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FINISHING MATERIAL
AFC-2
COURSE OBJECTIVE
By the end of this course you will be able to describe
Common types of fabric used & their characteristics
Common types of chords, tapes & threads used for
attaching fabric to aircraft structure
Different chemicals used with fabric covering
Different method of securing a fabric to an aircraft
structure
Various defects associated with fabric & means of
eliminating them
CONTENT
Introduction
Types of aircraft fabric
Basis for aircraft fabric re-covering
Aircraft fabric testing
Aircraft fabric covering preparation
Installing aircraft fabric
Finishing aircraft fabric covering
REFERENCES
Aircraft Maintenance Technician Series
Volume 1 Structures
Chapter 3 Non-Metallic Structure
AC65-9A Airframe Handbook
Chapter 3 Fabric Covering
INTRODUCTION
INTRODUCTION
Historical Background
Most popular few years back
Currently replaced by all metal construction
But still found on special purpose aircraft
Agricultural aircraft
Amateur built aircraft
Newly introduced light sport aircraft (LSA)
Antique/old aircraft that need restoration
INTRODUCTION CONTD
Definition
Fabric
Covering cloth/textile made from interwoven fibers
after undergoing thru careful manufacturing process
Fibers/yarns
Small fine filaments made from various materials and
used to make threads.
Cotton, linen, glass, cellulose or polyester
INTRODUCTION CONTD
Fabric Terms
Warp
INTRODUCTION CONTD
Fabric Terms cont.
Ply/layer/thickness
Number of yarns/fibers making up thread
Bias
Cut, fold, or seam made diagonally (45 degree) to
the warp/fill thread
Calendering
Process of ironing fabric by threading the fabric
between serious cold and hot rollers to produce
smooth finish
INTRODUCTION CONTD
Fabric Terms cont.
Mercerization
Dipping yarn/fabric in a hot solution of caustic soda
to shrink fabric & acquire great strength &
luster/shine.
Is a chemical process which increases the tensile
strength of the fibre and its absorption characteristics
Sizing
Material/lubrication such as starch used to stiffen
yarns for ease in weaving/interlacing
INTRODUCTION CONTD
Fabric Terms cont.
Pinked edge
Edge cut by machine or shears in a continuous series
of V to prevent raveling/knotting or twisting
Selvage edge
The edge of the cloth woven to prevent raveling
Bleaching
Chemical process used to whiten cotton fabric
Contd
Greige condition of polyester fabric upon
completion of the production process before
being heat shrunk.
Cross coatbrushing or spraying where the
second coat is applied 90 to the direction the
first coat was applied. The two coats together
make a single cross coat.
INTRODUCTION CONTD
Fabric Terms contd
TYPES OF FABRIC
POLYSTER FABRIC
Polyester fabric is a durable man made polymer (synthetic
fiber) which is resistant to moisture, acids, alkalis, fuel and oils.
It is susceptible to deterioration when exposed to ultraviolet
radiation for a long time and must therefore be completely
covered by protective coatings in service.
The material is produced by polymerization of selected
hydrocarbon materials, extruded in its molten state to form
filaments.
The filaments are then heat stretched to the desired denier
(or diameter) of fibre prior to weaving.
Contd
Advantage
Not affected by moisture, mildew/fungus/decay/rot,
chemical & acids and fire resistant
Disadvantage
Adds significant weight compared to linen, & cotton
Recovering Need
A/C DOPE
Dope is primarily used to protect the fabric covering of an
aircraft from damage by environmental factors such as
moisture, sunlight and pollution.
It also prevents the passage of air through the fabric and
reduces friction, which improves the efficiency of the airframe.
Certain dopes have the property that they shrink when drying
and tighten the fabric (used to tauten).
Most dopes can be used to stick/attach fabric patches onto the
covering for repairs and access holes and, sometimes, the
fabric to stick to the structure.
FABRICS
Inorganic Commercial Names:
Polyester Fabrics
. DACRON Base
Fiberglass
Extremely resistant to
deterioration from heat
and chemicals
SURFACE TAPE
Doped over each seam or rib to cover the stitching.
Provides a smooth appearance.
Can be:
Serrated/ragged or Pinked
Straight edge impregnated with a compound
For better adhesion and to prevent
raveling/twisting
Same material as the original fabric
Should be placed over all lacings, seams, corners, edges
and places where wear is expected.
Applied after the second wet coat of dope
SURFACE TAPE
REINFORCING TAPE
LACING CORD
Tensile Strength
Must be strong enough to transmit the force on the
upper surface of the wing
40 lb for single or 80 lb. for double
Should be waxed before use to lubricate it.
Can be done by hand
Specification
MIL-C -5649, MIL-C -5648, MIL-T -6779, MIL-T-5660
SPECIAL FASTENERS
Original fastening device must be duplicated.
Wire clips
Self tapping screws
At least two threads of the screw must extend
beyond the rib cap strip
A washer should be used under the head of the
screw
A pinked edge tape should be doped over the head of
the screw.
SEAMS/JOINTS
A series of stitches used to join two or more pieces of
material.
Characteristics
Strength
Must have sufficient strength to carry the stresses to
which it will be subjected.
Elasticity
Durability
Tightly woven stitches are more durable.
Appearance
SEAM-TYPES
1. Sewed seams
Machine sewed seams
Hand sewed seams
- To close final openings
- A inch hem/edge should be turned under all
seams
- Should be locked at 6 intervals.
