Contents (continued) Paragraph Page
Page xvi
4-59................................................................................REPAIRING CRACKED MEMBERS
.4-40
FIGURE 4-20.EXAMPLE OF INTERM EDIATE FRAME STRINGER SPLICE
(MATERIAL 2017-T3 AL ALLOY)4-41
FIGURE 4-21.TYPICAL METHODS OF REPAIRING CRACKED LEADING AND
TRAILING EDGES
AND RIB INTER SECTIONS4-42
FIGURE 4-22.TYPICAL METHODS OF REPLACING CRACKED MEMBER AT FITTINGS 4-43 FIGURE 4-23.TYPICAL METHODS OF REPAIRING CRACKED FRAME AND
STIFFENER COMBINATION4-44
FIGURE 4-24.TYPICAL REPAIRS TO RUDDER AND TO FUSELAGE AT TAIL POST 4-45
4-60................................................................................STEEL AND ALUMINUM FITTINGS
.4-40
FIGURE 4-25.TYPICAL METHODS OF REPAIRING ELONGATED OR WORN BOLT HOLES 4-46
4-61CASTINGS
.4-40
4-62.................................................. SELECTIVE PLATING IN AIRCRAFT MAINTENANCE
.4-40
4-63.4-73. [RESERVED.]4-51
SECTION 5. WELDING AND BRAZING
4-74GENERAL
.4-53
TABLE 4-12.CURRENT AND POLARITY SELECTION FOR INERT GAS WELDING 4-54 FIGURE 4-26.COMMON DEFECTS TO AVOID WHEN FITTING AND WELDING
AIRCRAFT CERTIFICATION CLUSTER4-55
TABLE 4-13.................................................................. TORCH TIP SIZES 4-55 FIGURE 4-27................. BU TT-WELDING STRENGTH CALCULATIONS 4-56
4-75......................................................................................................TYPES OF WELDING
.4-56
FIGURE 4-28.BASIC GAS-WELDING FLAMES: EACH HAS DISTINCTIVE SHAPE, COLOR AND SOUND.
................................................... NEUT RAL FLAME IS THE MOST USED 4-57 FIGURE 4-29.SET TIG WELDER TO DC CURRENT, STRAIGHT POLARITY
FOR WELDING MILD STEEL, ..........................................................STAINLESS STEEL AND TITANIUM 4-57 FIGURE 4-30.SET TIG TO AC CURRE NT FOR WELDING ALUMINUM AND MAGNESIUM 4-58
4-76............................................................................. ELECTRIC-RESISTANCE WELDING
.4-58
FIGURE 4-31.IN SPOT WELDING, HEAT IS PRODUCED BY ELECTRICAL
RESISTANCE BETWEEN COPPER ELECTRODES. PRESSURE IS SIMULTANEOUSLY APPLIED TO
ELECTRODE TIPS TO FORCE METAL TOGETHER TO COMPLETE FUSING PROCESS. SPOT-
WELD-NUGGET SIZE
Contents (continued) Paragraph Page
Page xvii .......................................................IS DIRECT LY RELATED TO TIP SIZE 4-58
4-77BRAZING
.4-58
TABLE 4-14.CALCULATED ALLO WABLE STRENGTH OF BASE METAL 4-59 FIGURE 4-32. ..................................................SILVER BRAZING JOINTS 4-60 FIGURE 4-33. ........................................... ELECTRIC SOLDERING IRON 4-61
4-78..................................................................... AIRCRAFT PARTS NOT TO BE WELDED
.4-61
4-79..........................................................................................WELDING ROD SELECTION
.4-62
TABLE 4-15....CHART SHOWING WELDING FILLER ROD SELECTION 4-62
4-80.................................................................................REPAIR OF TUBULAR MEMBERS
.4-62
FIGURE 4-34.FINGER PATCH REPAIRS FOR MEMBERS DENTED AT A CLUSTER 4-63
4-81.......................................................................................REPAIR BY WELDED SLEEVE
.4-64
FIGURE 4-35.MEMBERS DENTED IN A BAY (REPAIRS BY WELDED SLEEVE) 4-65
4-82........................................................................................REPAIR BY BOLTED SLEEVE
.4-64
4-83..............................................................................................WELDED-PATCH REPAIR
.4-64
FIGURE 4- 36. ................................................. WELDED PATCH REPAIR 4-66
4-84........................................................SPLICING TUBING BY INNER-SLEEVE METHOD
.4-64
FIGURE 4-37. ...........................SPLICING BY INNER-SLEEVE METHOD 4-67
4-85...................................................... SPLICING TUBING BY OUTER-SLEEVE METHOD
.4-66
FIGURE 4-38.SPLICING BY OUTE R-SLEEVE METHOD (REPLACEMENT BY
WELDED OUTSIDE SLEEVE)4-68
FIGURE 4-39.TUBE REPLACEMENT AT A STATION BY WELDED OUTER SLEEVES 4-69
