Standard

 

AST 104 – Structural Layout and Fabrication

Course Description:

Continues the development of knowledge and skills required to perform basic aerospace layout and fabrication.  Emphasizes the safe use of stationary equipment.  Topics include: machine safety, stationary equipment, bend allowance, fasteners layout, parts fabrication, special fasteners, and geometric functions.

 

Competency Areas:

Hours:

 

 

 

Machine Safety

Class

3

Stationary Equipment

D. Lab

2

Bend Allowance

P. Lab/O.B.I.

9

Fasteners Layout

Credit

7

Parts Fabrication

 

 

Special Fasteners

Geometric Functions

 

Prerequisite:

AST 101, AST 103

Corequisite:

AST 102

 

Course Guide

 

 

Competency

After completing this section, the student will:

Hours

Class

D. Lab

P. Lab/

O.B.I.

MACHINE SAFETY

1

1

0

Bench grinder

Demonstrate safe use of bench grinder.

 

 

 

Sander

Demonstrate safe use of sander.

 

 

 

Band saw

Demonstrate safe use of band saw.

 

 

 

Drill press

Demonstrate safe use of drill press.

 

 

 

Brake

Demonstrate safe use of brake.

 

 

 

Shear

Demonstrate safe use of shear.

 

 

 

Roll former

Demonstrate safe use of roll former.

 

 

 

Notcher

Demonstrate safe use of notcher.

 

 

 

STATIONARY EQUIPMENT

0

3

7

Bench grinder

Select correct grinding wheels for rough and finish work.

 

 

 

 

Remove and replace grinding wheels.

 

 

 

 

Demonstrate safe and proper use of bench grinder

 

 

 

 

Select correct belts for each job

 

 

 

 

Remove and replace belt and/or disk

 

 

 

 

Adjust belt

 

 

 

Band saw

Remove and replace blade.

 

 

 

 

Weld blade for band saw.

 

 

 

 

Adjust speed and feed according to type of metal used

 

 

 

 

Demonstrate safe and proper use of band Saw.

 

 

 

 

Select proper cutting tool.

 

 

 

 

Select correct blade for aluminum.

 

 

 

 

Select proper speed and feed for aluminum

 

 

 

Drill press

Demonstrate safe and proper use of drill press.

 

 

 

Brake

Adjust hand brake for aluminum and radius.

 

 

 

 

Make a 45 degree angle.

 

 

 

 

Make a 90 degree angle.

 

 

 

 

Demonstrate safe and proper use of hand brake.

 

 

 

 

Adjust stop.

 

 

 

Shear

Demonstrate safe and proper use of shear (foot).

 

 

 

 

Adjust setting for aluminum.

 

 

 

Roll former

Roll a single contour cone with aluminum.

 

 

 

 

Remove cone from roll former.

 

 

 

 

Demonstrate safe and proper use of roll former.

 

 

 

BEND ALLOWANCE

9

5

18

Formulas

Identify various formulas used to calculate bend allowances.

 

 

 

Calculation

Calculate bend allowance using various formulas and various metals.

 

 

 

FASTENERS LAYOUT

5

2

16

Blueprint location/ specification

Determine measurements for layout of fastener as per blueprint designation or writer specifications.

 

 

 

PARTS FABRICATION

5

5

37

Material selection

Select proper material.

 

 

 

Blueprint interpretation

Interpret the blueprint in the fabrication parts.

 

 

 

Fabrication

Fabricate aircraft parts as per blueprint.

 

 

 

SPECIAL FASTENERS

5

2

6

Interpret print

Interpret aircraft blueprints for special fastener applications.

 

 

 

Identification

Identify special fasteners used in aircraft fabrication and repair.

 

 

 

Specification sheet

Read and interpret specification sheet for special fastener applications.

 

 

 

Installation

Install special fasteners in aircraft fabrication and repair procedures.

 

 

 

GEOMETRIC FUNCTIONS

5

2

6

Pattern layout

Apply geometric formulas to the solution of pattern layout.

 

 

 

Fastener layout

Apply geometric formulas to the solution of fastener layout.

 

 

 

Bend allowance

Apply geometric formulas to the solution of bend allowance.

 

 

 

Parts fabrication

Apply geometric formulas to the solution of parts fabrication.

 

 

 

 

Suggested Resources

 

Books:

 

Bonacci, N.  (1987).  Aircraft sheet metal.  Casper, WY: IAP.

Delp, F., et al.  (1987).  Aircraft maintenance and repair (5th ed.).  New York: McGraw-Hill.

ITP Airframe Section Textbook (#EA-ITP-G).  Casper, WY: IAP.

ITP General Section Textbook (#EA-ITP-AB).  Casper, WY: IAP.

U.S. Department of Transportation (F.A.A.).  (1976).  Airframe and powerplant mechanics: Airframe handbook.  Casper, WY: IAP.

U.S. Department of Transportation (F.A.A.).  (1976).  Airframe and powerplant mechanics:  General handbook.  Casper, WY: IAP.

 

Audiovisuals:

 

Aircraft rivet I.D.:  The microcomputer.  (1980).  Casper, WY: IAP.

 

       IAP, Inc.

       P.O. Box 10000

       Casper, WY  82602-1000

       1-800-443-9250