Level III - Ata 51 Structure

A380
TECHNICAL TRAINING MANUAL

MAINTENANCE COURSE - T1 & T2 (RR / Metric)
LEVEL III - ATA 51 Structure
This document must be used for training purposes only
Under no circumstances should this document be used as a reference
It will not be updated.
All rights reserved

No part of this manual may be reproduced in any form,
by photostat, microfilm, retrieval system, or any other means,
without the prior written permission of AIRBUS S.A.S.
A380 TECHNICAL TRAINING MANUAL
LEVEL III - ATA 51 STRUCTURE

Theory System
Structure Presentation (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Doors Description (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Fuselage Description (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Pylons Description (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Nacelles Description (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Horizontal Stabilizer Description (3) . . . . . . . . . . . . . . . . . . . . . . . .110
Vertical Stabilizer Description (3) . . . . . . . . . . . . . . . . . . . . . . . . . .136
Windows Description (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Center Wing Box Description (3) . . . . . . . . . . . . . . . . . . . . . . . . . . .172
Outer Wing Description (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
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MAINTENANCE COURSE - T1 & T2 (RR / Metric) TABLE OF CONTENTS Apr 21, 2006
LEVEL III - ATA 51 Structure Page 1
STRUCTURE PRESENTATION (2)

WORK SHARING
Work sharing on the A380 is as follows: Airbus France is responsible
for the nose forward fuselage, the center fuselage (including the center
wing box), the ailerons, the pylons and the final assembly. Airbus
Germany is responsible for the forward fuselage, the aft fuselage, the
APU (Auxiliary Power Unit) cone, the vertical stabilizer, the passenger
and cargo doors, the flaps and the cabin interior assembly. Airbus Spain
is responsible for the main landing gear doors, the belly fairing, the rear
un-pressurized fuselage, the rudder, the horizontal stabilizer and the
elevators. Airbus United Kingdom is responsible for the wings. Belairbus
from Belgium is responsible for the slats.
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WORK SHARING

STRUCTURE ATA BREAKDOWN
The structure is divided into Air Transport Association (ATA) chapters
as follows: doors (ATA 52), fuselage (ATA 53), nacelles and pylons
(ATA 54), stabilizers (ATA 55), windows (ATA 56) and wings (ATA
57).
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STRUCTURE ATA BREAKDOWN

STRUCTURE ATA BREAKDOWN (continued)
DOORS - ATA 52
The doors include the nose, the body and the wing landing gear doors.
The A380-800 has 16 passenger doors/emergency exits, 8 on the upper
deck and 8 on the main deck floor.
Three cargo doors (the forward, the aft and the bulk cargo doors)
installed on the right hand side of the fuselage give access to the cargo
compartments.
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STRUCTURE ATA BREAKDOWN - DOORS - ATA 52

FUSELAGE - ATA 53
The fuselage is divided into sections, from section 11/12 to section
19.1. A detailed presentation shows the materials used on fuselage
skin panels:
- The glare, which is a fiber metal laminated material built up from
alternating layers of aluminum sheets and glass fibers,
- The 2XXX series aluminum alloys to which copper is the main
chemical element,
- The 6XXX series aluminum alloys to which magnesium is the main
chemical element; it is used on the welded skin/stringer assembly,
- The 7XXX series aluminum alloys to which zinc is the main chemical
element.
- Most of the upper deck cross-beams are made of Carbon Fiber
Reinforced Plastic (CFRP) and the main deck cross-beams are made
of aluminum alloy.
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STRUCTURE ATA BREAKDOWN - FUSELAGE - ATA 53

NACELLES AND PYLONS - ATA 54
The pylons include the pylon box, which includes the primary structure
and the pylon fairings. Pylon fairings are the secondary structure of
the pylons. The nacelles include the nose cowls, the fan cowls and
the thrust reversers.
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STRUCTURE ATA BREAKDOWN - NACELLES AND PYLONS - ATA 54

STABILIZERS - ATA 55
The stabilizers include two parts:
-The Trimmable Horizontal Stabilizer (THS) with two lateral boxes
and a center joint to make a single unit, and two elevators on each
side,
one inner and one outer elevator.
-The vertical stabilizer with the vertical stabilizer box and two rudders,
one upper and one lower rudder.
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STRUCTURE ATA BREAKDOWN - STABILIZERS - ATA 55

WINDOWS - ATA 56
The windows include the cockpit, the cabin and the doors windows.
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STRUCTURE ATA BREAKDOWN - WINDOWS - ATA 56

WINGS - ATA 57
The wings include the center wing box and the outer wing boxes with
the movable surfaces, the flaps, the ailerons, the spoilers, the droop
noses and the slats. A detailed presentation describes the new design
of the center wing box, which is mainly made from CFRP.
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STRUCTURE ATA BREAKDOWN - WINGS - ATA 57

COMPOSITE APPLICATIONS
MONOLITHIC STRUCTURE
The following parts are mainly made of monolithic CFRP,
thermoplastic and glare applications:
- the center wing box,
- the rear pressure bulkhead,
- the rear un-pressurized fuselage and the tail cone,
- the THS boxes and the elevators,
- the vertical stabilizer boxes and the rudders,
- the upper deck cross beams,
- the main landing gear doors,
- the mid and outer flaps, and the flap track panels,
- and the wing leading edge "J-nose".
All these components are made of CFRP, except:
- the wing leading edge made of thermoplastic,
- the vertical and horizontal leading edges made of glare.
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COMPOSITE APPLICATIONS - MONOLITHIC STRUCTURE

COMPOSITE APPLICATIONS (continued)
SANDWICH STRUCTURE
The major sandwich construction applications are used on:
- the radome, made from Quartz Fiber Reinforced Plastic (QFRP),
- the nose landing gear doors, made from CFRP,
- the belly fairing, made from CFRP,
- the flap track fairings, made from CFRP,
- the access panels of the aft secondary structure of the pylons, made
from CFRP or thermoplastic,
- the leading edge and the trailing edge access panels of the horizontal
stabilizer, made from CFRP,
- the leading edge and the trailing edge access panels of the vertical
stabilizer, made from CFRP and GFRP,
- the spoilers and the ailerons, made from CFRP.
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COMPOSITE APPLICATIONS - SANDWICH STRUCTURE
DOORS DESCRIPTION (3)

GENERAL ARRANGEMENT
The doors installed in the aircraft give access to the different
compartments. The main assemblies are:
- the passenger/crew doors and emergency exit doors used as an entrance
and an exit for the passengers and the crew,
- the cargo doors used for the loading and unloading of cargo and luggage,
- the landing gear doors.
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GENERAL ARRANGEMENT

PASSENGER/CREW DOORS AND EMERGENCY EXIT
DOORS
On the A380-800 there are sixteen passenger/crew doors and emergency
exit doors. They are located on the main and the upper deck as follows:
- eight passenger/crew doors on the main deck, four on each side of the
cabin,
- two emergency exit doors upon the wing, one on each side of the cabin,
- six passenger/crew doors on the upper deck, three on each side of the
cabin.
The passenger/crew doors can be used as emergency exits if needed. The
emergency exit doors have the same design principle as the
passenger/crew doors. The doors on the right hand side of the fuselage
are a mirror image of those on the left hand side.
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PASSENGER/CREW DOORS AND EMERGENCY EXIT DOORS

DOORS (continued)
MAIN DECK DOORS
The main deck doors have an external skin panel made of aluminum
alloy. It is riveted to six horizontal beams, six vertical frames and two
edge members, all made of aluminum alloy. During opening/closing
movements, the door is supported by a support arm made of Carbon
Fiber Reinforced Plastic (CFRP) and guided by two guide arms. An
emergency exit slide system is mounted on the main deck doors.
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PASSENGER/CREW DOORS AND EMERGENCY EXIT DOORS - MAIN DECK DOORS

DOORS (continued)
UPPER DECK DOORS
The upper deck doors have the same design principle as the main deck
doors. The difference between the main and the upper deck doors is
in their geometrical forms. The upper doors have seven horizontal
beams and only five vertical frames. Due to their position on the
fuselage, the upper deck doors are more inclined that the main deck
doors, and the support arm is located in the lower part of the door.
The emergency exit slide system is not mounted on the upper deck
door, but it is located underneath the door in a separated compartment
in the fuselage.
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PASSENGER/CREW DOORS AND EMERGENCY EXIT DOORS - UPPER DECK DOORS

CARGO DOORS
The A380-800 has three lower deck cargo compartment doors, located
on the fuselage right hand side:
- the forward cargo door, between frame (FR) 24 and FR 29, gives access
to the forward cargo compartment for loading and unloading of cargo,
- the aft cargo door, between FR 81 and FR 85A, gives access to the aft
cargo compartment for loading and unloading of cargo,
- the bulk cargo door, between FR 87 and FR 89, gives access to the aft
cargo compartment for loading and unloading baggage.
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CARGO DOORS

CARGO DOORS (continued)
FORWARD AND AFT CARGO DOORS
Forward and aft cargo doors have the same design principle. They
have internal and external skin panels made of aluminum alloy and
riveted to vertical frames and horizontal beams. The difference
between the forward and the aft cargo door is that the forward cargo
door has nine vertical frames while the aft cargo door has only eight
vertical frames. These doors are hinged on their upper end and latched
by hooks on the lower end. The piano hinges on the upper end make
a good load distribution possible. The forward and aft cargo doors are
hydraulically actuated.
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CARGO DOORS - FORWARD AND AFT CARGO DOORS

