TO 1-1A-1 NAVAIR 01-1A-1 - AF

1 TO 1-1A-1 NAVAIR 01-1A-1 TECHNICAL MANUALENGINEERING handbook SERIES FOR AIRCRAFTREPAIR GENERAL MANUAL FOR structural REPAIR(ATOS)THIS MANUAL SUPERSEDES AF TO 1-1A-1 AND NAVAIR 01-1A-1 , DATED 1 APRIL STATEMENT A: Approved for public release; distribution is unlimited. HQ AFMC PA Case Number 070201. Submitrecommended changes or problems with this technical order to 558 CBSS/GBHA, Bldg 3001/1AC1108B, Tinker AFB OK under authority of the Secretary of the Air Force15 JANUARY 2016TO 1-1A-1 NAVAIR 01-1A-1 INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES. LIST OF EFFECTIVE PAGESNOTE: The portion of the text affected by the changes is indicated by a vertical line in the outermargins of the page. Changes to illustrations are indicated by shaded or screened areas,or by miniature pointing of issue for original and changed pages 0.

2 15 January 2016 TOTAL NUMBER OF PAGES IN THIS MANUAL IS 160, CONSISTING OF THE FOLLOWING:Page*ChangePage*ChangePage* 0A .. 0i - ix .. 0x 01-1 - 02-1 - 03-1 - 04-1 - 04-20 05-1 - 05-10 06-2 07-1 - 07-12 08-1 - 08-30 09-2 0A-1 - 0A-8 0B-1 - 0C-1 - 0 Index 1 - Index 0*Zero in this column indicates an original 1-1A-1 TABLE OF vSAFETY SUMMARY ..vii1A DESCRIPTION OF THE MAIN ELE-MENTS IN AIRCRAFT STRUCTURE .. structural Units .. Surfaces .. Gear .. and Maintenance ofthe Wings, Fuselage, and .. Surfaces .. Gear ..1-102 DAMAGE ASSESSMENT .. of Aircraft Damage .. Classifications .. Classifications .. of Damage .. Inspection .. Inspection (NDI) .. Types .. WORKING PRACTICE .. of Aircraft Alloy Stressed SkinStructure .. Alloy Sheet Substitu-tions.

3 Of Substitution Table .. of Rule 1 .. of Rule 2 .. and Riveting Practice .. of Spot Welds andWorn .. of Spot Welds .. Weld Failures .. Broken Screws .. Composite Repair .. of Tubing Damage .. of Threaded Installations .. Cracks in SheetMaterial (Low- and Medium-Stress Areas) .. inspection .. evaluation .. repair and Scratches .. Repair Examples ..3-144 MATERIALS AND THEIR IDENTIFI-CATION .. Specifications .. for the Study and Use .. Composites .. Plastics .. Glass ..4-195 FASTENERS .. Fasteners .. 1-1A-16 WELDING ..6-17 ADHESIVES AND BONDING .. and Disadvantages ofAdhesive Bonding .. of Adhesive Mater-ials .. Classification .. Classification .. of Adhesive-Bonded Joints .. Lap Joints .. Lap Joints .. Joints .. Joints .. Considerations.

4 Preparation Treatments7-3for Adhesive Bonding (TankImmersion) .. of of Adhesive Primer Selection .. of Honeycomb withDry Ice .. enclosure .. Ice Information ..7-118 METAL WORKING .. Shop Metal Forming .. Pattern Allowance .. Sheet Metal Bend Ra-dii .. Pattern Layout Procedures .. Line .. Operations .. Pan or Cornice Brake Ma-chine Forming .. Roll Machine Forming .. Titanium Alloys .. and Grinding TitaniumAlloys .. and Reaming TitaniumAlloys .. and Joggle Blocks .. Titanium Titanium ofTitanium Alloys .. Stress-Relieving andAnnealing .. Blind Holes ..8-289 CABLE REPAIR ..9-1 AGRIT BLAST SILANE (GBS) PROCESS ..A-1 BPHOSPHORIC ACID NON-TANK ANO-DIZE (PANTA) PROCEDURES .. B-1 CSPECIAL CONSIDERATIONS RE-GARDING FASTENER HOLES .. Process Fluids (Sources).

5 Practices to ProduceQuality Holes in Metallic Air-craft Structures .. Motors .. Tools .. Speeds and Feeds .. Fluids .. Quality .. Working (CW) Of FastenerHoles; Split Sleeve Description .. Background and Jus-tification .. Inspection .. Expansion .. Margin Spacing Worked Hole Diameter .. Sizing of Cold WorkedHoles for Fastener .. and Deburring .. of Previously Counter-sunk Holes .. Diameter vs. Sheet Thick-ness Ratio .. Discontinuities .. 1-1A-1 INDEX .. Index 1 LIST OF ILLUSTRATIONSN umberTitlePageNumberTitlePage1-1 Principle structural Units .. 1-21-2 Semimonocoque Fuselage 1-31-3 Aircraft Wing Design .. 1-51-4 Typical Tail Structures .. 1-71-5 Typical Stabilizer Structures .. 1-71-6 Types of Wing Flaps .. 1-91-7 Leading Edge Flaps.

