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Aircraft Material, Hardware and Maintenance

  • Module code: AE5001
  • Year: 2018/9
  • Level: 5
  • Credits: 30
  • Pre-requisites: None
  • Co-requisites: None

Summary

This module comprises two parts; the first looks at aircraft materials and hardware and the second covers the theoretical aspects of aircraft maintenance practices. The practical work associated with this module takes place in other modules in the programme.

Part one of this module starts by exploring the characteristics, properties, applications and typical heat treatments of aircraft ferrous and non-ferrous metals before looking at the properties, characteristics and how to repair typical aircraft composite and non-metallic materials. The content of this element extends beyond the EASA syllabus and there will be a greater emphasis on the mechanical and physical characteristics of material, their time dependent behaviour, behaviour under various loading conditions and features related to the service environment. The module also looks at the selection and application of different types of materials in engineering applications. Where appropriate, state-of-the-art problems will be discussed to illustrate the structure-property relationship in materials. The final topic of this part covers aircraft hardware, here the properties, characteristics, uses and identification of fasteners, pipes, bearings, transmission systems, flying controls, and aircraft electrical cables and connectors are examined.

Part two provides students with the knowledge required to select and use the tools, materials, drawings and equipment necessary to perform aircraft maintenance tasks. It also provides them with the knowledge needed to enable them to work effectively and safely in an aircraft maintenance environment. Topics covered include: tools and equipment and their use, aircraft drawings and manuals, inspection and tolerance checking, electrical measurements, disassembly and reassembly, aircraft weighing and weight and balance calculations, aircraft handling; corrosion prevention removal, assessment and re-protection, non-destructive testing, aircraft storage and preservation and finally aircraft maintenance procedures.

Aims

  • Aircraft materials and hardware to underpin and support an understanding of aircraft structures .
  • Maintenance practices to underpin and support practical maintenance activities on aircraft.
  • Aircraft materials, hardware and maintenance practices sufficient for them to pass aviation authority engineering licence examinations at category B level.

Learning outcomes

On successful completion of the module, students will be able to:

  • Critically describe basic properties of engineering materials and be able to relate these properties to the microstructure of the materials.
  • Explain different modes of failure of engineering materials and relate these to service conditions, failure mechanisms and microstructural changes.
  • Compare and contrast the different properties and characteristics of materials used in the construction of aircraft.
  • Recognise and assess defects in and/or the deterioration of aircraft materials and hardware and determine the appropriate action to be taken.
  • Explain the practices and procedures associated with aircraft maintenance, be able to select the tools and equipment needed for specific activities and illustrate precautions to be observed when using them.
  • Demonstrate a thorough knowledge and understanding of the subject matter in the EASA Part-66 syllabus for Aircraft Materials and Hardware and Maintenance Practices (modules 6 and 7).

Curriculum content

The module covers the content of the EASA Part-66 syllabus for Module 6 - Material and Hardware and Module 7 - Maintenance Practices to the category B1.1 licence level. This module also covers a selection of  advanced  topics in material science including macrostructure and material properties, heat treatment,  time dependant behaviour of materials and material selection for engineering design.

Topics covered include but are not limited to:

  • Mechanical and Physical characteristics of material: Young's Modulus (E), Yield Strength, Ultimate Tensile Strength (UTS), Fracture resistance, Impact resistance
  • Behaviour of solid bodies under various loading conditions: Compression, Shear, Bending and Torsion
  • Time dependent behaviour of material: Creep, Fatigue
  • Heat treatment of metals
  • Features related to the service environment: Impact resistance, Corrosion resistance, Temperature
  • Material Selection & Design
  • Ferrous and non-ferrous aircraft materials: characteristics, properties and identification of common alloy steels used in aircraft.
  • Composites and non-metallic: characteristics, identification, sealant and bonding agents. Construction of wooden structures, characteristics and properties of wood and glue used. Preservation, maintenance, defects and repair of wooden structures.
  • Aircraft hardware such as fasteners, pipes and unions, springs, bearings, transmissions, control cables and aircraft electrical cables and connectors.
  • Aircraft and aircraft workshop practices and safety.
  • Tools and general avionic test equipment.
  • Engineering drawings, diagrams and standards; and fits and clearances.
  • Electrical Wiring Interconnection System (EWIS).
  • The handling of aircraft materials and maintenance practices associated with rivets, pipes and hoses, springs, bearings, transmissions and control cables.
  • Welding, brazing soldering and bonding.
  • Aircraft weight and balance, handling and storage and abnormal events.
  • Maintenance procedures and disassembly, inspection, repair and assembly techniques.

Teaching and learning strategy

The learning outcomes of this module will be achieved primarily through lectures because of the theoretical nature of a large proportion of the material; the practical work associated with this module takes place in other modules in the programme. However, where opportunities exist to break the monotony of lectures with practical activities or demonstrations they will be taken; some examples could be: aircraft weight and balance, engineering drawings and EWIS. The module teaching team will also ensure that as many "exhibits" as possible are available during lectures and, where necessary, will organise visits to tool stores, workshops and hangars to view tools, equipment and hardware.