Contents (continued) Paragraph Page
Page xviii
4-86............................... SPLICING USING LARGER DIAMETER REPLACEMENT TUBES
.4-67
FIGURE 4-40.SPLICING USING LARG ER DIAMETER REPLACEMENT TUBE 4-69
4-87.............................................................. REPAIRS AT BUILT-IN FUSELAGE FITTINGS
.4-70
FIGURE 4-41................... REPAIRS AT BUILT-IN FUSELAGE FITTINGS 4-71
4-88............................................................................................ ENGINE-MOUNT REPAIRS
.4-70
4-89................................................................BUILT-UP TUBULAR WING OR TAIL-SPARS
.4-72
FIGURE 4-42......... STREAMLINE TUBE SPLICE USING ROUND TUBE
(APPLICABLE TO LANDING GEAR)4-73
4-90....................................................WING-BRACE STRUTS AND TAIL-BRACE STRUTS
.4-72
FIGURE 4-43........ STREAMLINE TUBE SPLICE USING SPLIT SLEEVE (APPLICABLE TO WING AND TAIL SURFACE BRACE STRUTS AND OTHER MEMBERS) 4-74
4-91................................................................................................LANDING GEAR REPAIR
.4-72
FIGURE 4-44......... STREAMLINE TUBE SPLICE USING SPLIT INSERT
(APPLICABLE TO LANDING GEAR)4-75
FIGURE 4-45.STREAMLINE TUBE SPL ICE USING PLATES (APPLICABLE TO
LANDING GEAR)4-76
FIGURE 4-46.REPRESENTATI VE TYPES OF REPAIRABLE AXLE ASSEMBLIES 4-77 FIGURE 4-47.LANDING GEAR ASSEMBLIES THAT CANNOT BE REPAIRED BY WELDING 4-78
4-92...........................................................................REPAIRS TO WELDED ASSEMBLIES
.4-73
4-93..................................................................................STAINLESS STEEL STRUCTURE
.4-74
4-94.4-103. [RESERVED.]4-78
SECTION 6. WELDING AND BRAZING SAFETY
4-104GENERAL
.4-79
4-105..................................................................................FIRE AND EXPLOSION SAFETY
.4-79
4-106................................................................................................WELDING WORK AREA
.4-79
4-107.......................................................................................................FIRE PROTECTION
.4-79
4-108...............................................................................................PROTECTIVE APPAREL
.4-80
4-109.............................................................................................................FIRST-AID KITS
.4-80
4-110.4-128. [RESERVED.]4-80
Chapter 5. NonDestructive Inspection (Ndi) SECTION 1. GENERAL
Contents (continued) Paragraph Page
Page xix
5-1GENERAL
.5-1
5-2.............................................................................................APPROVED PROCEDURES
.5-1
5-3......................................................................................................................NDT LEVELS
.5-1
5-4...................................................... TRAINING, QUALIFICATION, AND CERTIFICATION
.5-2
5-5FLAWS
.5-2
5-6.......................................................................................SELECTING THE NDI METHOD
.5-5
TABLE 5-1. ADVANTAGES AND DI SADVANTAGES OF NDI METHODS 5-7
5-7................................................................................................ TYPES OF INSPECTIONS
.5-6
5-8.5-14. [RESERVED.]5-7
SECTION 2. VISUAL INSPECTION
5-15GENERAL
.5-9
5-16..............................................................................SIMPLE VISUAL INSPECTION AIDS
.5-9
5-17BORESCOPES
.5-10
FIGURE 5-1. ....................................... TYPICAL BORESCOPE DESIGNS 5-11
Contents (continued) Paragraph Page
Page xx
5-18........................................................................... VISUAL INSPECTION PROCEDURES
.5-10
FIGURE 5-2...........USING A FLASH LIGHT TO INSPECT FOR CRACKS 5-13
5-19.5-24. [RESERVED.]5-13
SECTION 3. EDDY CURRENT INSPECTION
5-25......................................................................................EDDY CURRENT INSPECTION
.5-15
FIGURE 5-3. ....................................GENERATING AN EDDY CURRENT 5-15 FIGURE 5-4. .......................................DETECTING AN EDDY CURRENT 5-15 FIGURE 5-5. ..................................... TYPICAL INSTRUMENT DISPLAYS 5-16
