RULES OF THUMB AND OTHER MYTHS 6


INTRODUCTION OF AIRCRAFT STRUCTURAL REPAIR TECHNIQUES FOR MECHANICS BY AN ENGINEER. This Blog’s target audience is A&P sheet metal mechanics and new structural engineers. Feel free to comment or ask questions.

Visit our website at www.Callahan.aero or e-mail us at der@callahan.aero for any questions or subject interest.

Posts will be on Mondays containing technical, quotes, and stories. The technical will be excerpts from my book or by request, quotes will be from several humor and historical sources, my personal stories, and some marketing I’m a capitalist).

I’ve decided to present my new book by way of online classes. Each chapter will be a class segment. Each module will be available online for a fee. This seems to be the future but it does allow me to teach a chapter at a time with no travel costs or hassles. There will be interaction by in class work and email. Access to me will also be available. Need feedback, what say you?

“1.5 e/d is okay” is NOT a good rule of thumb

Working the B757 start up on unit three (I think), we had a manufacturing boo boo. The shop installed the skin rivets all around the emergency exit door cutout with 2.0 e/D.  Isn’t that nice but when that barrel section went in for final company or FAA inspection it failed.  Why? Because the drawing required 2.5 e/D edge margin.

We figured the skin cutout’s corners lost one third of their life.  This means the probability of skin cracks was high after two thirds (20 years) of the B757 design life of 30 years.  The Liaison and Stress engineers from both the vendor and Boeing agreed it was unacceptable. But not manufacturing who complained through the Boeing Chief of Design, Jim to the DER, Pete. They agreed it was acceptable and I was informed to “buy it off.”  Little ol me, the peon sole On-site Liaison Engineer to the vendor was indirectly told to accept the damage as is.

Passionately I called the Boeing Chief of Design to tell him what for and heck no. He wasn’t known to be real nice to subordinates (remember the Peter Principle) but he was nice to me.  Lucky for me I took a Boeing fatigue class (that my Lead informed me was a dumb thing to do) because Jim walked me through their decision process by asking me Boeing technical fatigue and  historical maintenance issue questions. We had NO data on this never before completely fatigue designed aircraft! (You CHS engineers working for Tony pay attention) We were using Boeing’s DFR process for design and analysis for the first time. I answered his questions and he summed it by asking me if a crack IF it occurred on THIS aircraft would go UNDETECTED prior to a catastrophic failure (crash and burn).

The answer was “no.”

“And who is taking responsibility for it?”

“Rockwell,” the vendor I replied.

“And who would be paying for the repair?”

“Rockwell,” I replied.

He was willing to accept a low probability of a hit to Boeing’s reputation so I concurred on the acceptance on Rockwell’s paperwork.

The section rolled out, shipped, and received by Boeing in Renton just as I returned from my assignment. Boeing arrogance would not allow them to accept Rockwell acceptance so they wrote Boeing paperwork so Boeing accepted it.  I was the turkey to approve the acceptance but this time the DER consigned.  So much for the vendor taking responsibility. And a few years later Boeing bought that plant from Rockwell and therefore accepted the repair costs if any.

The point to that story is Boeing Commercial did use airplanes to make money not money to make airplanes like they do now.

A short comment about composite’s end or edge margin requirements.  2.5 e/d is the usual EM requirement but 3.0 e/d isn’t abnormal for graphite or fiberglass composite structure compared to most metals.  I don’t remember the requirements for plywood (used on C-130) or wood laminates. Yes, they are composites too making the Wright “Flyer” the first all composite aircraft. Beech’s Chief Engineer Wells book on structural guidelines includes good data for wood and resins and I would go there first, maybe the DC-3 SRM or AN5 Handbook (Army/Navy predecessor to MIL-HDBK-5) second.

DERs are only required for Major Repairs and the A&P mechanic makes that decision whether or not the repair is a Major Repair. Unlike engineers, DERs are a source for approved data and don’t answer to the A&P mechanic nor FSDO or MIDO.  A DER answers to the FAA ACO.

But y’all, DERs do take questions and are on the same team.  Most DERs are comfortable in their role and don’t mind giving free advice and aviation professionals.

CALLAHAN AIRCRAFT SERVICES CURRENT PROJECTS:

Next week’s topic will be “what is a DER” and coming soon topics will include identifying a shear joint and why some engineers or ARs don’t explain requirements making one feel small. AND shimming

O x y m o r o n s

Click the ‘Start’ button to Shut Down the computer.

Words of Wisdom and Warning

“It is the duty of the patriot to protect his country from its government.”
Thomas Paine

Aged to perfection

Peace is when time doesn’t matter as it passes by.

Sincerely,

James W. Callahan

General Manager / FAA DER

DER@CALLAHAN.AERO

256-891-3677
P.O. BOX 533
Albertville, AL 35950