CARGO DOORS (continued)
BULK CARGO DOOR
The bulk cargo door is a plug type design and opens up into the bulk
cargo compartment. The door structure is made of an external skin
panel riveted to horizontal beams and vertical frames. The skin panel,
beams and frames are made of aluminum alloy. The bulk cargo door
is manually operated and hinged to the fuselage by two hinge arms
made of aluminum alloy. A counterbalance mechanism is connected
to the hinge arms.
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CARGO DOORS - BULK CARGO DOOR

LANDING GEAR DOORS
The landing gear doors open to get extension and retraction of the landing
gears. After extension or retraction, the main doors close to align with
the aerodynamic profile of the wing and fuselage. The main gear doors
are:
- nose landing gear doors,
- wing landing gear doors,
- body landing gear doors.
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LANDING GEAR DOORS

LANDING GEAR DOORS (continued)
NOSE LANDING GEAR DOORS
The nose landing gear doors are installed between FR 1 and FR 16,
and they can be split into:
- the nose landing gear forward doors, between FR 1 and FR 10,
- and the nose landing gear aft doors, between FR 10 and FR 16.
They are all made of sandwich construction with CFRP skins. Hinge
and actuator fittings are made of aluminum alloy. The nose landing
gear forward doors are hydraulically actuated, while the aft doors are
mechanically linked to the nose landing gear leg.
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LANDING GEAR DOORS - NOSE LANDING GEAR DOORS

WING LANDING GEAR DOORS
The wing landing gear doors are installed in the belly fairing between
FR 56 and FR 63. The main and the auxiliary wing landing gear doors
are made of CFRP (monolithic) skin panels, stiffened by CFRP Omega
shape stiffeners. Hinge and actuator fittings are made of aluminum
alloy. To fulfill the aerodynamic continuity when the wing landing
gear is in stowed position, a wing gear hinged fairing and a wing gear
fixed fairing are linked to the wing landing gear leg.
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LANDING GEAR DOORS - WING LANDING GEAR DOORS

BODY LANDING GEAR DOORS
The body landing gear doors are installed in the belly fairing between
FR 63 and FR 72. The body landing gear doors are all made of CFRP
(monolithic) skin panels reinforced by CFRP Omega shape stiffeners.
Hinge and actuator fittings are made of aluminum alloy. The body
landing gear doors are split into an outer and an inner door.
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LANDING GEAR DOORS - BODY LANDING GEAR DOORS
FUSELAGE DESCRIPTION (3)

GENERAL ARRANGEMENT
SECTIONS BREAKDOWN
The fuselage is a semi-monocoque structure. Aluminum alloy circular
frames and longitudinal stringers support and strengthen the main
fuselage skin. The fuselage is divided into five main parts:
- the nose forward fuselage (section 11/12),
- the forward fuselage (section 13),
- the center fuselage (section 15/21),
- the aft fuselage (section 18),
- the cone/rear fuselage (section 19/19.1),
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GENERAL ARRANGEMENT - SECTIONS BREAKDOWN

GENERAL ARRANGEMENT (continued)
SKIN PANEL MATERIALS
The A380-800 includes the use of new materials and processes on
fuselage skin panels:
- The glare, which is a fiber metal laminated material built up from
alternating layers of aluminum sheets and glass fibers,
- The 2XXX series aluminum alloys to which copper is the main
chemical element,
- The 6XXX series aluminum alloys to which magnesium is the main
chemical element; it is used on the welded skin/stringer assembly,
- The 7XXX series aluminum alloys to which zinc is the main chemical
element.
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GENERAL ARRANGEMENT - SKIN PANEL MATERIALS

NOSE FORWARD FUSELAGE
SECTION LAYOUT
The nose forward fuselage extends from frame (FR) 0 to FR 22. It
includes section 11 from FR 0 to FR 15 and section 12 from FR 15
to FR 22.
The nose forward fuselage includes:
- the radome,
- the nose lower fairing,
- the nose lower unit,
- the nose forward unit (cockpit),
- and the nose rear unit.
Pressure bulkheads separate the pressurized areas from the
non-pressurized areas. The entire nose forward fuselage is pressurized
except:
- the radome (protection for the ILS antenna and the weather radar),
-the nose landing gear bay.
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NOSE FORWARD FUSELAGE - SECTION LAYOUT

NOSE FORWARD FUSELAGE (continued)
NOSE LOWER FAIRING
The nose lower fairing is part of section 11; it is fitted on the cockpit
structure, and contains the wheels in flying configuration and bears
the forward nose landing gear doors. It also supports the radome
attachment and the liner panels. The articulated liner panel give access
to the radar area and to the radome bolts attachment. FR 2 struts help
to withstand the loads of the doors actuators. They are attached onto
the cockpit lower pressure bulkhead. All skin panels are made of
aluminum alloy.
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NOSE FORWARD FUSELAGE - NOSE LOWER FAIRING

NOSE LOWER UNIT
The nose lower unit is installed between FR 10B and FR 22. The skin
panels of the nose lower unit are made of aluminum alloy. The nose
lower unit houses:
- the nose landing gear bay,
- the electronic bay (with an access door cutout),
- the nose jack fitting,
- and the external power receptacle housing.
The nose lower unit bears also the aft nose landing gear doors.
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NOSE FORWARD FUSELAGE - NOSE LOWER UNIT

NOSE FORWARD UNIT
The nose forward unit houses the flight deck compartment. The skin
panels of the upper structure are made of aluminum alloy. The cockpit
floor is located between FR 5 and FR 14. The cockpit floor structure
has crossbeams (see illustration) and longitudinal beams (not shown)
made of aluminum alloy. Front and curved bulkhead panels separate
the pressurized and non-pressurized areas; they are made of aluminum
alloy.
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NOSE FORWARD FUSELAGE - NOSE FORWARD UNIT

NOSE REAR UNIT
The nose rear unit extends from FR 15 to FR 22. This section bears
passenger doors M1L and M1R, between FR 17 and FR 19. The upper
deck floor structure extends from FR 17 to FR 20; it is made of
aluminum alloy in this unit. The main deck floor structure extends
from FR 16 to FR 21, and is also made of aluminum alloy.
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NOSE FORWARD FUSELAGE - NOSE REAR UNIT

FORWARD FUSELAGE
SECTION LAYOUT
The forward fuselage, section 13, extends from FR 22 to FR 38. This
assembly bears the passenger doors M2L, M2R, and the forward cargo
door on the right hand side of the fuselage. The main sub-assemblies
of this section are:
- the upper shell, from FR 22 to FR 38, between stringers (STGR)
22LH and STGR 22RH where skin panels are made of GLARE,
- side shells, from FR 22 to 38, between STGR 22LH and STGR 53LH
and between STGR 22RH and STGR 53RH, where most of skin panels
are made of GLARE, except between FR 22 and FR 31, from STGR
39RH to STGR 53RH. Around the cargo door, skin panels are made
of aluminum alloy,
- the lower shell, from FR 22 to FR 38, between STGR 53LH to STGR
53RH, where the skin panels are made of aluminum alloy with welded
stringers.
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FORWARD FUSELAGE - SECTION LAYOUT

FORWARD FUSELAGE (continued)
TYPICAL FUSELAGE CROSS SECTION
The typical fuselage with constant section starts after FR 30. In this
typical section, the upper deck floor is located at STGR 26 level. The
main deck floor is located at STGR 43 level, and the cargo floor at
STGR 62 level. The main deck floor structure is reinforced by CFRP
rods.
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FORWARD FUSELAGE - TYPICAL FUSELAGE CROSS SECTION

FORWARD FUSELAGE (continued)
FLOOR STRUCTURE
The main deck floor has a classical structure with crossbeams made
of aluminum alloy supporting the seat tracks. The upper deck structure
bears the staircase torsion box up to FR 26. Crossbeams are made of:
- aluminum alloy from FR 21 to FR 26,
- Carbon Fiber Reinforced Plastic (CFRP) after FR 26. The cargo
floor structure is also made with aluminum alloy crossbeams. It
supports the roller tracks and the cargo loading system.
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FORWARD FUSELAGE - FLOOR STRUCTURE

CENTER FUSELAGE
SECTION LAYOUT
The center fuselage, section 15/21, extends from FR 38 to FR 74. All
this section is pressurized, except the center wing box and the landing
gear bays.
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CENTER FUSELAGE - SECTION LAYOUT

CENTER FUSELAGE (continued)
STRUCTURE ARRANGEMENT
The main components of this section are:
- the upper forward unit,
- the upper middle shell,
- the door M3 panels,
- the upper rear unit,
- the lower forward unit,
- the rear lateral gear bays,
- the rear lower shell,
- and the belly fairing.
The upper shell of section 15/21 has the upper forward unit, the upper
middle shell, the doors M3 panels and the upper rear unit.
The upper forward unit bears the passenger door U1L and U1R
cutouts.
There are two door M3 panels; they bear the passenger doors M3L
and M3R.
The upper rear unit bears the passenger doors U2L and U2R.
The upper forward unit skin panels are made of GLARE; all remaining
skin panels in this section are made of aluminum alloy.
The upper deck crossbeams are made of aluminum alloy from FR 38
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to FR 40, and CFRP from FR 41 to FR 74.
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CENTER FUSELAGE - STRUCTURE ARRANGEMENT

