RAJALAKSHMI ENGINEERING COLLEGE

BE AERONAUTICAL ENGINEERING
SEMESTER VI
AE-6611 : AERO ENGINE AND AIRFRAME LAB
LIST OF EXPERIMENTS
1. AIRCRAFT WOOD GLUING-SINGLE SCARF JOINT
2. WELDED SINGLE AND DOUBLE V JOINT
3. PATCH REPAIR WORK ON PERPEX
4. LAP AND BUTT JOINT BY RIVETTING
5. PIPE BENDING AND FLARING
6. MAKING A CHANNEL SECTION BY BENDING ALUMINIUM STRIP
7. PREPARATION OF FIBRE GLASS EPOXY REINFORCED COMPOSITE LAMINATES
8. DISMANTLING AND REASSEMBLING OF AN AIRCRAFT PISTON ENGINE
9. STUDY OF CARBURETOR
10. CRANKSHAFT RUNOUT CHECK
11. INTRODUCTION TO AIRCRAFT RECIPROCATING ENGINE AND ITS COMPONENTS
12. JET ENGINE Identification of component defects
AUGMENTED EXPERIMENTS
13. NDT USING OIL AND WHITE CHALK METHOD
14. NDT BY USING ELECTROMAGNETIC YOKE METHOD
(A) DRY METHOD & (B) WET METHOD
15. NDT USING FLUORESCENT PENETRANT METHOD

AIRCRAFT WOOD GLUING SINGLE SCARF JOINT

EXPT.NO:

DATE:

AIM:
To make an aircraft wood gluing by using single scarf joint.
THEORY:
Scarf joints are often used in boat building. A scarf joint is a long angled joint.
The long angle provides a lot of "glue surface" for the joint, making it very strong.
A scarf joint is made by joining two pieces of wood having tapered, beveled, or
chamfered ends which over-lap together, as opposed to a butt joint where squared ends of
the mating pieces simply butt together. Scarf joints are used to make longer members
where single members of sufficient length are not available or are too costly. Both solid
wood pieces and sheets of plywood can be scarf joined using epoxy. With the proper
cutting and gluing methods, such joints will be amazingly strong, exceeding that of the
joining wood members.
With scarf joints, it is preferable for the two pieces to fit as closely as possible for
ultimate strength. However, minor irregularities of fit are acceptable since the epoxy will
have the ability to bridge these without significant loss of strength.
APPARATUS REQUIRED:
1. Marking tools
2. Measuring tools
3. Bench vice
4. Cutting tools
5. Jack plane
6. Rasp file

MATERIAL REQUIRED:
Soft wood of size:

mm

DIAGRAM:

Fig.1 Aircraft wood gluing-single scarf joint

PROCEDURE:
1. The given work piece is firmly clamped in the carpentry vice.
2. Using the try square, the right angles of the faces are checked.
3. Using the steel rule, make a mark at the centre of the work piece.
4. Using the try square, make a right angle mark at the centre of the work piece.
5. Using the steel rule, make a mark ( mm) from the centre of the work piece to both
right and left end.
6. Using the try square, make a right angle mark mm from the centre of the work
piece to both right and left end.
7. Repeat the above steps for the other side of the work piece and mark a diagonal for
scarf joint.
8. Using the steel rule and marking gauge, marking is done for single scarf joint.
9. Using the cutting tool makes the cut and in one half, the unwanted portions of
wood are removed by using the tenon saw and firmer chisel. The same procedure is done for
the other half of work piece.
10. The finished two pieces are glued together to form the scarf joint.

RESULT:
Thus the required single scarf joint is obtained.
VIVA-VOCE QUESTIONS:
1. What is scarf joint?
2. Where the scarf joint is used?
3. What is the difference between butt joint and scarf joint?
UNIVERSITY QUESTIONS:
1. Make single scarf joint in the given work piece as per the given dimensions.

