Process Description Project

Process Analysis: Repairing an aircraft skin.

I.

Analyze the damaged area.

II. If damage occurs or is found.

Inspect the area and check for corrosion, structural damage and other
forms of damage.
III. Classify the damage.
The damage can be negligible and does not affect the part i.e. small
cracks, scratches or dents.
Damage can cause replacement of part if the damage is too extensive,
inaccessible or there isnt enough time to correct the damage.
The damage can be repairable in a reasonable amount of time.
IV. Remove damaged material and parts.
1. Assuming that the damage on the F22 Raptor aircraft skin is repairable acquire
the tools to remove the damage i.e. drills, reamers and rotary files.
A. Drills

Use a pneumatic drill because they are the safest to use around aircrafts
of this class.

The initial drill size should be about #30(one eight of an inch in diameter)
Another drill size is used depending on the extent of the damage. (usually
one quarter inch)
Use the drill to stop drill both ends of the damage.

 Stop drilling stops the large cracks from extending further in the skin and
causing more damage.
B. Rotary files.
A cylindrical file specialized for removing damage.
Use the file to enlargen the drilled hole in order to make allowance for the
reamer.
C. Reamers
These are used to smooth and enlargen holes to a specified size.
A size of the wanted hole is obtained depending on the size of the damage
or crack.
The reamer is a tool that will open up the hole from .003 to .007 inch.
When the reaming is complete you will have one smooth perfectly round
hole in place of the initial damage.
V. Fabricate The Flush Patch and aerodynamic plug.
1. The round patch is often used for small areas of damage; it minimizes drag and
provides uniform distribution of skin strength.
A. Flush patches are used on the top of airfoils and high speed aircraft.
B. They are installed on the inside of the structure.
C. 100 degree countersunk rivets and a decorative plug are used to provide
aerodynamic smoothness.
VI. Find the amount of rivets needed for the flush patch.
A. Determine and measure the size of the pretty new hole in the aircraft skin.
B. Find the maximum number of rivets needed on the flush patch.

 Use the formula {(L x T x 75000) / DSS} x 2 to find this.

L= Diameter of Damage hole, T= thickness of the metal, 75000 is a
constant for aircraft skin strength calculated by aeronautical engineers and
DSS= shear strength of one rivet which is given by the manufacturer.
A Rivet is a nail like fastener device used to hold two pieces of metal
together.
VII. Ascertain the size of the patch
A. To find the radius of your flush patch keep in mind three simple rules.
-the distance of the rivets from the edge of the circle patch must be 3D or
three times the rivet diameter.
-the distance between each rivet in each row must be 3D.
-the distance from each rivet in adjacent rows must be 4D.
Now add 3D + 4D +3D + radius of damage hole and you will get the
radius of the flush patch.
VIII. Lay out the rivets on the patch.
Draw out the flush patch on paper with the appropriate diameter.
Create one row of rivets on the patch keeping in mind the 3D edge
distance rule. And then create another row of rivets keeping in mind the
4D row distance rule.
IX. Create patch and aerodynamic plug.
Using the paper as a guide, fabricate the patch out of aluminum.
Mark the areas to drill holes for the rivets
Create an aerodynamic plug to fit snuggly in the damage hole area.

X. Obtain countersunk rivets.

A. Counter sunk Rivets are rivets with flat heads that lay flush with the surface of
the aircraft skin (primarily used on high sped aircraft like F22 raptor to reduce
drag.).
XI. Drill holes slightly larger than the rivet diameter in the newly fabricated patch
using the trusty pneumatic drill.
XII. Drill holes through the aircraft skin while patch is held in place by clamps on the
skin.
.XIII Prepare skin and patch for installation of countersunk rivets.
Turn you attention to the skin of the aircraft.
The holes on the skin will have to be countersunk with a special tool in
order to make the rivets flush with surface.
Use a rosebud counter sunk with a micro stop*(countersinking tools)
attached to the drill, in order to make a v-like depression in the drilled
holes.
Ensure that the rivets fit in the newly countersunk holes.
.XIV Install the flush patch and the rivets using a pneumatic rivet gun.
.XV Inspection of Job.
An IA (Inspector of authorization) should inspect the newly installed
patch.
XVI. Write up a 337 form.
A. The FAA requires a 337 form for all major repairs and alteration to document
changes to a particular aircraft.

B. After the 337 form is filled out and signed the aircraft is released for flight.