LOWER CENTER FUSELAGE
The lower center fuselage has the lower forward unit, the center wing
box, the rear lateral gear bays and the rear lower shell. The center
wing box is not described in ATA 53 chapter as it is a part of the wing
(ATA 57 chapter).
The lower center fuselage hosts the rear lateral gear bays from FR 56
to FR 72, at each side of the aft cargo compartment. The gear bays
are limited on the inboard side by the landing gear bays walls/cargo
compartment lateral walls, which are pressurized bulkheads. On the
outboard side, they are limited by canted beams and stiffened skin
panels. The rear lateral gear bays have on each side of the fuselage,
one wing gear bay from FR 56 to the center bulkhead at FR 63, and
one body gear bay from the center bulkhead at FR 63 to the rear
pressure bulkhead at FR 72.
All skin panels of the lower center fuselage are made of aluminum
alloy.
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CENTER FUSELAGE - LOWER CENTER FUSELAGE

BELLY FAIRING
The belly fairing structure is located at the bottom part of the fuselage
between FR 35 and FR 81 and bears the wing and body landing gear
doors, external access panels and access doors for maintenance.
It is made of:
- a metallic framework that gives shape to the structure and holds the
panels
- belly fairing panels attached to the framework, to give a soft
aerodynamic surface to the air-stream. Panels are sandwich panels
made of sandwich Nomex honeycomb core on CFRP skins.
The panels are held by a longitudinal and a transversal framework
made of aluminum alloy sheet metal. On the lower area, the frame
foots and the stringers of the framework are made of titanium alloy,
due to high exposure to corrosion.
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CENTER FUSELAGE - BELLY FAIRING

AFT FUSELAGE
SECTION LAYOUT
The aft fuselage section extends from FR 74 to FR 95. This section
is constant up to FR 79. It bears, on the right hand side, the aft and
bulk cargo doors. The aft fuselage bears also the passenger door
M4L/R, M5L/R, and U3L/R cutouts. The upper skin panels from
STGR 39LH to STGR 39RH are made of GLARE and the lower skin
panels from STGR 39 on each side are made of aluminum alloy. The
cross-section is a typical structure with upper deck crossbeams made
of CFRP, and main deck crossbeams made of aluminum alloy.
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AFT FUSELAGE - SECTION LAYOUT

CONE/REAR FUSELAGE
SECTION LAYOUT
The cone/rear fuselage, section 19/19.1 is a non-pressurized area,
which extends from FR 95 to FR 120. This section is divided into two
sub sections:
- first, section 19 from FR 95 to FR 110; the rear pressure bulkhead
makes the junction between section 18 and 19 at FR 95. It also bears
the Vertical Tail Plane (VTP) and the Trimmable Horizontal Stabilizer
(THS). This section is made of CFRP excepted the frames and the
fittings at attachment areas of VTP and THS, made of aluminum alloy.
- the last part of the aircraft is the tail cone section, section 19.1, from
FR 110 to FR 120. It bears the Auxiliary Power Unit. This section is
made of CFRP excepted the rear fairing made of titanium alloy.
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CONE/REAR FUSELAGE - SECTION LAYOUT

CONE/REAR FUSELAGE (continued)
SECTION 19 - REAR PRESSURE BULKHEAD
The rear pressure bulkhead is made of monolithic CFRP construction.
It has 15 radial aligned stiffeners on its outer side, and cutouts for
pressure discharge valves. The rear pressure bulkhead is attached to
the fuselage skin and the frame 95 through tension struts and by
titanium alloyed finger straps.
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CONE/REAR FUSELAGE - SECTION 19 - REAR PRESSURE BULKHEAD

SECTION 19 - VTP AND THS ATTACHMENT
The VTP is attached to section 19 through 12 fail-safe fittings made
of aluminum alloy. They are installed between FR 98 and FR 104. At
FR 98 and FR 103, lateral load fittings carry a part of lateral loads
coming from the VTP front and rear spars. The cutout for the THS is
located between FR 102 and FR 108.
The THS is attached (at the rear spar) to section 19 by means of THS
hinge fittings; lateral load fittings carry a part of loads coming from
THS. It is installed in the LH and RH sides of the center frame part
of frame 108.
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CONE/REAR FUSELAGE - SECTION 19 - VTP AND THS ATTACHMENT

SECTION 19.1 - TAIL CONE
The tail cone section (section 19.1) extends from FR 110 to the end
of the aircraft. It houses the APU between FR 112 and FR 117, in a
special fire proof compartment made of CFRP with a special resin.
The exhaust muffler is installed at the rear fairing zone of the section.
Skin panels of this section are made of laminated CFRP, and two
maintenance doors at the lower part of the section give access for
maintenance operations. The rear fairing is made of titanium and is
removable.
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CONE/REAR FUSELAGE - SECTION 19.1 - TAIL CONE
PYLONS DESCRIPTION (3)

GENERAL
The function of the engine pylons installed under each wing is:
- to support the engine,
- to transmit the engine thrust to the aircraft,
- to enable the routing and attachment of all the systems connected with
the engine (electrical wiring, hydraulic, bleed air and fuel lines).
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GENERAL

GENERAL ARRANGEMENT
The pylon has:
- a primary structure attached to the wing and supporting the engine,
- a secondary structure, essentially aerodynamic fairings, housing most
of the systems.
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GENERAL ARRANGEMENT

PRIMARY STRUCTURE (PYLON BOX)
GENERAL ARRANGEMENT
The pylon box is composed of ribs, two upper spars, one lower spar
and two machined sidewalls. This structure is made of titanium alloy.
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PRIMARY STRUCTURE (PYLON BOX) - GENERAL ARRANGEMENT

PRIMARY STRUCTURE (PYLON BOX) (continued)
PYLON TO WING FORWARD ATTACHMENT
The forward attachment transmits vertical loads. It has an inner and
an outer fork attachments to rib 9.
Pylon and wing forward fitting are joined by two sets of twin titanium
links. Straight behind the forward fitting, a spherical bearing (spigot
fitting) transmits longitudinal and lateral loads to the wing. It is bolted
through the bottom wing skin panel to the forward attachment fittings.
The bearing is directly installed through the aft upper spar.
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PRIMARY STRUCTURE (PYLON BOX) - PYLON TO WING FORWARD ATTACHMENT

PYLON TO WING AFT ATTACHMENT
The aft attachment has:
- the rib 14 lugs and the wing fitting between ribs 10 and 10A for the
inner pylon,
- the rib 14 lugs and the wing fitting at rib 25 for the outer pylon.
The two parts are attached by means of titanium alloy links.
NOTE: Note: Each links are fail-safe designed.

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PRIMARY STRUCTURE (PYLON BOX) - PYLON TO WING AFT ATTACHMENT

PYLON TO ENGINE ATTACHMENT
The pylon "Dog head" is attached to the pylon box in front of rib 3.
The "Dog head" is attached onto the forward upper and lower spars,
and both machined sidewalls.
The thrust fitting transmits longitudinal loads. It has a titanium fitting
with a fail-safe inconel shaft and installed through the lower spar in
front of rib 7. Fixed stops will stop the rotation of cross beam in case
of thrust rods failure.
The rear main beam located at rib 7 reacts to vertical loads and roll
moment.
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PRIMARY STRUCTURE (PYLON BOX) - PYLON TO ENGINE ATTACHMENT

SECONDARY STRUCTURE
FORWARD AND KARMAN FAIRINGS
The forward pylon fairings give an aerodynamic contour between the
engine nose cowl and the pylon main structure.
The forward pylon fairing is mainly made of titanium, it houses an
air pre-cooler.
The Karman fairing gives an aerodynamic contour between the primary
structure and the wing.
The Karman fairing panels are made of carbon epoxy and honeycomb
core sandwich structure. Only the Karman fairing behind the pre-cooler
exhaust is made of titanium, because of possible extreme temperature.
The internal structure is made of aluminum, titanium and
thermoplastic.
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SECONDARY STRUCTURE - FORWARD AND KARMAN FAIRINGS

SECONDARY STRUCTURE (continued)
AFT PYLON FAIRING (APF) AND REAR SECONDARY
STRUCTURE (RSS)
The Aft Pylon Fairing (APF) is made of titanium and aluminum alloys.
The APF gives an aerodynamic contour between the pylon box and
the engine nozzle. In addition, its function is:
- to give a thermal protection to the pylon from the engine exhaust
gases,
- to smooth aerodynamic drag.
The Rear Secondary Structure (RSS) is made of Carbon Fiber
Reinforced Plastic (CFRP) panels attached to a structure made of
aluminum alloy This structure is housing equipments attached to the
wing lower skin as hydraulic tank, hydraulic collectors, electrical
pumps, and extinguishing bottles.
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SECONDARY STRUCTURE - AFT PYLON FAIRING (APF) AND REAR SECONDARY STRUCTURE (RSS)
NACELLES DESCRIPTION (3)

GENERAL ARRANGEMENT
The four Rolls Royce RB 211-Trent 900 engines of the A380 are fitted
under the wings of the aircraft.
The nacelles give a smooth airflow around the engines and its accessories.
It also gives:
- engine protection,
- engine ventilation,
- noise attenuation,
- thrust reverse (inboard engines).
The nacelle includes:
- an air intake cowl,
- two fan cowls,
- a thrust reverser on the inboard engines, and a fan exhaust cowl on the
outboard engines,
- an exhaust system.
The nacelle cowls give access to the engine components.
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GENERAL ARRANGEMENT