6 1-102-1 Negligible Damage .. 2-32-2 Damage Repairable by Patching .. 2-42-3 Damage Repairable by Insertion .. 2-42-4 Damage Requiring Replacement .. 2-52-5 Typical Borescope .. 2-82-6 Types of 2-82-7 Locating Cracks by Radiography .. 2-102-8 Eddy Currents Produced in a Conductorby a Varying Electromagnetic Field .. 2-112-9 Path of Eddy Currents Around a 2-112-10 Detecting Flaw with Ultrasonic Inspec-tion Method .. 2-112-11 Fluorescent Penetrant 2-122-12 Crack in Bar Magnet Attracting Mag-netic Particles .. 2-132-13 Electric Current Creating a CircularMagnetic Field in a Part .. 2-133-1 Aluminum Alloy Sheet Substitution andConversion Table for CommercialTemper Designations .. 3-23-2 Drill Sizes for Removal of Spot 3-53-3 Method of Shearing Spot Welds forRiveting .. 3-63-4 Locating and Transcribing Tool.

7 3-63-5 Spot Weld Shearing Chisel .. 3-73-6 Piloting Drill .. 3-73-7 Drilling 3-73-8 Removing Spot Welded Skin fromStructure .. 3-73-9 Repair for Sheared Spot Welds .. 3-83-10 Drilling a Hole in a Broken Screw .. 3-93-11 Removing a Broken 3-113-12 Stress Concentration and Blending .. 3-153-13 Typical Splice Repair .. 3-163-14 Typical Splice Tee Repair .. 3-173-15 Typical Angle 3-183-16 Typical Channel Repairs .. 3-193-17 Typical Zee Repair .. 3-223-18 Typical Rib 3-243-19 Typical Aluminum Honeycomb Repair .. 3-254-1 Tension Load Example .. 4-14-2 Compression Load 4-24-3 Shear Load 4-24-4 Bending Load Example .. 4-34-5 Torsion Load Example .. 4-45-1 Parts of a 5-27-1 Types of Adhesive-Bonded 7-58-1 Technical Forming Terms .. 8-28-2 Bend 8-38-3 Setback 8-58-4 Minimum Bend Radii.

8 8-68-5 Layout 8-88-6 Use of Bend Lines on Cornice Brake .. 8-98-7 Cornice Brake Operation .. 8-118-8 Form Correction 8-138-9 Forming 8-148-10 Hand-Forming Concave 8-158-11 Hand-Forming Convex Surfaces .. 8-168-12 Hand-Forming Extruded Shapes .. 8-178-13 Joggle Dimension Chart - Flat Sheet,Joggle 8-188-14 Joggle Dimension Chart - FlangedSheet, Rubber Formed and JoggleCold .. 8-208-15 Joggle Dimension Chart - Extruded orBent Sheet Sections, Die 8-228-16 Forming Joggle Using Cornice 8-238-17 Forming Joggle Using Joggle Blocks .. 8-258-18 Forming Joggle Using Joggle Clip .. 8-268-19 Drills for 8-288-20 Locating and Transcribing Tool .. 8-29A-1 Grit Containment Box Example .. A-4C-1 Split Sleeve Cold Working of of the Cold Working Process .. 1-1A-1 LIST OF TABLESN umberTitlePageNumberTitlePage1 Related Air Force (TO) and NAVAIR (TM) vi2-1 Types of Damage.

9 2-22-2 Advantages and Disadvantages of Com-mon Aircraft NDI Techniques .. 2-143-1 Drill and Extractor Sizes .. 3-104-1 Cross-Reference of Steel Specifications .. 4-64-2 Basic Temper Designations and Subdivi-sions for Aluminum Alloys .. 4-104-3 Cross-Reference for Common 4-124-4 Typical Mechanical Properties of Com-mon Aluminum 4-134-5 Mechanical Properties of Titanium .. 4-154-6 Density of structural 4-164-7 Casting Specification .. 4-174-8 Fiber 4-184-9 Resins .. 4-184-10 Prepregs and Laminates .. 4-195-1 Hole Size 5-35-2 Rivet Identification and Characteristics .. 5-75-3 Shear Strength of Aluminum Alloy Riv-ets (Pounds Per Rivet) .. 5-97-1 Types of 7-37-2 Adhesives Classified by Form .. 7-47-3 Surface Preparation Treatments for Ad-hesive Bonding (Tank Immersion) .. 7-77-4 Non-Tank Surface Preparation Treat-ments for Adhesive Bonding on Alu-minum, Titanium, Steel, andFiberglass.

10 7-97-5 Federal and Military Adhesive 7-107-6 Thermosetting Adhesives Classified byActivation and Cure 7-11C-1 Maximum Recommended Drill Speedsfor Holes up to Inch Diameter ..C-5C-2 Maximum Recommended ReamingSpeeds for Holes up to InchDiameter ..C-6C-3 Recommended Flex Honing Parameters ..C-6C-4 Recommended Speeds for Countersink-ing and Counterboring ..C-6C-5 Recommended Cutting Fluids ..C-6ivTO 1-1A-1 NAVAIR Order (TO) 1-1A-1 is one of a series of manualsprepared to assist personnel engaged in the general mainte-nance and repair of military aircraft. This manual coversgeneral aircraft structural is a Joint-Service manual and some information maybe directed at one branch of the service and not the the text of the manual refers to Air Forcetechnical orders for supportive information, refer to thecomparable Navy documents (see Table 1).