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AIRCRAFT HARDWARE
OBJECTIVE: Identify com- Many types of bolts are used in modern aircraft,
mon types of threaded fasteners and the and each type is used to fasten something in place.
methods used to properly install and safety Before discussing some of these types, it might be
them. helpful if we list and explain some commonly used
In modern aircraft construction, thousands of bolt terms. You should know the names of bolt parts
rivets are used, but many parts require frequent and be aware of the bolt dimensions that must be
dismantling or replacement. It is more practical for considered in selecting a bolt.
you to use some form of threaded fastener. Some The three principal parts of a bolt are the head,
joints require greater strength and rigidity than can be grip, and threads, as shown in figure 5-1. Two of
provided by riveting. We use various types of bolts, these parts might be well known to you, but perhaps
screws, and nuts to solve this problem. grip is an unfamiliar term. The grip is the unthreaded
Bolts and screws are similar in that both have a part of the bolt shaft. It extends from the threads to the
head at one end and a screw thread at the other. bottom of the bolt head. The head is the larger
diameter of the bolt and may be one of many shapes or
designs.
61
To choose the correct replacement for an
unserviceable bolt, you must consider the length of the
bolt. As shown in figure 5-1, the bolt length is the
distance from the tip of the threaded end to the head of
the bolt. Correct length selection is indicated when the
bolt extends through the nut at least two full threads.
See figure 5-2. If the bolt is too short, it will not
extend out of the bolt hole far enough for the nut to be
securely fastened. If it is too long, it may extend so far
that it interferes with the movement of nearby parts.
In addition, if a bolt is too long or too short, its
grip will usually be the wrong length. As shown in
figure BOLT GRIP LENGTH CORRECT
5-2, the grip length should be approximately the same
as the thickness of the material to be fastened. If the
grip is too short, the threads of the bolt will extend
into the bolt hole. The bolt may act like a reamer when
the material is vibrating. To prevent this, make certain
that no more than two threads extend into the bolt
hole. Also, make certain that any threads that enter the
bolt hole extend only into the thicker member that is
being fastened. If the grip is too long, the nut will run
out of threads before it can be tightened. In this event,
a bolt with a shorter grip should be used. If the bolt
grip extends only a short distance through the hole, a
washer may be used.
A second bolt dimension that must be considered
is diameter. As shown in figure 5-1, the diameter of
BOLT GRIP LENGTH TOO SHORT
the bolt is the thickness of its shaft.
The results of using a wrong diameter bolt should
be obvious. If the bolt is too big, it cannot enter the
bolt hole. If the diameter is too small, the bolt has too
much play in the bolt hole.
The third and fourth bolt dimensions that should
be considered when you choose a bolt replacement are
head thickness and width. If the head is too thin or too
narrow, it might not be strong enough to bear the load
imposed on it. If the head is too thick or too wide, it
LENGTH
CLEVIS BOLT
EYEBOLT
HEAD MARKINGS
CLOSE
ALUMINUM CORROSION STEEL STEEL
TOLERANCE
ALLOY RESISTANT 125,000 P.S.I) (150,000 P.S.I.)
(STEEL OR
(62,000 P.S.I.) STEEL
ALUMINUM ANF0503
(125,000 P.S.I.)
ALLOY)
Figure 5-3.Types of bolts and bolt head markings.
MACHINE SCREW
STRUCTURAL SCREW SELF-TAPPING
Structural screws are used for assembly of
SCREW structural parts, as are structural bolts. They are made
of alloy steel and are properly heat-treated. Structural
screws have a definite grip length and the same shear
PHILLIPS HEAD REED AND
PRICE HEAD
and tensile strengths as the equivalent size bolt. They
ANF0504
Figure 5-4.Screws. differ from structural bolts only in the type of head.
These screws are available in countersunk head, round the casting after a hole has been predrilled undersize.
head, and brazier head types. See figure 5-5. Sheet metal self-tapping screws are used for such
Machine Screws purposes as temporarily attaching sheet metal in place
for riveting. Sheet metal self-tapping screws may be
The commonly used machine screws are the round used to permanently assemble nonstructural units
head, flat head, fillister head, pan head, truss head, and where it is necessary to insert screws in difficult to get
socket head types. to areas.
Self-Tapping Screws CAUTION
A self-tapping screw is one that cuts its own Self-tapping screws should never be used to
internal threads as it is turned into the hole. replace standard screws, nuts, or rivets originally
Self-tapping screws may be used only in used in the structure.
comparatively soft metals and materials. Self-tapping
screws may be further divided into two classes or Setscrews
groupsmachine self-tapping screws and sheet metal
self-tapping screws. Setscrews are used to position and hold com-
ponents in place, such as gears on a shaft. Setscrews
Machine self-tapping screws are usually used for are available with many different point styles. They
attaching removable parts, such as nameplates, to are classified as hexagon-socket and fluted-socket
castings. The threads of the screw cut mating threads headless setscrews.
in
NUTS
Aircraft nuts may be divided into two general
groupsnonself-locking and self-locking nuts.
Nonself-locking nuts are those that must be safetied
by external locking devices, such as cotter pins, safety
wire, or locknuts. The locking feature is an integral
COUNTERSUNK part of self-locking nuts.
HEAD GRIP
Nonself-locking Nuts
LENGTH
The most common of the nonself-locking nuts are
the castle nut, the plain hex nut, the castellated shear
nut, and the wing nut. Figure 5-6 shows these
nonself-locking nuts.
ROUND
HEAD GRIP
LENGTH
BRAZIER
HEAD GRIP
this chapter.
ANF0508
Figure 5-8.Sheet spring nut.