AIR INTAKE COWL
The air intake cowl is an interchangeable aerodynamic fairing installed
on the forward part of the engine; it collects and ducts the airflow to the
engine. Its structure almost has a cylindrical shape. It is composed of:
- an air intake-cowl leading-edge (lip) assembly, made of aluminum alloy,
which is de-iced,
- an inner and an outer barrel, both made of Carbon Fiber Reinforced
Plastic (CFRP). Wire mesh is bonded to the inner barrel shell to enhance
noise reduction. This assembly is maintained by a forward and an aft
bulkhead made of titanium alloy,
- a flange (for the attachment to the engine) made of titanium alloy; it is
fitted to the inner barrel,
- and four access panels (not shown).
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AIR INTAKE COWL

FAN COWLS
The fan cowls are interchangeable aerodynamic fairings installed behind
the air intake cowl, around the engine fan. The fan cowl doors are two
semi-cylindrical and symmetrical panels made of Carbon Fiber Reinforced
Plastic (CFRP), stiffened by longitudinal and transversal CFRP stiffeners.
They are attached to the aircraft pylons by hinge fittings, made of titanium
alloy, at 12 o'clock. They are electrically opened and held in position by
Hold Open Rods (HOR). When closed, they are locked by 6 o'clock
titanium alloy latches.
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FAN COWLS

THRUST REVERSER AND FAN EXHAUST COWL
THRUST REVERSER
The thrust reverser is located behind the fan cowls. It consists of a
fixed structure (inner fixed structure), which provides support for the
thrust reverser actuators, and a translating cowl.
In forward thrust configuration it encloses the engine core with an
aerodynamic flow path, and uses the translating cowl to provide a fan
exhaust duct and a nozzle exit. In reverse thrust configuration, the
blocker doors reverse the fan flow to forward direction trough
cascades, while the translating cowl moves aft in order to let the flow
pass trough.
The inner fixed structure has two halves, each made of CFRP sandwich
construction. It is hinged to the pylon at the top with the 12 o'clock
hinge beam and is locked at the bottom centerline with the 6 o'clock
latch beam (aluminum alloy parts). Each half is electrically opened
and held in position by HOR (not illustrated).
The forward frame, designed as a torsion box, is fitted to the forward
of the inner fixed structure and made of CFRP. Its main functions are
to attach the thrust reverser to the engine and to provide structural
support to the actuation system and the cascades.
The following elements are attached to the inner fixed structure:
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- the cascades (CFRP),

- the blocker doors (CFRP), hinged to the translating cowl and attached
to links,
- the translating cowl.
The translating cowl is an assembly of:
- the acoustic barrel (CFRP sandwich), which enhance noise reduction,
- the external barrel (CFRP).
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THRUST REVERSER AND FAN EXHAUST COWL - THRUST REVERSER

THRUST REVERSER AND FAN EXHAUST COWL
(continued)
FAN EXHAUST COWL
The fan exhaust cowl is located behind the fan cowls; it encloses the
engine core with an aerodynamic flow path, and provides a fan exhaust
duct and a nozzle exit. It is made of two halves with the same design
principles as for the thrust reverser, excepting that the (outer) cowl is
fixed. This cowl is fitted to the inner fixed structure via the forward
frame, the 12 o'clock hinge beam and the 6 o'clock latch beam.
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THRUST REVERSER AND FAN EXHAUST COWL - FAN EXHAUST COWL

EXHAUST SYSTEM
The exhaust system is located at the aft of the engine and provides flow
contour for engine exhaust gas.
It is composed of the nozzle and the plug. They are fitted to the turbine
bearing housing of the engine:
- the nozzle to its outer flange,
- the plug to its inner flange.
The nozzle is the assembly of:
- the acoustic primary nozzle made of titanium alloy sandwich,
- the nozzle outer cowl, made with two titanium skins, welded together.
The acoustic primary nozzle is attached at its forward end to the engine
with a titanium alloy mounting flange. The nozzle outer cowl interfaces
with the lower pylon fairing (not illustrated) via titanium alloy fire seals
which provide a fireproof barrier.
The plug is the assembly of:
- the forward plug, made of titanium sandwich,
- the aft plug, made with two titanium skins, welded together,
The aft plug is fitted to the forward plug with a titanium alloy attachment
ring; the unit is attached at its forward end to the engine with a titanium
alloy mounting flange.
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EXHAUST SYSTEM
HORIZONTAL STABILIZER DESCRIPTION (3)

GENERAL
The horizontal stabilizer gives pitch stability and pitch control to the A/C.
It is installed at the rear of the fuselage and mounted at the rear of section
19.
It is 30.372 m (99.66 ft) wide.
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GENERAL

GENERAL (continued)
GENERAL ARRANGEMENT (CONT'D)
- the spar box,
- the leading edge,
- the trailing edge,
- the tip,
- the fuselage attachment,
- and the elevators, each being split into an inner and a outer section.
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GENERAL - GENERAL ARRANGEMENT (CONT'D)

SPAR BOX
STRUCTURE LAYOUT
The complete spar box is made of LH and RH sub assemblies, put
together at the center joint. Each sub assembly is made of top and
bottom skin panels, front and rear spars, and twenty-five ribs. The
fuselage attachment is composed of the trim screw jack fitting at the
forward center spar box and two pivot attachments on the rear spar.
The spar box is used as ballast fuel tank between ribs 8LH and RH.
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SPAR BOX - STRUCTURE LAYOUT

SPAR BOX (continued)
SKIN PANELS AND COVERS
The top and bottom skin panels are made on the same principle.
Carbon Fiber Reinforced Plastic (CFRP) is used for the conception.
Co-bonded T-shape stringers, which are parallel to the rear spar, make
the skin panels stronger.
The LH bottom skin panel has ten manholes for accessibility, the RH
bottom skin panel has eleven manholes, including one NACA. They
are positioned at stringers 5 and 13.
The manhole covers are made of CFRP thermoplastic. In fuel tank
area, excepted inside the fuselage, an aluminium protective plate is
screwed on the fuel tank covers to protect it about the impact.
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SPAR BOX - SKIN PANELS AND COVERS

SPARS
The spar box has two C-shape spars made of CFRP.
Vertical T-shape stiffeners are bonded to the front and rear spar aft
faces.
Horizontal T-shape stiffeners are bonded to the forward face of the
front spar.
In the dry zone, two access holes give access to each rib bay.
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SPAR BOX - SPARS

CENTER JOINT
The RH side and LH side of the spar box are joined at Rib 1 in a single
joint.
To get this junction, the following elements are used:
- six upper and six lower Tees (titanium alloy) joining the skin panels,
- five upper and five lower Tees (titanium alloy) joining the upper
and lower tees,
at the forward part:
- one inner T profile (titanium alloy) joining Rib 1 to front fitting,
- four plates (titanium alloy) joining the front spar flanges to the front
fitting,
- a front fitting (aluminum alloy) joining the front spar webs,
at the aft part:
- a rear outer plate (aluminum alloy) joining the rear spar webs,
- and two rear inner profiles (titanium alloy), joining Rib 1 to the rear
spar webs.
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SPAR BOX - CENTER JOINT

RIBS
The spar box has twenty-five ribs per side and a rib at the center joint.
All of them are riveted to the skin panels and the spars.
The center joint rib 1 connects the LH side and RH side of the spar
box to make one unit. It has a web and stiffeners made of CFRP.
Ribs 2 and 3 are truss work assemblies, made with CFRP diagonal
bars and formers.
Ribs 4 to 25 have a web and stiffeners made of CFRP.
Rib 26 has a web and stiffeners made of CFRP.
Ribs 2 to 25 are riveted:
- to the skin panels with titanium alloy clips,
- and to the spars with aluminum alloy T-fittings.
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SPAR BOX - RIBS

FUSELAGE ATTACHMENT
The support fittings are installed:
- on the front spar by the screw jack fitting, attached onto the center joint
at Rib 1, and connecting the THS to the trim actuator,
- on the rear spar by the rear support fittings (two pivot points) attached
onto 4 LH and RH ribs. These fittings fulfill the rotation of the THS;
rotation axes carry possible side loads.
All fittings are made of aluminum alloy.
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FUSELAGE ATTACHMENT

LEADING EDGE
The leading edge has an aerodynamic chape at the front of the THS. On
each side of the THS centerline, the leading edge is composed of eight
replaceable sections. Each section has:
- top and bottom panels, made of CFRP skins bonded to a honeycomb
core,
- a diagonal and a vertical spars, made of aluminum alloy, and riveted to
the panels,
- ribs, manufactured from CFRP, attached with anchor nuts to the panels,
- and a D-nose panel made from aluminum alloy up to MSN 006, from
GLARE from MSN 7 and subsequent. The outer D nose section remains
aluminum alloy on all MSN's due to its double curvature.
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LEADING EDGE

TRAILING EDGE
The trailing edge is an aerodynamic surface between the THS spar box
and the elevators.
On each side of the THS centerline, seven upper and lower trailing edge
access panels are supported by ribs.
The trailing edge has:
- ten intermediate ribs made from CFRP, which give support the trailing
edge access panels made of CFRP,
- ten elevator hinge ribs (four outer and six inner) with a web made from
CFRP and a fitting made from aluminum alloy. These 10 hinge ribs
support the trailing edge access panels and give attachment to the
elevators,
- four elevator actuator fittings (two fittings per elevator) made of
aluminum alloy.
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TRAILING EDGE

