PHILIPPINE STATE COLLEGE OF AERONAUTICS

INSTITUTE OF ENGINEERING AND TECHNOLOGY

Aircraft Maintenance Technology Department
Module 8 (Mid Term) AIRCRAFT FASTENERS AND PLASTIC MATERIALS

AMT 4103
AIRCRAFT MECHANICAL PROCESSES

Module 8
AIRCRAFT FASTENERS AND PLASTIC MATERIALS

Roderick C. Santiago
AMT Instructor

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
Aircraft Maintenance Technology Department
Module 8 (Mid Term) AIRCRAFT FASTENERS AND PLASTIC MATERIALS

TABLE OF CONTENTS

Title Ref. no Page

Aircraft Fasteners and Drilling
1 and 2 5
Processes
Determining Aircraft Fasteners
1 and 2 5
Hole Size and Drill Size
Installation of Aircraft Safety Lock
1 and 2 7
Wires
Aircraft Plastic Materials 1 and 2 11
Aircraft Mechanical Cleaning
1 and 2 12
Materials
Activity 12

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
Aircraft Maintenance Technology Department
Module 8 (Mid Term) AIRCRAFT FASTENERS AND PLASTIC MATERIALS

TABLE OF REFERENCES

References No.
Jepessen A and P Technician Textbook, Airframe Handbook, Jepessen
Sanderson Incorporated 1

Aviation Maintenance Technician Handbook – General (2018), US Department of

Transportation, Federal Aviation Administration 2

TIMEFRAME:

You should be able to complete this module including all the self-assessments, research works, assignments,
and other performance tasks within 3 hours.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
Aircraft Maintenance Technology Department
Module 8 (Mid Term) AIRCRAFT FASTENERS AND PLASTIC MATERIALS

Flexible Learning Outcome

Course Learning Outcomes [CLO]

CLO 7. Select, install, and remove Module Learning Outcomes [MLO]
special fasteners for metallic,
bonded, and composite Topic Learning Outcomes [TLO]
structures. MLO 1. The students can able to TLO 1. Distinguish the Aircraft
CLO 10. Apply knowledge, skills, explain clearly the proper Fasteners and discuss the Drilling
and competence in every aspect procedures on the drilling for Process
of mechanical repair, inspection, aircraft fasteners including the
maintenance and safety determining the hole size and TLO 2. Explain on how to
concerns. proper drill size for aircraft Determine Aircraft Fasteners
fasteners. Hole Size and Drill Size
CLO 11. Discusses their future
role as aircraft mechanic and to MLO 2. The students can able to TLO 3. Discuss the Installation of
have continuous interest for discuss accurately the uses of Aircraft Safety Lock Wires
safety awareness plastic materials and the TLO 4. Discuss the Aircraft Plastic
mechanical cleaning. Materials
.
TLO 5. Explain the Aircraft
Mechanical Cleaning Materials

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
Aircraft Maintenance Technology Department
Module 8 (Mid Term) AIRCRAFT FASTENERS AND PLASTIC MATERIALS

Aircraft Fasteners and Drilling Processes:

Drilling Holes:

• To make a good fastener joint, it is essential that the fastener hole be prepared properly.

• There are three (3) steps in preparing the fastener hole as drilling, reaming, and the deburring.

• Drilling provides the initial hole, reaming enlarges the hole to the proper size and finish condition, and
deburring the hole finishes the process by removing any rough edges that remain.

Drilling Process:

• During the drilling process, the material is first sheared and then routed away from the hole through the
flutes of the drill.

• As the drill begins to penetrate the material, the process gradually changes from a shearing action to a
ripping.

• The results of this ripping action are seen as burrs on the edges of the hole. What the technician does not
see are the minute cracks that are generated during the process

Determining Aircraft Fastener Hole Size and Drill Size:

• After selecting the fastener size, the first requirement for a perfectly drilled hole is the use of a drill that is
ground accurately.

• New drills usually have a satisfactory point, but after they are worn, they should be sharpened or
discarded. The dimensions for a ground point should be correct.

DIMENSIONS FOR A CORRECTLY GROUND DRILL POINT

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
Aircraft Maintenance Technology Department
Module 8 (Mid Term) AIRCRAFT FASTENERS AND PLASTIC MATERIALS

• Observe the drill-point angle of 118 degrees and the drill-rake angle of 12 degrees.

• For soft materials, for example, soft aluminium, lead, wood, and plastics, it is better to have the drill
sharpened with a smaller drill-point angle, such as 90 degrees for medium-soft materials and 45 degrees
for very soft materials.

