... 3-7

Repair for Sheared Spot Welds...................... 3-8

Drilling a Hole in a Broken Screw ................ 3-9

Removing a Broken Screw........................... 3-11

Stress Concentration and Blending .............. 3-15

Typical Splice Repair ................................... 3-16

Number

3-14

3-15

3-16

3-17

3-18

3-19

4-1

4-2

4-3

4-4

4-5

5-1

7-1

8-1

8-2

8-3

8-4

8-5

8-6

8-7

8-8

8-9

8-10

8-11

8-12

8-13

8-14

8-15

8-16

8-17

8-18

8-19

8-20

A-1

C-1

C-2

Title

Page

Typical Splice Tee Repair ............................ 3-17

Typical Angle Repair.................................... 3-18

Typical Channel Repairs .............................. 3-19

Typical Zee Repair ....................................... 3-22

Typical Rib Repair........................................ 3-24

Typical Aluminum Honeycomb Repair ....... 3-25

Tension Load Example................................... 4-1

Compression Load Example........................... 4-2

Shear Load Example....................................... 4-2

Bending Load Example .................................. 4-3

Torsion Load Example ................................... 4-4

Parts of a Screw.............................................. 5-2

Types of Adhesive-Bonded Joints.................. 7-5

Technical Forming Terms .............................. 8-2

Bend Allowance.............................................. 8-3

Setback Dimensions........................................ 8-5

Minimum Bend Radii ..................................... 8-6

Layout Development....................................... 8-8

Use of Bend Lines on Cornice Brake............ 8-9

Cornice Brake Operation .............................. 8-11

Form Correction Chart.................................. 8-13

Forming Parts................................................ 8-14

Hand-Forming Concave Surfaces................. 8-15

Hand-Forming Convex Surfaces .................. 8-16

Hand-Forming Extruded Shapes .................. 8-17

Joggle Dimension Chart - Flat Sheet,

Joggle Cold............................................... 8-18

Joggle Dimension Chart - Flanged

Sheet, Rubber Formed and Joggle

Cold .......................................................... 8-20

Joggle Dimension Chart - Extruded or

Bent Sheet Sections, Die Joggle.............. 8-22

Forming Joggle Using Cornice Brake.......... 8-23

Forming Joggle Using Joggle Blocks .......... 8-25

Forming Joggle Using Joggle Clip .............. 8-26

Drills for Titanium........................................ 8-28

Locating and Transcribing Tool ................... 8-29

Grit Containment Box Example .................... A-4

Split Sleeve Cold Working of Fastener

Holes...........................................................C-7

Steps of the Cold Working Process ...............C-8

iii

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