TRAILING EDGE ACCESS PANELS
The trailing edge is divided into seven upper and lower access panels by
side.
The lower access panels are hinged to give access to the elevator leading
edge and actuators.
The upper access panels are riveted except panels 1, 2 and 5. These panels
are screwed.
Panels 2 and 5 give access to actuator areas, while panel 1 needs to be
removed to give access for THS section 19.
The upper and lower access panels are made of CFRP sandwich; the
upper panels are hinged to get access to the elevator leading edge and
actuators.
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TRAILING EDGE ACCESS PANELS

TIP AND APRON
The THS tip is a metallic element attached to the spar box (top and bottom
skins and to the front and rear spar).
It is also connected to the trailing edge Rib 10 with a removable joint.
This part is interchangeable.
The tip structure includes:
- skin panels,
- spars,
- ribs,
- 3 hoisting points (not shown),
- and 2 lower access covers.
The THS tip is made of aluminum alloy.
The horizontal stabilizer aprons have an aerodynamic seal between the
horizontal stabilizer and the fuselage. Each apron has three sections, an
upper, a lower and a forward section. The aprons are made of CFRP. To
minimize friction between the aprons and the fuselage, the contact edge
of each apron has a segmented slide lip of polytetra-fluorethylene (PTFE).
The apron support fittings are made of aluminum alloy.
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TIP AND APRON

ELEVATORS
The THS has two elevators per side:
- an inner (shown on the illustration)
- an outer.
The structure of the inner elevator has a front spar, a top and a bottom
skin panels and nine ribs. All these parts are made of CFRP.
Four hinge fittings attach the inner elevator to the hinge arms of the THS
and two actuator fittings. All fittings are made of aluminum alloy.
NOTE: Note: The outer elevator composition is based on the same

principle but, has fifteen ribs and six elevator hinge fittings.
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ELEVATORS
VERTICAL STABILIZER DESCRIPTION (3)

GENERAL ARRANGEMENT
The vertical stabilizer is installed at the rear of the fuselage, mounted on
top of section 19.
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GENERAL ARRANGEMENT

GENERAL ARRANGEMENT (continued)
GENERAL ARRANGEMENT (CONT'D)
-the spar box,
-the leading edge,
-the trailing edge,
-the lower fairings,
-the tip,
-the rudder which is split into an upper and a lower section.
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GENERAL ARRANGEMENT - GENERAL ARRANGEMENT (CONT'D)

SPAR BOX
STRUCTURE LAYOUT
The vertical stabilizer spar box has two side skin panels, two spars
(one front and one rear) and nineteen ribs. The leading edge is located
forward of the front spar and the trailing edge after the rear spar. The
lower part of the vertical stabilizer (up to rib 8) is accessible through
an access door from inside the fuselage section 19. The upper part of
the vertical stabilizer (from rib 8 to 19) is accessible through the front
and rear spars holes/manholes.
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SPAR BOX - STRUCTURE LAYOUT

SKIN PANELS
The two skin panels are made of Carbon Fiber Reinforced Plastic
(CFRP) tape with co-bonded T shape stringers, which are parallel to
the rear spar. The fuselage interface concept is based on six main lugs
for each side, two bolts per lug, fulfilling a load path with large
redundancy.
Skin panels are reinforced by main lug doublers at the interface with
the fuselage.
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SPAR BOX - SKIN PANELS

SPARS
Spars are from C shape with flanges pointing inwards and are made
of CFRP.
T shape horizontal stiffeners are bonded to the forward face of the
spars, and T shape vertical stiffeners are bonded to the aft face. Both
are made of CFRP.
The rib to spar attachment is done with horizontal rib feet made of
CFRP.
Skin panels are riveted to the flanges of the spars.
On each spar a transverse load fitting made of CFRP does the
connection with the fuselage through adjustable length clevis rods. A
coupling made of CFRP connects the transverse load fitting to the
spar and titanium angles connect it to the skin panels.
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SPAR BOX - SPARS
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SPAR BOX - SPARS
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RIBS
The seven lower ribs, from rib one to seven, are truss work assemblies
made with CFRP C shape profiles and closed section struts.
The twelve upper ribs, from rib eight to nineteen, are C shape solid
ribs made of CFRP with T shape bonded stiffeners.
All the ribs are connected to the skin panels using blind bolts.
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SPAR BOX - RIBS

LEADING EDGE
The vertical stabilizer leading edge has:
- seven leading edge panels per side,
- sixteen leading edge ribs made from CFRP sandwich with honeycomb
core,
- and six D nose sections,
The D nose has five sections with GLARE skin and one lower section
with a skin made of Glass Fiber Reinforced Plastic (GFRP).
Each D-nose section has:
- a D-nose spar,
- and aluminum alloy D nose ribs attached to the D-nose spar and to the
D-nose skins.
The left hand side leading edge panels are removable while the right hand
side panels are fixed. The panels one to six are made of CFRP sandwich
with honeycomb core and the panel seven made of GFRP sandwich. A
taxi camera is located in the upper leading edge section.
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LEADING EDGE

TRAILING EDGE
The vertical stabilizer trailing edge has:
- nine rudder hinge fittings,
- four rudder actuator attachment fittings (two for each rudder),
- two vertical load fittings,
- an auxiliary spar,
- and trailing edge panels.
The rudder hinge and actuator attachment fittings are made of CFRP and
have aluminum alloy fork heads. The hinge fittings are directly attached
to the rear spar, while the actuator attachment fittings are attached with
CFRP brackets. The vertical load fittings are made of CFRP and have
fork heads made of titanium alloy. Brackets attach vertical load fittings
to the rear spar.
The auxiliary spar is attached to the rudder attachment fittings and has
CFRP webs, stiffeners, aluminum alloy chords and splices.
The trailing edge has seven removable panels per side:
- panels one to six are made from CFRP sandwich with honeycomb core
- and the panel seven is made from GFRP sandwich with honeycomb
core. The left hand side panels are hinged to allow easy access.
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TRAILING EDGE

LOWER FAIRING AND TIP
The lower fairings at the junction between the vertical stabilizer and the
fuselage are made of CFRP sandwich with honeycomb core.
The vertical stabilizer tip is made of GFRP sandwich with honeycomb
core and has internal GFRP ribs. The tip is protected against lightning
strike with an aluminum strip on the top of it.
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LOWER FAIRING AND TIP

RUDDER
LOWER RUDDER
The lower rudder has:
- two CFRP skin panels with thirty-one co-bonded U shape stringers
parallel to the rudder hinge line,
NOTE: Note: A bronze mesh layer is bonded on the outer surface

of the skin panels to protect the structure against lightning
strike.
- a C shape spar with flanges pointing outwards and made of CFRP,
reinforced through fourteen CFRP stiffeners installed on the outer
surface of the spar,
- six CFRP box ribs (RR rib) attached to the rudder spar through an
angle,
- four CFRP simple load ribs (BR rib) and two CFRP double load ribs
at the location of rudder actuators 1 and 2. All these ribs are attached
to the rudder spar through a spine hinge fitting,
- two actuator fittings and four hinge fittings, made of aluminum alloy,
- and a leading edge, which has fourteen CFRP ribs, riveted to the
spar and CFRP leading edge panels. The left hand side leading edge
panels are removable and screwed to the leading edge ribs. The right
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hand side leading edge panels are fixed and riveted to the leading edge
ribs.
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RUDDER - LOWER RUDDER

RUDDER (continued)
UPPER RUDDER
The lower rudder has:
- two CFRP skin panels with thirty-one co-bonded U shape stringers
parallel to the rudder hinge line,
NOTE: Note: A bronze mesh layer is bonded on the outer surface

of the skin panels to protect the structure against lightning
strike.
- a C shape spar with flanges pointing outwards and made of CFRP,
reinforced through twenty-two CFRP stiffeners installed on the outer
surface of the spar,
- six CFRP box ribs attached to the rudder spar through an angle,
- seven CFRP simple load ribs and two CFRP double load ribs at
location rudder actuators 3 and 4. All these ribs are attached to the
rudder spar through a spine hinge fitting,
- two actuator attachment fittings and seven hinge fittings made of
aluminum alloy,
- a leading edge, which consists of twenty-six CFRP ribs riveted to
the spar and CFRP leading edge panels. The left hand side leading
edge panels are removable and screwed to the leading edge ribs. The
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right hand side leading edge panels are fixed and riveted to the leading
edge ribs,
- a rudder tip made of aluminum alloy.
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RUDDER - UPPER RUDDER
WINDOWS DESCRIPTION (3)

GENERAL
The windows are installed in:
- the cockpit,
- the cabin,
- the doors,
- inspection and observation areas (not illustrated).
All the windows, which are installed in pressurized areas of the fuselage
structure, are fail-safe.
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MAINTENANCE COURSE - T1 & T2 (RR / Metric) WINDOWS DESCRIPTION (3) Apr 18, 2006
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GENERAL

COCKPIT WINDOWS
GENERAL ARRANGEMENT
The cockpit windows are installed on the left and the right hand sides
and at the front of the cockpit. They are fitted on a framework made
of aluminum alloy.
There are two types of cockpit windows
- the fixed windows (windshields and aft fixed windows),
- the sliding windows.
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COCKPIT WINDOWS - GENERAL ARRANGEMENT