5-26........................................................................ EDDY CURRENT COILS AND PROBES
.5-15
5-27........................................... FIELD APPLICATION OF EDDY CURRENT INSPECTION
.5-15
5-28................................................................................................. SURFACE INSPECTION
.5-16
FIGURE 5-6. .............................................. TYPICAL SURFACE CRACKS 5-16
5-29..........................................................................................SUBSURFACE INSPECTION
.5-17
FIGURE 5-7. .......................................TYPICAL SUBSURFACE CRACKS 5-18
5-30............................................................................................CORROSION INSPECTION
.5-17
FIGURE 5-8. ................................TYPICAL STRUCTURAL CORROSION 5-18
5-31................................ESTABLISHING EDDY CURRENT INSPECTION PROCEDURES
.5-17
5-32.5-39. [RESERVED.]5-18
SECTION 4. MAGNETIC PARTICLE INSPECTION
5-40GENERAL
.5-19
5-41........................................................................................PRINCIPLES OF OPERATION
.5-19
FIGURE 5-9. ........................................... MAGNETIC FIELD DISRUPTED 5-19 FIGURE 5-10.CRACK DETECTION BY MAGNETIC PARTICLE INSPECTION 5-19
5-42APPLICATIONS
.5-20
5-43...................................................................ELECTRICAL MAGNETIZING EQUIPMENT
.5-20
5-44....................................... MATERIALS USED IN MAGNETIC PARTICLE INSPECTION
.5-20
TABLE 5-2... LISTING OF COMMONLY ACCEPTED STANDARDS AND ................SPECIFICATIONS FOR MA GNETIC PARTICLE INSPECTION 5-21
Contents (continued) Paragraph Page
Page xxi
5-45....................................................................................... PREPARATION OF SURFACE
.5-22
5-46........................................................................................METHODS OF EXAMINATION
.5-22
5-47.................................................................. APPLICATION OF MAGNETIC PARTICLES
.5-22
5-48MAGNETIZATION
.5-23
FIGURE 5-11. ............................................ CIRCULAR MAGNETIZATION 5-23 FIGURE 5-12. .................................... LONGITUDINAL MAGNETIZATION 5-24
5-49.....................................................................DETERMINATION OF FIELD STRENGTH
.5-25
5-50........................................................................SPECIAL EXAMINATION TECHNIQUES
.5-25
5-51......................................DEMAGNETIZATION AND POST-EXAMINATION CLEANING
.5-27
5-52.5-59. [RESERVED.]5-28
SECTION 5. PENETRANT INSPECTION
5-60GENERAL
.5-29
FIGURE 5- 13.......................... PENETRANT AND DEVELOPER ACTION 5-30
5-61........................... EQUIPMENT USED IN THE PENETRANT INSPECTION PROCESS
.5-29
TABLE 5-3.CLASSIFICATION OF PENETRANT INSPECTION MATERIALS
COVERED BY MIL-I-25135E5-30
Contents (continued) Paragraph Page
Page xxii
5-62.......................................BASIC STEPS TO PERFORM PENETRATION INSPECTION
.5-29
TABLE 5-4.. FLUORESCENT AND VI SIBLE PENETRANT INSPECTION ........................GENERAL PR OCESSING PROCEDURES FLOWSHEET 5-31 TABLE 5-5.PRE-CLEANING METH ODS FOR PENETRANT INSPECTION 5-32
5-63CLEANERS
.5-33
5-64. TECHNICAL STANDARDS5-34
TABLE 5-6... LISTING OF COMMONLY ACCEPTED STANDARDS AND
SPECIFICATIONS FOR ........................................................................PENET RANT INSPECTION 5-35
5-65.5-72. [Reserved.]5-35
SECTION 6. RADIOGRAPHY (X-RAY) INSPECTION
5-73GENERAL
.5-37
FIGURE 5-14RADIOGRAPHY
5-38
5-74LIMITATIONS
.5-37
5-75..................................................................................FILM OR PAPER RADIOGRAPHY
.5-37
5-76...........................................................................................REAL-TIME RADIOGRAPHY
.5-37
5-77.............ADVANTAGE OF REAL-TIME RADIOGRAPHY OVER FILM RADIOGRAPHY
.5-37
5-78.................................................................................COMPUTED TOMOGRAPHY (CT)
.5-37