• For very hard and tough materials such as steal, stainless steel, and titanium, a larger drill-point angle of
125 to 150 degrees and a smaller drill-rake angle of 10 degrees are recommended.

• The dimensions suggested here are for guidance and are not meant to indicate an absolute requirement.

• The experienced technician will adjust the dimension to get the best results for the job at hand. Drill speed
is also an important factor in getting good results.

• The proper speed for aluminum alloy will not produce the best results with stainless steel or titanium.

• Drill speed determines the rate at which the outer cutting edge of the drill is moving across the material
being cut.

• For example, a 3.18 milimeters drill having a circumference of 9.97 milimeters turning at the rate of 1,222
revolution per minute (RPM) will have a cutting speed of 1,219.2 centimeters per minute.

• When harder materials are drilled, slower speeds are required. In addition, a cutting and cooling lubricant
is needed. Lubricating oil, lard oil, water-soluble oil, and others are used.

• A cutting speed of 3,048 centimeters per minute is recommended for aluminum alloys; however, lower
speeds can be used very satisfactorily.

• For stainless steel and titanium, a cutting speed of 914.4 centimeters per minute is recommended, but a
lower or higher speed can be used.

• Care must be taken with the harder and tougher materials to avoid too much speed and pressure, which
will result in overheating the drill and rendering it useless. In drilling larger holes of 4.76 centimeters or
more, it is wise to drill a pilot hole first.

• The pilot drill should not be more than one-half the diameter of the final hole. This is particularly true when
drilling harder materials.

• Before using a drill bit, the technician should examine it to see that it is straight, that the point conforms to
required standards, and that the shank is not scored or otherwise damaged.

• The location of a hole to be drilled may be indicated by marking with a pencil or, in the case of heavy sheet
stock, by making a slight indentation with a center punch.

• For holes that must be held within extremely close tolerance, a drill fixture is normally used. This device
holds the drill accurately in position while the hole is being drilled.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
Aircraft Maintenance Technology Department
Module 8 (Mid Term) AIRCRAFT FASTENERS AND PLASTIC MATERIALS

• When beginning to drill a hole, the technician must be very careful to hold the drill perpendicular to the
material being drilled and must also steady the drill and motor so that the drill will not move away from the
correct position and turning it by hand before turning on the electric or air power to operate the motor. By
this method the holes will started, and the drill will usually remain in the proper position.

• A hole is not complete until it is both drilled and burred. Burring is the process of removing rough edges
and chips from newly drilled hole.

• It is usually done by hand with a drill larger than the hole, or it can be done with a special burring tool,
which is merely a piece of metal with sharp edges.

• When two or more sheets are drilled at the same time, it is necessary to remove chips and burrs from
between the sheets.

• Removal of burrs from drilled holes (deburring) may be accomplished with a manufactured deburring tool,
a countersink using a very light cut or other tool that will clear the edges of drill or punched hole. Care must
be taken to remove only the rough edges and chips from the hole.

Installation of Aircraft Safety Lock Wires:

In order to perform safety lock wiring or wire twisting, there some steps to be followed strictly:

a. Step 1. Decide the length. The length of the piece of wire to be used is determined by the distance
between the bolts that need to be lock wired.

DECIDE THE LENGTH

b. Step 2. Cut the length. The wire should be cut to a length that is a little bit longer than twice that
distance between the bolts.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
Aircraft Maintenance Technology Department
Module 8 (Mid Term) AIRCRAFT FASTENERS AND PLASTIC MATERIALS

CUT THE LENGTH

c. Step 3. Take the safety wire, thread one end of the safety wire through one of the holes and pull it back,
and thread the other end through another hole in the same bolt and bring them together.

TAKE THE SAEFTY WIRE

d. Step 4. Put the two (2) ends of the wire equal in length and form a loop through the bolt head.

WIRE EQUAL IN LENGTH

e. Step 5. Grab the wire a short distance before the loose ends with using the safety wire pliers tool. Pull
together until the two (2) ends are firm and tied around the first drilled-head bolt.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
Aircraft Maintenance Technology Department
Module 8 (Mid Term) AIRCRAFT FASTENERS AND PLASTIC MATERIALS

GRAB THE WIRE

f. Step 6. Using safety wire pliers grab the two (2) wires where they reach the halfway of the second bolt
and twist the 2 to 9 times depending on the diameter of the wire used, the thicker the wire is the less
turns needed.

GRAB THE TWO WIRES

g. Step 7. Release the wire from the tool with the two loose ends remaining adjacent to each other.