COCKPIT WINDOWS (continued)
FIXED WINDOWS
The fixed window panels are all composed of 3 layers (panes) of
hardened glass laminates, a layer of plastic material separates each
one. The panes, mounted in directly molded seals, are clamped by
means of a retainer from:
- the outside of the aircraft for the windshields,
- the inside of the aircraft for the aft fixed windows.
The windshields are of integral security type and give protection
against bird impacts and bad meteorological conditions.
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COCKPIT WINDOWS - FIXED WINDOWS

COCKPIT WINDOWS (continued)
SLIDING WINDOWS
The two sliding windows, on the left and the right hand sides, are
installed between the fixed windows. The crew can use the sliding
windows as emergency exits.
The sliding window panels are clamped within the retainer and the
mobile frame, which lets the windows move on the rails attached onto
the aircraft structure.
Each window panel is an assembly of 3 layers (panes) of hardened
glass laminates; a layer of plastic material separates each one. A
peripherical seal made of silicone used for the sealing between the
panel and the mobile frame.
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COCKPIT WINDOWS - SLIDING WINDOWS

CABIN WINDOWS
The cabin windows are installed between the frames of the fuselage. They
give visibility to the passengers in all seating arrangements.
Each cabin window set is an assembly of two panes, one inner and one
outer pane, which can carry the load of the full differential cabin pressure.
The inner and the outer panes are made of stretched acrylic resin. They
are installed into the window frame (made of aluminum alloy) by means
of a retainer ring (made of aluminum alloy) and 6 attached eyebolts (made
of stainless steel). A seal made of silicone makes sure that the window
is pressure tight when it is installed in the window frame.
There is a small hole (vent hole) in the bottom part of the inner pane.
This lets the pressure between the two panes stay the same than in the
cabin.
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CABIN WINDOWS

DOOR WINDOWS
The passenger/crew doors and emergency exit doors have a circular
window, larger than a conventional passenger window. They give an
improve sight of the outdoor especially to the ground, in order to be used
for inspection and observation.
Each door window set is composed of two panes, one inner and one outer
pane, made of stretched acrylic resin, separated by a Fresnel lens. They
are installed into the window frame (made of aluminum alloy) by means
of a retainer ring (made of aluminum alloy) and 6 attached eyebolts (made
of stainless steel). A seal made of silicone makes sure that the window
is pressure tight when it is installed in the window frame.
There is also a vent hole, which uses the same technology as the hole
illustrated on the cabin windows.
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DOOR WINDOWS
CENTER WING BOX DESCRIPTION (3)

GENERAL
The center wing box (section 21) is installed in the center fuselage
between frame (FR) 46 and FR 56. It gives the cantilever attachment for
the wings, while distributing their loads into the fuselage. The center
wing box can be used as a fuel tank depending on the aircraft versions;
the A380-800 has a dry center wing box.
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MAINTENANCE COURSE - T1 & T2 (RR / Metric) CENTER WING BOX DESCRIPTION (3) Apr 18, 2006
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GENERAL

GENERAL ARRANGEMENT
The main structure of the center wing box comprises:
-two ribs (Rib 1), left and right,
-2 lower skin panels,
-2 upper skin panels,
-a front spar at FR 46 with a pressure bulkhead,
-a center spar at FR 51,
-a rear spar at FR 56 with a pressure bulkhead,
-a set of 143 integral carbon fiber reinforced plastic rods,
-outer wing attachment fittings.
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GENERAL ARRANGEMENT

SKIN PANELS
The top skin panel assembly is the roof of the center wing box. It also
supports the cabin floor structure. The forward panel goes from the front
spar (FR 46) to the center spar (FR 51), and the rear panel goes from the
center spar to the rear spar (FR 56). The two top skin panels are made of
Carbon Fiber Reinforced Plastic (CFRP) and have CFRP stiffeners on
the inner surface. On their outer surface, eleven beams, running in the
longitudinal direction, give further strength to the assembly. These beams
are made of aluminum alloy up to Manufacturer's Serial Number (MSN)
27 and CFRP from MSN 28. The bottom skin panel assembly comprises
two bottom skin panels, which are made of CFRP. The forward panel
goes from the front spar (FR 46) to the center spar (FR 51), and the
afterward panel goes from the center spar to the rear spar (FR 56). The
forward skin panel has CFRP stiffeners on the upper surface for all its
length. The rear skin panel only has five stiffeners and is smooth on the
rear part. On the outer surface, eleven I-shaped beams running in the
longitudinal direction give further strength to the assembly. They are
made of aluminum alloy up to MSN 4 and CFRP from MSN 5. A flange
angle made of CFRP connects the two top and the two bottom skin panels
and gives the upper and lower attachment of the center spar.
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SKIN PANELS

SPARS
FRONT SPAR
The front spar web is made of CFRP tapes, it has horizontal CFRP
stiffeners on the forward face and vertical stiffeners made of aluminum
alloy on the rear face. The forward top skin panel is directly attached
to the front spar. Stiffener fittings made of aluminum alloy enable the
upper attachment of the vertical stiffener. A lower flange angle made
of CFRP connects the forward bottom panel to the front spar. The
internal junction between the front spar, the rib 1 and the forward top
panel is achieved by the forward vertical tee fitting and an internal
corner fitting, both made of aluminum alloy. The internal junction
between the front spar, the rib 1 and the forward bottom panel is
achieved by the forward vertical tee fitting and an internal corner
fitting made of aluminum alloy.
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SPARS - FRONT SPAR

corner fitting made of aluminium alloy and a junction fitting made of
SPARS (continued) CFRP. The internal junction between the rear spar, rib 1 and the rear
bottom skin panel is achieved by the rear vertical cross fitting, an
CENTER SPAR
internal corner fitting made of aluminum alloy and a junction fitting
The center spar web is made of CFRP; and is reinforced with made of CFRP.
aluminum alloy vertical stiffeners on the forward face, and CFRP
horizontal stiffeners on the rear face. A stabilizing angle made of
CFRP borders the spar hole edge. On the forward face of the center
spar, the junction between the center spar and the rib 1 is achieved by
a continuity fitting and a lower continuity fitting, both made of
aluminum alloy. On the rear face, the junction is achieved by upper
and lower continuity fittings made of aluminum alloy. The junction
between the center spar and the skin panels (top and bottom) is
achieved by two flange angles (upper and lower), made of CFRP.
REAR SPAR
The rear spar web is made of CFRP with aluminum alloy vertical
stiffeners on the forward face and 2 horizontal CFRP stiffeners on the
rear face. The access for maintenance to the center wing box inner
structure is through two holes in the rear spar. The doors, which close
the access holes of the rear spar, are made of aluminum alloy. A shield
made of aluminum alloy covers each door and protects them about
runway debris and in case of tire blast. The rear spar is connected to
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the rear bottom skin panel with a lower flange angle made of CFRP.
For the rear spar, at the locations related to the wing landing gear bay
walls, the vertical stiffeners are replaced by two rod fittings and
intrados fittings, made of aluminum alloy. Compression fittings made
of aluminum alloy are installed between the two intrados fittings. The
rear spar is connected to the rear top panel by means of an upper flange
angle made of CFRP. At the locations related to the wing landing gear
bay walls, vertical stiffeners are replaced by the two- rod fittings and
extrados fittings, made of aluminum alloy. The internal junction
between the rear spar, rib 1 and the rear top skin panel is achieved by
the rear vertical cross fitting made of aluminium alloy, an internal
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SPARS - CENTER SPAR & REAR SPAR

RODS
Inside the center wing box, 143 CFRP rods form 11 bay-truss ribs of 13
rods each. The rods are connected to the skin panels and to the spars with
rod fittings. Most of the fittings are integrated on the spar vertical
stiffeners.
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RODS

WING ROOT JOINT
The rib 1 web is surrounded by the following junction fittings, which
allow the junction with the other center wing box elements on one side
and with the outer wing box elements on the outboard side:
- cruciform fitting,
- triform fitting,
- lower butt strap fitting,
- rear vertical cross fitting,
- forward vertical tee fitting.
The junction between the front spar and rib 1 is made with the vertical
tee fitting. The junction between the rear spar and rib 1 is achieved by
the vertical cross fitting. The junction between rib 1 and the lower skin
panels is achieved by the triform fitting, and the junction between rib 1
and the top skin panel is achieved by the cruciform fitting.
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WING ROOT JOINT
OUTER WING DESCRIPTION (3)

GENERAL
The aircraft outer wing is divided into six parts:
- the outer wing box,
- the wing tip,
- the leading edge and leading edge devices,
- the trailing edge and trailing edge devices.
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MAINTENANCE COURSE - T1 & T2 (RR / Metric) OUTER WING DESCRIPTION (3) Apr 18, 2006
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GENERAL

OUTER WING BOX
GENERAL ARRANGEMENT
The two outer wing boxes are connected to the center wing box at
Rib 1, providing a continuous wing structure.
The main components of each outer wing box are:
- top and bottom skin panels,
- front, center, and rear spars,
- and ribs.
This module will present also the attachments for pylons and wing
landing gear.
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OUTER WING BOX - GENERAL ARRANGEMENT

OUTER WING BOX (continued)
SKIN PANELS
The outer wing box has 5 top skin panels and 5 bottom skin panels.
Both extend a short distance in front of the front spar and behind the
rear spar. They have attachment for the fixed leading edge trailing
edge structures.
Top skin panels 1 to 5 are machined from aluminum alloy and the
following aluminum alloy stringers reinforce them:
- 29 top stringers of "J"section extrusion,
- 33 bottom stringers of "I" section extrusion.
The joints between panels are achieved by aluminum alloy butt strap.
Top skin panel 5 has integral stringers.
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OUTER WING BOX - SKIN PANELS