5-79..............................................................................................USES OF RADIOGRAPHY
.5-38
5-80...............................................................COMPARISON WITH OTHER NDI METHODS
.5-38
5-81FLAWS
.5-39
5-82........................................................................................................ FIELD INSPECTION
.5-39
5-83SAFETY
.5-39
5-84.5-88. [RESERVED.]5-39
SECTION 7. ULTRASONIC INSPECTION
5-89GENERAL
.5-41
FIGURE 5- 15ULTRASOUND
5-42
5-90.....................................................................................................SOUND REFLECTION
.5-41
5-91..................................................................ULTRASONIC INSPECTION TECHNIQUES
.5-41
FIGURE 5-16.PULSE-ECHO AND T HROUGH-TRANSMISSION ULTRASONIC
INSPECTION TECHNIQUES5-42
Contents (continued) Paragraph Page
Page xxiii
5-92..........................................................................................................FLAW DETECTION
.5-41
5-93........................................................................................................ BASIC EQUIPMENT
.5-41
FIGURE 5-17.TYPICAL PORTABLE ULTRASONIC INSPECTION INSTRUMENT 5-43 FIGURE 5-18.................EXAMPLE OF POSITION FIXTURE AND SHOE 5-44 FIGURE 5-19.EXAMPLE OF THE U SE IF A TRANSDUCER POSITIONING FIXTURE 5-44 FIGURE 5-20........EXAMPLE OF A TYPICAL REFERENCE STANDARD 5-44
5-94................................................................... INSPECTION OF BONDED STRUCTURES
.5-43
FIGURE 5-21.EXAMPLES OF BONDED STRUCTURE CONFIGURATIONS
AND SUGGESTED INSPECTION COVERAGE5-47
TABLE 5-7........ ACCEPTABLE UL TRASONIC INSPECTION METHODS
ASSOCIATED WITH THE EXAMPLE BONDED STRUCTURE CONFIGURATIONS SHOWN IN FIGURE 5-
21. 5-48 TABLE 5-8.ULTRASONIC INSPECTION METHODS FOR BONDED STRUCTURES 5-49
5-95................................................................................... BOND TESTING INSTRUMENTS
.5-46
5-96..................................................................................... THICKNESS MEASUREMENTS
.5-50
5-97................................................................................................................LEAK TESTING
.5-50
5-98.5-104. [RESERVED.]5-51
Contents (continued) Paragraph Page
Page xxiv SECTION 8. TAP TESTING
5-105GENERAL
.5-53
FIGURE 5-22. ................................SAMPLE OF SPECIAL TAP HAMMER 5-53
5-106.5-111. [RESERVED.]5-53
SECTION 9. ACOUSTIC-EMISSION
5-112GENERAL
.5-53
5-113APPLICATIONS
.5-54
5-114.5-119. [RESERVED.]5-54
SECTION 10. THERMOGRAPHY
5-120GENERAL
.5-54
5-121.5-126. [RESERVED.]5-54
SECTION 11. HOLOGRAPHY
5-127GENERAL
.5-54
5-128.5-133. [RESERVED.]5-54
SECTION 12. SHEAROGRAPHY
5-134GENERAL
.5-55
5-135.5-140. [RESERVED.]5-55
Chapter 6. Corrosion, Inspection & Protection SECTION 1. GENERAL
6-1GENERAL
.6-1
FIGURE 6-1.SIMPLIFIED CORRO SION CELL SHOWING CONDITIONS
WHICH MUST EXIST FOR
ELECTROCHEMICA L CORROSION6-2
FIGURE 6-2. ELIMINATION OF CORROSION BY APPLICATION OF AN
ORGANIC FILM TO METAL SURFACE6-2
6-2......................................................................... FACTORS INFLUENCING CORROSION
.6-1
6-3....................................................................................COMMON CORROSIVE AGENTS
.6-3
6-4MICRO-ORGANISMS
.6-3
6-5.6-10. [RESERVED.]6-4
SECTION 2. TYPES OF CORROSION
6-11GENERAL
.6-5
FIGURE 6- 3........................................................... CORROSION ATTACK 6-5
6-12...............................................................................GENERAL SURFACE CORROSION
.6-5
Contents (continued) Paragraph Page
Page xxv FIGURE 6-4. .....................................GENERAL SURFACE CORROSION 6-5
6-13.................................................................................................... PITTING CORROSION
.6-5
FIGURE 6-5(A). PITTING CORRO SION (EXTERNAL VIEW)6-5
FIGURE 6-5(B). PITTING CORRO SION (MAGNIFIED CROSS SECTION) 6-5
Contents (continued) Paragraph Page
Page xxvi
6-14.........................................................................CONCENTRATION CELL CORROSION
.6-6