CAMLOC FASTENERS
OUTER MEMBER
STUD ASSEMBLY
RIVET
FLUSH OR
PROTRUDING
GROMMET
INNER
MEMBER
RECEPTACLE STUD
GROMMET RETAINING
RETAINING RING
RING
PROTRUDING TYPE INSTALLATION
STUD RETAINING
OUTER MEMBER
RING (USED ON
SOME FASTENERS) STUD ASSEMBLY
GROMMET
GROMMET
RETAINING
RECEPTACLE
RING
RIVET
INNER
MEMBER
RECTACLE
2 6 7
1 6
8
3
4 9
10
5
10
ANF0511
PANEL STUD
Figure 5-11.Airloc fastener.
A C
OVAL
TYPE
FLUSH
TYPE WING
TYPE
STUD
SPRING
ANF0516
ANF0518
1/4 INCH MINIMUM
TERMINALS
manual. The crimped-type terminals are generally Figure 5-20.Basic types of solderless terminals.
recommended for use on naval aircraft. Soldered-type
terminals are usually used in emergencies only.
The basic types of solderless terminals are shown An aircraft can become highly charged with static
in figure 5-20. They are the straight, right angle, flag, electricity while in flight. If the aircraft is improperly
and splice types. There are variations of these types. bonded, all metal parts do not have the same amount
of static charge. A difference of potential exists
BONDING
between the various metal surfaces. If the resistance
between insulated metal surfaces is great enough,
When you connect all the metal parts of an aircraft
charges can accumulate. The potential difference
to complete an electrical unit, it is called bonding.
could become high enough to cause a spark. This
Bonding connections are made of screws, nuts,
constitutes a fire hazard and also causes radio
washers, clamps, and bonding jumpers. Figure 5-21
interference. If lighting strikes an aircraft, a good
shows a typical bonding link installation.
conducting path for heavy current is necessary to
minimize severe arcing and sparks.
Bonding also provides the necessary low-
resistance return path for single-wire electrical
systems. This low-resistance path provides a means of
bringing the entire aircraft to the earth's potential
RECEPTACLE when it is grounded.
ASSEMBLY
COUPLING
NUT
PLUG SOCKET
ASSEMBLY
ANF0519 ANF0521
STEP 1 STEP 2
STEP 3 STEP 4
STEP 5 STEP 6
STEP 7
STEP 8
STEP 9
STEP 10
ANF0522
1 4 5
2
6 3
ANF0523 7
8
Figure 5-23.Safety wiring methods.
OIL CAPS
DRAIN COCKS
NOTE:
THE SAFETY WIRE IS
SHOWN INSTALLED
FOR RIGHT-HAND
THREADS. THE SAFETY
WIRE IS ROUTED IN THE
OPPOSITE DIRECTION
FOR LEFT-HAND THREADS.
ANF0523
VALVES
Figure 5-24.Safety wiring oil caps, drain cocks, and valves.
STANDARD FILLISTER
HEAD SCREW
(DRILLED HEAD)
ADAPTER
ANF0525 PLUG
STRAIGHT
HOOK END
SHOULDER
LOOP
HOOK END
HOOK
LOOP
LIP
HOOK
END
(A)
TURNBUCKLE
4 TURNS EYE AN170 THIMBLE
WRAP AN100
LOCK
WIRE 4 TURNS
WRAP
SWAGED TERMINAL
AN666 OR AN669
(B)
ANF0526
LENGTH WASHERS
LEARNING OBJECTIVE: Recognize the
two primary functions of washers as used in
aircraft/engine construction.
DIAMETER
Washers used in aircraft structures may be
grouped into three general classesplain, lock
UNEVEN
PRONG washers, and
OPTIONAL
ANF0527
Figure 5-27.Types of cotter pins. Figure 5-28.Cotter pin installations.
special washers. Figure 5-29 shows some of the most must not be used as part of a fastener for primary or
commonly used types. secondary structures.
PLAIN WASHERS Star Lock Washers
Plain washers are widely used under AN hex nuts The star lock or shakeproof washer is a round
to provide a smooth bearing surface. They act as a washer made of hardened and tempered carbon steel,
shim in obtaining the correct relationship between the stainless steel, or Monel. This washer can have either
threads of a bolt and the nut. They also aid in internal or external teeth. Each tooth is twisted, one
adjusting the position of castellated nuts with respect edge up and one edge down. The top edge bites into
to drilled cotter pin holes in bolts. Plain washers are the nut or bolt and the bottom edge bites into the
also used under lock washers to prevent damage to working surface. It depends on spring action for its
surfaces of soft material. locking feature. This washer can be used only once
because the teeth become somewhat compressed after
LOCK WASHERS being used.
Lock washers are used whenever the self-locking Tab Lock Washers
or castellated type nut is not used. Sufficient friction is
provided by the spring action of the washer to prevent Tab lock washers are round washers designed with
loosening of the nut because of vibration. Lock tabs or lips that are bent across the sides of a hex nut
washers or bolt to lock the nut in place. There are various
methods of securing the tab lock washer to prevent it
from turning, such as an external tab bent downward
90 degrees into a small hole in the face of the unit, an
external tab that fits a keyed bolt, or two or more tab
lock washers connected by a bar. Tab lock washers
can withstand higher heat than other methods of
safetying, and can be used safely under high vibration
conditions. Tab lock washers should be used only
once because the tab tends to crystallize when bent a
PLAN BALL SEAT TAPER PIN
second time.
& SOCKET
SPECIAL WASHERS SPECIAL WASHERS
SUMMARY
In this chapter you have been introduced to the
various types of aircraft hardware used in naval
TAB LOCK WASHER STAR LOCK WASHER ANF0529 aircraft and the procedures for maintaining their
security. It is essential that the correct hardware be
Figure 5-29.Various types of washers. used at all times for the safe and efficient operation of
naval aircraft.