Students will be provided with comprehensive teaching material and, where necessary, worked examples and practice questions. Students will guided through the theory and worked examples in class; given questions, problems and, where possible,  practical (class based) activities to work on during lecture sessions and in their own time. Feedback from regular, informal in-class tests and two summative in-class tests will enable students to gauge their level of knowledge and understanding and help them prepare for the written examination that takes place at the end of the module.

Breakdown of Teaching and Learning Hours

Definitive UNISTATS Category Indicative Description Hours
Scheduled learning and teaching Lectures/tutorial 120
Guided independent study 180
Total (number of credits x 10) 300

Assessment strategy

The summative assessment for this module will comprise  a portfolio of in-class tests (two 1hr short ans. in-class tests,10% each), a written assignment and an end-of-module examination. The two in-class tests will focus on the knowledge aspect of the module. The written assignment will focus on topics requiring understanding such as corrosion identification, interpreting engineering drawings, weight and balance and maintenance procedures. The written assignment will be used to gauge student's knowledge and understanding of the subject matter and it will also be used to assess the students writing skills.

The end-of-module examination will be a 3-hour, two part written paper. Part-1 (50%) comprising short answer questions worth 1 to 10 marks each covering whole syllabus. Part-2 (50%) answer 2 from 3 essay questions worth 25% each.  The end-of-module examination intends to cover all of the module learning outcomes. This is considered necessary because all of the learning outcomes contain an element of fundamental, must-know knowledge; knowledge students will need to know in order to pass the aviation authority examinations for the licence.

The in-class tests and the assignment will be formative as well as summative. The results and feedback from the in-class tests and the assignment will enable students to gauge their level of knowledge and understanding and help them to prepare for the final examination. Feedback on the assignment will provide information on their communication skills and feed-forward for written work that is to follow in the programme. The coursework will also provide staff with an indication of the level of knowledge and understanding of the students and enable them to manage the teaching and learning.

Assessment - Aviation Authority Approved programmes

Students completing this module on an aviation authority approved training course will be expected to complete all of the assessment associated with the approved course. A failure to do may result in a loss of the benefits associated with study on an aviation authority approved course.

Details of the assessment students are required to complete on aviation authority approved courses will be given in the relevant course handbook issued at the start of the course. It should be noted that aviation authority assessment will be changed, if and when necessary, to ensure continued compliance with the approval.

Mapping of Learning Outcomes to Assessment Strategy (Indicative)

Learning Outcome Assessment Strategy
1. Critically describe basic properties of engineering materials and be able to relate these properties to the microstructure of the materials. Examination. Coursework.
2. Explain different modes of failure of engineering materials and relate these to service conditions, failure mechanisms and microstructural changes Examination. Coursework.
3. Compare and contrast the different properties and characteristics of materials used in the construction of aircraft. Coursework. Examination.
4. Recognise and assess defects in and/or the deterioration of aircraft materials and hardware and determine the appropriate action to be taken. Examination. Coursework.
5. Explain the practices and procedures associated with aircraft maintenance, be able to select the tools and equipment needed for specific activities and illustrate precautions to be observed when using them. Coursework. Examination.
6. Demonstrate a thorough knowledge and understanding of the subject matter in the EASA Part-66 syllabus for Aircraft Materials and Hardware and Maintenance Practices (modules 6 and 7). Coursework. Examination.

Elements of Assessment

Description of Assessment Definitive UNISTATS Categories Percentage
Written Exam Written Exam 50%
Portfolio of in-class tests Written Exam 20%
Written assignment Coursework 30%
Total (to equal 100%) 100%

Achieving a pass

It IS NOT a requirement that any major assessment category is passed separately in order to achieve an overall pass for the module.

Bibliography core texts

The course material supplied by the module teaching team at the start of the module.

Hosford, W. (2012). Elementary Materials Science. Materials Park: A S M International.

Bibliography recommended reading

Callister, W. (2007). Materials science and engineering : An introduction (7th ed.). New York ; Chichester: Wiley.

Federal Aviation Administration  (1998)  Advisory Circular  AC 43.13 - 1B with CHANGE 1, AC 43.13 - 2A Combined  -  acceptable methods, techniques, and practices - aircraft inspection and repair  USA, Englewood, Jeppesen

Larry Reithmaier and Ron Sterkenburg (2013) Standard Aircraft Handbook for Mechanics and Technicians. 7th ed. McGraw-Hill Professional. ISBN-13 978-0071826792

Jeppesen  Sanderson Inc. (2009) A & P Technician General Textbook. Jeppesen.
ISBN-13 978-0884875222

Jeppesen  Sanderson Inc. (2003)  A & P Technician Airframe Textbook. 3rd ed. Jeppesen.
ISBN-13 978-0884873310

Eismin, T (2013) Aircraft Electricity & Electronics. 6th ed. McGraw-Hill Professional.
ISBN-13 9780071799157

DeGarmo, E. Paul, Temple Black, and Ronald A. Kohser (2017) Materials and processes in manufacturing, John Willey & Sons, ISBN 0-471-0306-5.

Aviation Authority Approval - Course Material

Aviation authorities normally require approved training organisations to produce and maintain training material for the modules associated with the courses they deliver under their approval.  Students on aviation authority approved courses will be provided with training material in accordance with the requirements of the approval and the conditions specified by the training organisation. Partner organisations may charge for this material.

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