MANHOLES
Fuel tank accesses are through 32 manholes, which are closed by
doors. Each door set comprises an inner and an outer access panel
made of aluminum alloy, a knitted wire gasket and a seal.
2 loaded access panels made of aluminum alloy are installed between
Rib 46 and Rib 48, the NACA and the overpressure panels.
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OUTER WING BOX - MANHOLES

FRONT AND REAR SPARS
The front spar extends from Rib 1 to Rib 49. It has 5 aluminum alloy
C-shape sections, joined using joint plates at Ribs 8, 14, 29 and 38
with top and bottom straps. The rear spar extends from Rib 1 to Rib
49. It has 4 aluminum alloy C-shape sections, joined at Ribs 11, 17
and 33 with top and bottom straps.
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OUTER WING BOX - FRONT AND REAR SPARS

CENTER SPAR
The center spar is "C" shaped, made of aluminum alloy, having two
sections using a single joint plate between Ribs 11 and 12, and
extending from Rib 1 to Rib 17.
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OUTER WING BOX - CENTER SPAR

RIBS
There are 49 metallic and non metallic ribs. Ribs are continuous
between front and rear spars, except for ribs 2 to 17 which are half
ribs to accommodate the center spar. Ribs 18 to 49 are full ribs joined
to the front and the rear spars.
There are 40 ribs and half ribs, made of aluminum alloy, in various
locations.
There are 23 non-metallic ribs and half ribs, used mainly for the weight
saving. The rib web is made of Carbon Fiber Reinforced Plastic
(CFRP), and the rib feet are made of aluminum alloy.
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OUTER WING BOX - RIBS

WING ROOT JUNCTION
The outer wings boxes are joined to the center wing box at Rib 1,
using the following elements:
- a cruciform fitting (junction of the center and outer wing box top
skin panels, and the fuselage skin panel),
- a triform fitting, (junction of the outer and center wing box bottom
skin panels)
- a (lower skin) butt strap, which secures the bottom skin panels
junction,
- a forward vertical tee fitting (front spars junction),
- a rear vertical cross fitting (rear spars junction).
All fittings are made of aluminum alloy.
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OUTER WING BOX - WING ROOT JUNCTION

WING LANDING GEAR ATTACHMENT
The followings fittings attach the wing landing gear to the aft face of
the rear spar:
- the gear rib, made of aluminum alloy,
- the pintle fitting, made of titanium alloy, which holds the wing
landing gear forward pintle pin,
- the side stay fitting, made of aluminum alloy, which holds the cardan
pin of the undercarriage.
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OUTER WING BOX - WING LANDING GEAR ATTACHMENT

PYLON ATTACHMENTS
There are forward and rear attachment fittings on the wing box for
each engine pylon.
All these fittings are machined from titanium alloy.
The forward attachment is composed of the following parts:
- a forward fitting, which carries the vertical loads to the outer wing
box,
- and a thrust (spigot) fitting, that carries the longitudinal and lateral
loads from the engine to the outer wing box. The forward pylon
attachment fitting is fastened to the front spar.
The spigot fitting is fastened through the bottom skin panel, to the
forward attachment fitting.
The aft attachment is the aft pick-up fitting, which carries the vertical
and lateral loads to the outer wing box. It is attached, through the
bottom skin panel, to one or two diaphragms, fastened to one (or two)
ribs of the outer wing box.
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OUTER WING BOX - PYLON ATTACHMENTS

WING TIP (INCLUDING WINGLET)
The wing tip is bolted to the outer wing box, immediately outboard of
Rib 49. The winglet is fitted to the outboard end of the wing tip. The
wing tip and winglet structures are made of aluminum alloy. The wing
tip has a leading and trailing edges attached to the main structure (wing
tip box). The wing tip box is attached to the outer wing box with
compression and tension fittings, and spar fittings.
The winglet is composed of two fences, both connected to the wing tip
box from Rib 54 to Rib 58.
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WING TIP (INCLUDING WINGLET)

LEADING EDGE AND LEADING EDGE DEVICES
GENERAL ARRANGEMENT
The leading edge and leading edge devices give an aerodynamic shape
to the front of the outer wing.
It is composed of the following elements installed forward of the front
spar:
- the fixed leading edge, made of 3 structure assemblies and attached
to the front spar, bears the leading edge devices,
- and the leading edge devices: the droop noses at the inner and the
slats at the center and outer areas of the outer wing.
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LEADING EDGE AND LEADING EDGE DEVICES - GENERAL ARRANGEMENT

(continued)
FIXED LEADING EDGE
The fixed leading edge has three sections which extends forward of
the front spar:
- the inboard fixed leading edge located between Rib 1 and Rib 16
and divided into two parts, the inboard inner fixed leading edge (bath
tub) and the inboard outer fixed leading edge,
- the mid fixed leading edge, located between Rib 16 and Rib 27,
- and the outboard fixed leading edge, located between Rib 27 and
Rib 49 (tip rib).
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LEADING EDGE AND LEADING EDGE DEVICES - FIXED LEADING EDGE

(continued)
INBOARD FIXED LEADING EDGE
The inboard inner fixed leading edge (bath tub) and the inboard outer
fixed leading edge has a "D"-nose assembly supported by leading
edge ribs, attached to the outer wing box front spar. Leading edge ribs
are either truss work or full web. The inboard outer fixed leading edge
has support ribs, located in pairs at each location of the droop nose
hinge arms. The inboard outer fixed leading edge has three top panels
made of Glass Fiber Reinforced Plastic (GFRP) and bottom panels
made of CFRP, of sandwich construction, attached to the leading edge
ribs. The bottom panels give access to the droop noses driving
mechanism.
The D-nose assemblies are composed of the following aluminum alloy
parts:
- sub spar,
- open ribs,
- stringers,
- and skin panels.
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LEADING EDGE AND LEADING EDGE DEVICES - INBOARD FIXED LEADING EDGE

(continued)
MID AND OUBTBOARD FIXED LEADING EDGE
The mid and outboard fixed leading edges have a thermoplastic
"J"-nose assembly (stiffened skin panel, sub-spar and riblets) supported
by ribs attached to the outer wing box front spar. Slats are installed
on this structure. The followings ribs, made of aluminum alloy, are
fitted to the outer wing box rear spar:
- the hold down ribs receive the slat bumb,
- the track ribs support the rollers and rotary actuator for slats,
- the intermediate ribs support the leading edge.
The inboard outer fixed leading edge has bottom panels (not shown)
made of CFRP, of sandwich construction, attached to the leading edge
ribs. They give access to the slats driving mechanism.
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LEADING EDGE AND LEADING EDGE DEVICES - MID AND OUBTBOARD FIXED LEADING EDGE

(continued)
DROOP NOSES
On each side, the 2 droop noses are located on the inboard outer fixed
leading edge and are composed of:
- 1 aluminum alloy top skin panel with stringers and girders, and 1
back skin panel (not shown in the illustration),
- 9 CFRP bottom panels (5 for the droop nose No 1 and 4 for the droop
nose No 2),
- 1 trailing edge profile made of aluminum alloy sandwich,
- 1 rear spar,
- 8 hinge arms ribs, sheet metal ribs and end ribs made of aluminum
alloy.
The actuation is driven by 4 master driven hinge arms (two for each
droop nose) made of aluminum, driven links made of stainless steel
and links made of titanium alloy. 4 undriven hinge arms with links
support the droop nose structure during the actuation.
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LEADING EDGE AND LEADING EDGE DEVICES - DROOP NOSES

(continued)
SLATS
On each outer wing side, six slats are distributed respectively three
on the mid (slats 3, 4 and 5) and three on the outboard fixed leading
edge (slats 6, 7and 8). Slats are composed of the following parts (some
parts are not illustrated):
- 1 top skin, bottom skins, stringers and girders,
- a trailing edge of aluminum sandwich construction,
- a rear spar,
- track ribs, hold down ribs, sheet metal ribs and end ribs.
All these parts are made of aluminum alloy.
The slats are supported by curved tracks, which run on rollers. Rotary
actuators drive some tracks.
Each slat is installed on 2 tracks (a master and a slave tracks),
excepting slat 8 installed on 3 tracks.
Track ribs are attached to slat tracks via titanium alloy links.
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LEADING EDGE AND LEADING EDGE DEVICES - SLATS

TRAILING EDGE AND TRAILING EDGE DEVICES
GENERAL ARRANGEMENT
The trailing edge and trailing edge devices give an aerodynamic shape
to the aft of the outer wing.
They are composed of the following elements:
- the fixed trailing edge, made of 3 structure assemblies and attached
to the rear spar, bears the trailing edge devices,
- the trailing edge devices: 3 flaps with six flap tracks, 3 ailerons and
8 spoilers.
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TRAILING EDGE AND TRAILING EDGE DEVICES - GENERAL ARRANGEMENT

(continued)
FIXED TRAILING EDGE
The fixed trailing edge structure extends aft of the rear spar. It has
attachments for the trailing edge devices and also panels which give
an aerodynamic shape to the trailing edge. It is divided into 3 sections:
- the inner rear spar fixed trailing edge,
- the mid rear spar fixed trailing edge,
- the outer rear spar fixed trailing edge.
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TRAILING EDGE AND TRAILING EDGE DEVICES - FIXED TRAILING EDGE