2. Doped seams
46
SEAMS CONT.
48
SEAMS CONTD
FAA approved machine seams
BUTYRATE DOPE
GENERAL
All covering must be tauten and smooth for the best
appearance and performance of the aircraft.
Storage
- Materials must be stored in a cool, dry place.
Hence therefore the fabric shop must be:
Clean
Well lighted and
Well ventilated
74
Easels
- To support a wing vertically
Needles
Shears
Sewing thimble/cap
sewing machine
75
76
A. Lacing
Lacing contd
Lacing contd
Lacing cont.
TYPES OF STITCHES
FABRIC COVERING
Clipping
C. Screwing
REPAIR METHOS
If the fabric has been damaged extensively, it is usually
impractical and uneconomical to make satisfactory
repairs by sewing and patching.
Cuts and tears in fabric are sometimes caused by stones
thrown up by the slipstream or wheels, from accidental
damage during ground movement or servicing.
Damage may also be caused by bird strikes.
METHODS:
Repair of tears
Sewed - In repair
Doped - On repair
Doped In panel repair
Tears
REPAIR OF TEARS
DOPED-ON REPAIR
Used:
When VNE < 150 MPH
And damage is < 16
Remove damaged area
Remove the finish back from the edge of the cutout for
about 2.
Dope on patch (up to 16 in any direction)
Up to 8 hole needs 2 overlap
12 hole = 3 overlap
REPAIR BY DARNING/RENOVATION.
SEWED-IN REPAIR
When damage area exceeds 16 inches and the never
exceed speed is greater than 150 MPH.
The damage is removed and a rectangular or square patch
is sewed to the edges of the cutout.
A patch is applied over the seams
117
INTRODUCTION
Paint
A colored liquid applied to a surface in order to
decorate it or to protect it, or to create a
painting/image/picture/work of art.
Finish
To treat something, especially wood or metal, in order
to achieve a desired surface effect
Purpose of finishes:
Protection from deterioration
Pleasing appearance (desired appearance)
CLASSIFICATION OF FINISHES/PAINTS
Protective
For interior and exterior surfaces
Appearance
For exterior surfaces
Decorative
Emblems (logo) - symbols
Decals (stickers) - signs
Identification numbers and letters
FINISHING MATERIALS
Cleaning agents
Dope
Thinners
Primers
Paints
Additives
Rejuvenators
Masking materials
CLEANING AGENTS
Are used to clean:
Surfaces to be painted
Painting equipment
Examples:
Acetone
Removing grease from fabric
Cleaning spray paint guns
Benzene
Cleaning equipment
THINNERS
To thin dopes, enamels and paints for spraying and
brushing consistency.
Use correct thinner:
Toluene - for zinc chromate primer
Turpentine - for varnish, enamels and other oil base
paints.
PRIMERS
Zinc chromate Primer
For corrosion protection
As a base for protective topcoats
Is also a good dope proof paint
Standard wash primer
Used with some paints that require an under coat (a metal pre
treatment coating compound)
Leaves a very thin layer
Contains phosphoric acid as one of its component at the time
of application.
Acrylic cellulose nitrate modified primer
Used between wash primer and nitrocellulose topcoat
PRIMERS CONT
Red iron oxide
Gray enamel undercoat
Under top coats
Suitable for sanding to create a perfectly smooth base
for paint.
Polyurethane
Epoxy
PAINTS
Types of paints
Lacquer /varnish
Easy to apply
Easy to repair
Can be fuel or chemical resistant
May need to be buffed/polished to reach
maximum glossiness/smoothness
Acrylic nitrocellulose and nitrocellulose
PAINTS CONT
Enamel
Acrylic enamels provide a glossy/shine/smooth
surface which is very resistant to scratching due
to its hardness
More care is needed during application
Drying time is longer
Harder to repair
PAINTS CONT
Polyurethane
Excellent durability
Excellent weather resistance
Excellent chemical resistance
Used in areas exposed to chemical attack such as
Skydrol.
Should not be waxed/polished
Hard to strip/cut up
CONTENTS OF PAINT
Pigment
Provides color and durability.
Also improves the strength and adhesion of the paint.
Binder
Holds the pigment in liquid form.
When applied it gives the paint the ability to adhere to
the surface.
Backbone of the paint
ADDITIVES CONT.
EXAMPLES:
Butyl Alcohol
Mixed with dope to retard drying
Turpentine
As a quick drier for enamels
Paint drier
To improve drying properties
REJUVENATOR CONT
Can extend life of cover, but must check the underneath
material.
When the rejuvenator dries, the surface should be sprayed
with two coats of aluminium pigmented dope, then sanded
and a third coat of pigmented dope applied, followed with
the coloured dope finish.
RETARDERS:
MASKING MATERIAL
To exclude areas not to be painted
Metal
Held in place by weights
Fiberboard (compressed wood)
Held in place by weights
Paper
Held in place by masking tape
Masking tape
SPRAY PAINTING
Requires:
Source of compressed air
A reservoir or feed tank
To hold supply of the finishing material
Device for controlling the combination of air and
finishing material (spray gun)
ASSINMENTS
1. Discuss about the different varieties of a/c finishing
materials
2. Discuss and characterize the different types of fabric
materials commonly used for wooden a/c cover
3. Explain about a/c fabric installation procedures (the
seven steps)
4. Discus about on how we determine the strength of a
fabric material
THE END
THANK YOU