FIGURE 6-6. ...............................CONCENTRATION CELL CORROSION 6-6
6-15............................................................................................... ACTIVE-PASSIVE CELLS
.6-6
FIGURE 6-7.........................................................ACTIVE-PASSIVE CELL 6-7
6-16................................................................................................. FILIFORM CORROSION
.6-7
FIGURE 6- 8........................................................ FILIFORM CORROSION 6-7
6-17................................................................................... INTERGRANULAR CORROSION
.6-7
FIGURE 6-9. INTERGRANULAR CORROSION OF 7050-T6 ALUMINUM
ADJACENT TO STEEL FASTENER6-8
6-18.......................................................................................... EXFOLIATION CORROSION
.6-7
FIGURE 6- 10............................................... EXFOLIATION CORROSION 6-8
6-19................................................................................................GALVANIC CORROSION
.6-8
FIGURE 6-11.GALVANIC CORROSION OF MAGNESIUM ADJACENT TO
STEEL FASTENER6-9
6-20................................................................................STRESS CORROSION CRACKING
.6-8
FIGURE 6-12. ....................................STRESS CORROSION CRACKING 6-9
6-21...................................................................................................FATIGUE CORROSION
.6-9
6-22................................................................................................ FRETTING CORROSION
.6-10
FIGURE 6- 13..................................................... FRETTING CORROSION 6-10
6-23.6-28. [RESERVED.]6-10
SECTION 3. CORROSION PROTECTION MEASURES FOR BASIC MATERIALS
6-29GENERAL
.6-11
6-30....................................................................ANODIZING AND RELATED PROCESSES
.6-11
6-31PLATING
.6-11
6-32....................................................................................PHOSPHATE RUST-PROOFING
.6-11
6-33....................................................................................CHROME-PICKLE TREATMENT
.6-11
6-34..........................................................................................DICHROMATE TREATMENT
.6-11
6-35......................................................................... STANNATE IMMERSION TREATMENT
.6-11
6-36...........................................................................GALVANIC ANODIZING TREATMENT
.6-12
Contents (continued) Paragraph Page
Page xxvii
6-37CLADDING
.6-12
6-38..........................................................................................................METAL SPRAYING
.6-12
6-39SHOT-PEENING
.6-12
6-40.....................................................................................................ORGANIC COATINGS
.6-12
6-41........................................................................................................... DOPE PROOFING
.6-12
6-42........................................................................................................... TUBE INTERIORS
.6-12
6-43.6-49. [RESERVED.]6-12
SECTION 4. CORROSION PREVENTIVE MAINTENANCE
6-50........................................................................................ GUIDELINES: ALL AIRCRAFT
.6-13
6-51......................................GUIDELINES: AIRCRAFT OPERATING OVER SALT WATER
.6-13
6-52.6-62. [RESERVED.]6-14
SECTION 5. VISUAL CORROSION INSPECTION GUIDE FOR AIRCRAFT
6-63GENERAL
.6-15
6-64................................................................................................ EXHAUST TRAIL AREAS
.6-15
6-65................................BATTERY COMPARTMENTS AND BATTERY VENT OPENINGS
.6-15
6-66.........................................................................................LAVATORIES AND GALLEYS
.6-15
6-67..................................................................................................................BILGE AREAS
.6-15
6-68..........................................................................WHEEL WELLS AND LANDING GEAR
.6-15