(continued)
INNER REAR SPAR FIXED TRAILING EDGE
The structure of the inner rear spar fixed trailing edge gives support
for the spoilers 1 and 2 and the flap track beam 2. This structure also
holds panels, which are aerodynamic fairings.
It is composed of the following elements made of aluminum alloy
(excepting for some panels):
- the false rear spar, which holds the spoilers 1 and 2 fittings and the
flap track beam 2 aft attachment fitting,
- top and bottom trailing edge panels, made of CFRP sandwich
incorporating a GFRP leading edge and supported by the trailing edge
ribs,
- the inner fixed shroud, with panels made of CFRP sandwich,
- the shroud box, of same design as the inner fixed shroud,
- the overwing panel made of CFRP sandwich,
- the underwing panel made of aluminum alloy.
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TRAILING EDGE AND TRAILING EDGE DEVICES - INNER REAR SPAR FIXED TRAILING EDGE

(continued)
MID REAR SPAR FIXED TRAILING EDGE
The mid rear spar fixed trailing edge gives support for spoilers 3 to 8
and for the flap track beams 3 to 5, and holds also panels.
It is composed of:
- the flap track beams 3 to 8 aft attachment fittings,
- the spoiler 3 to 8 fittings (hinge ribs, common ribs and actuator
fittings),
- the top and bottom trailing edge panels, made of CFRP sandwich
ribs.
All parts are made of aluminum alloy, excepting the top and bottom
panels.
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TRAILING EDGE AND TRAILING EDGE DEVICES - MID REAR SPAR FIXED TRAILING EDGE

(continued)
OUTER REAR SPAR FIXED TRAILING EDGE
The outer rear spar fixed trailing edge provides support for the inner,
center and outer ailerons and holds also panels.
It is composed of:
- the inner, center and outer aileron fittings (hinge ribs, actuator fittings
and intermediate ribs), made of aluminum alloy,
- the top and bottom trailing edge panels, made of CFRP sandwich
ribs.
L1W06161 - L0KT0T0 - LM51D8000000001
L1W06161 - L0KT0T0 - LM51D8000000001
TRAILING EDGE AND TRAILING EDGE DEVICES - OUTER REAR SPAR FIXED TRAILING EDGE

(continued)
FLAPS
The flaps system is composed of 3 single slotted flaps per wing. Each
flap is supported by 2 tracks.
The inner flap has a torsion box made with aluminum alloy skins and
stringers, ribs and spars, and a trailing edge of sandwich construction.
The center and the outer flaps have a torsion box made with CFRP
skins and stringers, ribs and spars and an aluminum alloy sandwich
trailing edge. In load introduction areas, aluminum alloy ribs (track
ribs and end ribs) are used.
A rubbing strip made of stainless steel is bonded to the outer surface
of the top skins.
L1W06161 - L0KT0T0 - LM51D8000000001
L1W06161 - L0KT0T0 - LM51D8000000001
TRAILING EDGE AND TRAILING EDGE DEVICES - FLAPS

(continued)
FLAP TRACK BEAMS
Tracks and carriages hold the flaps. Carriages move onto roller tracks.
Roller tracks are parts of flap track beams.
There are 2 types of flap track beams:
- No 1, attached to the fuselage with support struts,
- No 2 to 6, attached to the outer wing box ribs at their forward end,
and to the flap track beam aft attachment fittings at the center.
The flap track beam No 1 is machined from titanium alloy, while the
other ones have a box structure made of CFRP and a roller track made
of titanium alloy.
L1W06161 - L0KT0T0 - LM51D8000000001
L1W06161 - L0KT0T0 - LM51D8000000001
TRAILING EDGE AND TRAILING EDGE DEVICES - FLAP TRACK BEAMS

(continued)
FLAP TRACK FAIRINGS
The flap track fairings enclose the flap track beams 2 to 6. They are
made with a CFRP sandwich shell and aluminum alloy frames and
have 3 parts:
- a fixed fairing,
- a movable mid fairing, hinged to the flap track beam,
- and a movable tail cone.
The LH fixed fairing 2 bears the Ram Air Turbine and fixed fairings
6 are integrated in the outboard engine pylons.
L1W06161 - L0KT0T0 - LM51D8000000001
L1W06161 - L0KT0T0 - LM51D8000000001
TRAILING EDGE AND TRAILING EDGE DEVICES - FLAP TRACK FAIRINGS

(continued)
AILERONS
There are 3 ailerons per wing located at the end of the wing trailing
edge side. The inner and the center ailerons have 4 hinges and the
outer aileron has 5 hinges.
Each aileron is composed of the following parts:
- skin panels made of CFRP sandwich,
- leading edge and ribs made of thermoplastic,
- spars with integrated hinges made of CFRP,
- main hinge fittings and actuator fittings made of titanium alloy,
L1W06161 - L0KT0T0 - LM51D8000000001
L1W06161 - L0KT0T0 - LM51D8000000001
TRAILING EDGE AND TRAILING EDGE DEVICES - AILERONS

(continued)
SPOILERS
There are 8 spoilers per wing. They are mainly made of CFRP
sandwich construction with aluminum alloy hinge fittings. A single
actuator operates each spoiler through the titanium alloy bridge plate
and 2 actuator fittings.
L1W06161 - L0KT0T0 - LM51D8000000001
L1W06161 - L0KT0T0 - LM51D8000000001
TRAILING EDGE AND TRAILING EDGE DEVICES - SPOILERS
AIRBUS S.A.S.
31707 BLAGNAC cedex, FRANCE
STM
REFERENCE L1W06161
APRIL 2006
PRINTED IN FRANCE
AIRBUS S.A.S. 2006
ALL RIGHTS RESERVED
AN EADS JOINT COMPANY

WITH BAE SYSTEMS

Level III - Ata 51 Structure

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Level III - Ata 51 Structure

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A380

TECHNICAL TRAINING MANUAL

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LEVEL III - ATA 51 STRUCTURE

STRUCTURE PRESENTATION (2)

STRUCTURE PRESENTATION (2)

STRUCTURE ATA BREAKDOWN

STRUCTURE PRESENTATION (2)

STRUCTURE ATA BREAKDOWN - DOORS - ATA 52

STRUCTURE PRESENTATION (2)

STRUCTURE ATA BREAKDOWN - FUSELAGE - ATA 53

STRUCTURE PRESENTATION (2)

STRUCTURE ATA BREAKDOWN - NACELLES AND PYLONS - ATA 54

STRUCTURE PRESENTATION (2)

STRUCTURE ATA BREAKDOWN - STABILIZERS - ATA 55

STRUCTURE PRESENTATION (2)

STRUCTURE ATA BREAKDOWN - WINDOWS - ATA 56

STRUCTURE PRESENTATION (2)

STRUCTURE ATA BREAKDOWN - WINGS - ATA 57

STRUCTURE PRESENTATION (2)

COMPOSITE APPLICATIONS - MONOLITHIC STRUCTURE

STRUCTURE PRESENTATION (2)

COMPOSITE APPLICATIONS - SANDWICH STRUCTURE

DOORS DESCRIPTION (3)

DOORS DESCRIPTION (3)

PASSENGER/CREW DOORS AND EMERGENCY EXIT DOORS

DOORS DESCRIPTION (3)

PASSENGER/CREW DOORS AND EMERGENCY EXIT DOORS - MAIN DECK DOORS

DOORS DESCRIPTION (3)

PASSENGER/CREW DOORS AND EMERGENCY EXIT DOORS - UPPER DECK DOORS

DOORS DESCRIPTION (3)

DOORS DESCRIPTION (3)

CARGO DOORS - FORWARD AND AFT CARGO DOORS

DOORS DESCRIPTION (3)

CARGO DOORS - BULK CARGO DOOR

DOORS DESCRIPTION (3)

LANDING GEAR DOORS

DOORS DESCRIPTION (3)

LANDING GEAR DOORS - NOSE LANDING GEAR DOORS

DOORS DESCRIPTION (3)

LANDING GEAR DOORS - WING LANDING GEAR DOORS

DOORS DESCRIPTION (3)

LANDING GEAR DOORS - BODY LANDING GEAR DOORS

FUSELAGE DESCRIPTION (3)

GENERAL ARRANGEMENT - SECTIONS BREAKDOWN

FUSELAGE DESCRIPTION (3)

GENERAL ARRANGEMENT - SKIN PANEL MATERIALS

FUSELAGE DESCRIPTION (3)

NOSE FORWARD FUSELAGE - SECTION LAYOUT

FUSELAGE DESCRIPTION (3)

NOSE FORWARD FUSELAGE - NOSE LOWER FAIRING

FUSELAGE DESCRIPTION (3)

NOSE FORWARD FUSELAGE - NOSE LOWER UNIT

FUSELAGE DESCRIPTION (3)

NOSE FORWARD FUSELAGE - NOSE FORWARD UNIT

FUSELAGE DESCRIPTION (3)

NOSE FORWARD FUSELAGE - NOSE REAR UNIT

FUSELAGE DESCRIPTION (3)

FORWARD FUSELAGE - SECTION LAYOUT

FUSELAGE DESCRIPTION (3)

FORWARD FUSELAGE - TYPICAL FUSELAGE CROSS SECTION

FUSELAGE DESCRIPTION (3)