RELEASE THE WIRE

h. Step 8. Insert one of those ends through one of the holes on the bolt, and pulled through the other hole,
then insert the other end through the hole and bring the two ends together.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
Aircraft Maintenance Technology Department
Module 8 (Mid Term) AIRCRAFT FASTENERS AND PLASTIC MATERIALS

INSERT ON END OF WIRE

i. Step 9. Put the two ends of the wire equal in length and form a loop through the bolt head.

WIRE EQUAL IN LENGTH

j. Step 10. Repeat the twisting process on the two loose ends and fold them towards the bolt in a way so
the wire won’t lose itself.

REPEAT THE TWISTING PROCESS

k. Step 11. When done, cut and twist the loose end with a pair of diagonal cutters or the safety wire
cutters to prevent cutting fingers.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
Aircraft Maintenance Technology Department
Module 8 (Mid Term) AIRCRAFT FASTENERS AND PLASTIC MATERIALS

CUT AND TWIST THE LOOSE END

Aircraft Plastic Materials

In the manufacture and repair of aircraft, plastic materials are used because they can be manufactured to
provide the following:

a. Strength
b. Light Weight
c. Freedom from Corrosion
d. Good Insulating Properties
e. Less Expensive than other Materials

The two (2) general types of Plastic based on reaction to heat:

a. Thermoplastic – becomes softened by the application of heat

b. Thermosetting – material is hardened by heat

• Acrylic and Cellulose Acetate. Used for transparent sheet to be used in aircraft windshields and windows

• Synthetic Resin Polyester, Epoxy and Phenolic. This is often used for the manufacture of aircraft parts.
The resins are usually reinforced with various fabrics or glass fiber to provide a maximum of durability and
strength.

• Resin. It is usually a clear, syrup like liquid that will become hard after the addition of a suitable catalyst.

Aircraft Mechanical Cleaning Materials

There are four (4) cleaning materials used in aircraft such as Powdered Pumice, Impregnated Cotton,
Aluminum Metal Polish and the Lacquer Rubbing Compound.

a. Powdered Pumice. It is used for cleaning corroded aluminum surfaces of the aircraft structures.

b. Impregnated Cotton. It is used for removal of exhaust gas stain and polishing corroded aluminium
surfaces.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
Aircraft Maintenance Technology Department
Module 8 (Mid Term) AIRCRAFT FASTENERS AND PLASTIC MATERIALS

c. Aluminum Metal Polish. It is used to produce a high-luster, long-lusting polish on unpainted aluminium
clad surface. It should not be used on anodized surface because it will remove the oxide coat.

d. Lacquer Rubbing Compound. It can be used to remove engine exhaust residues and minor oxidation.
Heavy rubbing over rivet heads or edges where protective coating may be worn is avoided.

Summing up:

This module has dealt with the aircraft fasteners and plastic materials. These include the aircraft fasteners and
the drilling process, the procedure on how to determine the aircraft fasteners hole size and drill size, the
procedure of installation of aircraft safety lock wires, aircraft plastic materials, and the aircraft mechanical
cleaning materials.

Enrichment Activity

In your own words, discuss briefly how to determine the aircraft fasteners hole size and the drill size. (30
minutes)

Honesty Clause:

“I affirm that I will not give or receive any unauthorized help on this module activities, and that all work will be
my own understanding in each topic content and discussion”

______________________
Signature over Printed Name

Rubrics for Essay:

Needs
Excellent Very Satisfactory Satisfactory Unsatisfactory
Category Improvement Total
(96 – 100) (91- 95) (86 – 90) (76 – 80)
(81 – 85)
A Comprehensive grasp A thorough grasp of the A basic grasp of the Subject content show Major issues with
of the subject matter is subject matter is subject matter is some articulating the key
demonstrated including demonstrated demonstrated misunderstanding of elements of the
Subject Content an in-depth major points, is issues
understanding of the missing elements.
relevant concepts,
theories and related
issues of the topic
An awareness of An awareness of differing Asserts viewpoints without The topic is lack of The topic is
differing viewpoints is viewpoints is demonstrated acknowledging alternative supporting ideas unsupported and it
Awareness of demonstrated and a and an assessment of viewpoints is not completely
the topic rigorous assessment of these attempted where articulated
the undertaken where relevant
relevant
An ability to think The answers go beyond Accurate information The information Answers do not
critically is description to interpretation, incorporating relevant needs more align with the
demonstrated in the analysis and evaluation answers is conveyed supporting details description to
Critical Thinking
problem of the relevant that is relevant to the interpretation,
information topic analysis and
evaluation

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
Aircraft Maintenance Technology Department
Module 8 (Mid Term) AIRCRAFT FASTENERS AND PLASTIC MATERIALS

Total: __________________________

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