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Name of Course AIRCRAFT STRUCTURES

Course Code: xxxxxx


Rationale for inclusion of the course in the program:
Aircraft structures is a subject that covers all the aspect of the aircraft construction features and components,
analysis of structures, designing methods, classifications, assembling techniques, defect identification and inspection
methods, repair methods and procedures in order to ensure structural integrity and hence maintain the airworthiness
of the aircraft.

Course Outcomes:
Upon completion of this course students should be able to:
1. Describe the various aircraft structural designs and its airworthiness consideration.
2. Write, explain, and apply the standard knowledge in maintenance practices in practical.
3. Observe and perform the safety measures in maintenance practices in practical.
4. Diagnose and identify the defect using appropriate tools and equipment as per standard maintenance
practices.
5. Perform the entire necessary repair and demonstrate the understanding of the subject in accordance
with maintenance practical discipline and work ethics.
Synopsis
This course covers the basic and immediate level of aircraft structure as per standard guidelines of maintenance
practices and approved maintenance manuals. It includes the introduction to the aircraft structural design,
classifications, and structural components, sheet metal repairs, welding techniques, non- destructive testing and
painting. It also includes the defect recognition, defect inspection, defect evaluation and repair if necessary as per
standard maintenance practices.

Assessment Methods and Types

Assignment : 50 %
Quizzes : 10 %
Mid Term : 10 %
Final Exam : 30 %
Total : 100 %
1. INTRODUCTION
1.1 Introduction to aircraft construction methods, structures assembly and parts.
1.2 Airframe Symmetry and Design.
1.3 Basic Flight Loading Condition

Tutorial (Airframe Structures)
Structure that produce lift and control.
Structure that modified lift.
Fuselage, powerplant, landing gear, and wing configuration.
Basic math and convert fractions into decimals (micrometers or vernier calliper).
2. WORKSHOP PRACTICES
2.1 Basic Principle of Sheet Metal Repair
2.2 Maintaining Original Strength
2.3 Maintaining Original Contour
2.4 Keeping Weight to a Minimum
2.5 Inspection of Damage
2.6 Defect Definitions
2.7 Damage Classification
Tutorial (Basic knowledge aircraft construction):
Warren Truss Girder vs. Stress Skin Construction.
3. SHEET METAL
3.1 Sheet Metal Fabrication.
3.2 Layout and Forming.
3.3 Riveting
3.3 Inspection of Rivet Joints.
3.4 Sheet Metal Repair

Tutorial (Rivet and Fastener):
Rivet Identification.
Special Fastener Identification.
Rivet Equipment
Rivet Installation Techniques
Rivet Removal Techniques

4. PRACTICAL SHEET METAL 1
4.1 Practical A-15A : Surface Patch
4.2 Practical A-15 B: Flush Patch

5. PRACTICAL SHEET METAL 2
5.1 Practical A-15C : Access Panel

6. PRACTICAL SHEET METAL 3
6.1 Practical A-16A : U-channel Fabrication
6.2 Practical A-16B : Joggling

7. WELDING
7.1 Basic Welding and its Application
7.2 Welding Method
7.3 Welding Equipment
7.4 Welding Storage
7.5 Welding Safety

Tutorial
Equipment Set-up.

BRAZING AND SOLDERING
8.1 Brazing and Soldering Basic Theory
8.2 Soldering Techniques and Application
8.3 Brazing Techniques and Application
8.4 Advantages and Disadvantages of Welding and Brazing
8.5 Gas Cutting

PRACTICAL WELDING
9.1 PRACTICAL A-17 : Weld Magnesium and Titanium
9.2 PRACTICAL A-18 : Solder Stainless Steel
9.3 PRACTICAL A-19 : Inspect Tubular Structures

PRACTICAL WELDING
10.1 PRACTICAL A-20: Solder, braze, gas weld and arc weld
steel.
10.2 PRACTICAL A-21: Weld Aluminum and Stainless Steel.

Non-Destructive Testing
11.1 Introduction to NDT
11.2 History and definition of NDT
11.3 Purpose of NDT
11.4 Benefits of NDT
11.5 Quality of NDT

Tutorial
Defects: Definition, Types and Origin

NON-DESTRUCTIVE TESTING
12.1 Basic Inspection
12.1. 1 Visual Inspection
12.1.2 Borescope
12.1.3 Liquid Penetrant Inspection
12.1.4 Magnetic Particle Inspection
12.2 Electronic Inspection
12.2.1Eddy Current Inspection
12.2.2 Ultrasonic Inspection
12.2.3 Radiography Inspection
12.2.4 Composite Inspection
12.2.5 Acoustic Emission
Tutorial
Modern Technology for Damage Detection
PRACTICAL NDT
13.1 G-14 : NDT General
13.2 G-15 A : Liquid Penetrant Inspection
13.2 G-15B : Magnetic Particle Inspection
PRACTICAL NDT
14.1 G-15C : Eddy Current Inspection
14.2 G-15D: Ultrasonic Inspection
PAINTING
15.1 Introduction to Aircraft Painting and Finishes
15.2 Painting Types
15.3 Painting Defect
15.4 Painting Procedures

Painting (continued)
16.1 Painting Defect
16.2 Paint Removal/Paint Strip
16.3 Wash Primer
16.4 Re-painting

PRACTICAL PAINTING
17.1 A6- Apply trim, letter and touch up paint
17.2 A7- Identify and select aircraft finishing material
17.3 A8-Apply finishing material
17.4 A9-Inspect finishes and identify