AVM 105 - Aircraft Sheet Metal Repair I

3.5 Credits, 7 Contact Hours
1.75 lecture periods 5.25 lab periods
Principles and procedures for fuselage, wing, and empennage sheet metal repair. Includes safety, hand tools, layout methods, materials, fasteners, repair techniques, parts fabrication, and corrosion prevention and control.

    

1. Recall proficient knowledge of various inspection and repair techniques
2. Recall proficiency in the identification and use of aircraft fasteners and pattern layout
3. Demonstrate common processes/procedures associated with various parts of the fabrication processes

1. Aircraft Metal Structural Repair
   1. Stresses in Structural Members
2. Tools for Sheet Metal Construction and Repair
   1. Layout Tools
   2. Marking Tools
   3. Punches
   4. Hole Duplicator
   5. Cutting Tools
   6. Shop Tools
   7. Hand Cutting Tools
3. Hole Drilling
   1. Portable Power Drills
   2. Drill Press
   3. Drill Extensions and Adapters 
   4. Types of Drill Bits
   5. Drill Bit Sizes
   6. Drill Lubrication
   7. Reamers
   8. Drill Stops
   9. Drill Bushings and Guides
   10. Drill Bushing Holder Types
   11. Hole Drilling Techniques
   12. Chip Chasers
4. Forming Tools
   1. Bar Folding Machine
   2. Cornice Brake
   3. Box and Pan Brake (Finger Brake)
   4. Press Brake
   5. Slip Roll Former
   6. Rotary Machine
   7. Stretch Forming
   8. Drop Hammer
   9. Hydropress Forming
   10. Spin Forming
   11. Forming with an English Wheel
   12. Piccolo Former
   13. Shrinking and Stretching Tools
5. Sheet Metal Holding Devices
   1. Clamps and Vises 
   2. Reusable Sheet Metal Fasteners
6. Aluminum Alloys
7. Structural Fasteners 
   1. Solid Shank Rivet 
   2. Special Purpose Fasteners
8. Forming Process
9. Forming Operations and Terms
   1. Stretching
   2. Shrinking
   3. Bumping
   4. Crimping
   5. Folding Sheet Metal
10. Layout and Forming
    1. Terminology 
    2. Layout or Flat Pattern Development
    3. Making Straight Line Bends
    4. Using a Sheet Metal Brake to Fold Metal
    5. Folding a Box
    6. Open and Closed Bends
    7. Hand Forming
    8. Working Stainless Steel
    9. Working Inconel® Alloys 625 and 718
    10. Working Magnesium
    11. Working Titanium
11. Basic Principles of Sheet Metal Repair
    1. Maintaining Original Strength
    2. Maintaining Original Contour
    3. Keeping Weight to a Minimum
    4. Flutter and Vibration Precautions
    5. Inspection of Damage
    6. Types of Damage and Defects
    7. Classification of Damage
12. Repairability of Sheet Metal Structure
    1. Structural Support During Repair
    2. Assessment of Damage
    3. Inspection of Riveted Joints
    4. Inspection for Corrosion
    5. Damage Removal
    6. Approval of Repair
    7. Repair of Stressed Skin Structure
    8. Typical Repairs for Aircraft Structures