WELDED SINGLE AND DOUBLE V JOINT

EXPT.NO:

DATE:

AIM:
To join the given work pieces as a single and double V butt joint by arc welding.
THEORY:
Welding is the process of joining similar metals by the application of heat. Welding can
be done with or without application of pressure. While welding, the edge of metal piece
are either melted or brought to a plastic condition. Welding can be done with the addition
of filler material or without it. Welding is used for making permanent joints.
Types of welding
There are two types of welding process. They are
1. Plastic welding
2. Fusion welding
Plastic welding
In plastic welding the metal pieces are heated to a plastic state. Then they are
pressed together to make the joints. The plastic welding is also known as pressure
welding. During plastic welding there is no filler metal is required.
Example: spot welding, projection welding.
Fusion welding
In fusion welding the metal at the joint is heated to a molten state. Then it is
allowed to solidify. Pressure is not applied in this welding process. Addition of filler
metal is required for this type of welding. So it is known as non-pressure welding.
Example: gas welding, arc welding.
Arc welding
Arc welding is the process of joining two metal pieces by melding their edges by
an electric arc. The electric arc is produced between to conductors. The electrode is one
conductor and the work piece is another conductor. The electrode itself melts and
supplies the necessary filler metal.

MATERIAL USED:
Mild Steel plates
TOOLS REQUIRED:
Welding power supply
Flat file
Welding rod
Chipping hammer
Electrode holder
Wire brush
Gloves and apron
Earthing clamps
Shield and goggles
PROCEDURE:
For single V joint,
0

1. Fix the first work piece in the bench vice, make chamfering to the bevel angle 30 on
right side and maintain the root face of m.
2. Fix the second work piece in the bench vice, make chamfering to the bevel angle
0

30 on left side and maintain the root face of m.

3. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and other
foreign materials.
4. Then the given work pieces are placed on the table in such a way that work pieces are
brought close to close to each other so that it forms a V shapes when the plates butt each
other.
5. Appropriate power supply should be given to the electrode and the work pieces.
6. Now the welding current output may be adjusted.
7. When current is passed, arc is produced between electrode and work piece.
8. Now set the two work pieces in correct position and maintain the gap 3mm and tag at
both ends of the work pieces as shown in figure.
9. Then the welding is carried out throughout the length.

10. As soon as the welding process is finished, switch off the current supply and allow
the work piece to cool.
11. Slag is removed by chipping process with the help of chipping hammer.
12. Finally using wire brush, welded portions are cleaned.
For double V joint,
1. Fix the first work piece in the bench vice, make chamfering to the bevel angle 30 0 on
right side to the depth of

m.

2. Fix the other side of first work piece in the bench vice, make chamfering to the bevel
angle 300 on right side to the depth of

m.

3. Fix the second work piece in the bench vice, make chamfering to the bevel angle 30 0
on left side to the depth of

m.

4. Fix the other side of second work piece in the bench vice, make chamfering to the
bevel angle 300 on left side to the depth of

m.

5. First of all, the work pieces must be thoroughly cleaned to remove rust, scale and other
foreign materials.
6. Then the given work pieces are placed on the table in such a way that work pieces are
brought close to close to each other so that it forms a V shapes when the plates butt each
other.
7. Appropriate power supply should be given to the electrode and the work pieces.
8. Now the welding current output may be adjusted.
9. When current is passed, arc is produced between electrode and work piece.
10. Now set the two work pieces in correct position and maintain the gap 3mm and tag at
both ends of the work pieces as shown in figure.
11 Then the welding is carried out throughout the length.
12. As soon as the welding process is finished, switch off the current supply and allow
the work piece to cool.
13. Slag is removed by chipping process with the help of chipping hammer.
14. Finally using wire brush, welded portions are cleaned.

DIAGRAM:

Fig.1 Root diagram for single V joint

Fig.2 Root diagram for double V joint

RESULT:
Thus the required single and double V butt joint is made by arc welding process.

VIVA-VOCE QUESTIONS:
1. What is a root face?
2. What is a root gap?
3. What is the difference between single and double V joint?
UNIVERSITY QUESTIONS:
1. Make the patch repair by single and double V joint in the given work piece.

PATCH REPAIR WORK ON PERPEX

EXPT.NO:

DATE:

AIM:
To learn permissible repair practices on transport surfaces and side windows.
REQUIREMENTS:
Rough file 12
Smooth file 6
Round file 6
Steel file 6
Hand vice
TOOLS REQUIRED:
Man hour 3
Man power 1
Document Aircraft repair model
Perpex 6mm thickness
Synthetic glue
PROCEDURE:
1.
2.
3.
4.

Size the given piece accurately.

Dressing of damaged area is done.
Marking of patch piece is done.
Glue is applied and pasted.

RESULT:
The repair work is carried out successfully and checked for
any crack after application of patch and found satisfactory.

LAP AND BUTT JOINT BY RIVETING

EXPT.NO:

DATE:

AIM:
To carry out a repair on aircraft metal skin by making a Lap and Butt joint.
THEORY:

Rivets are a permanent mechanical fastener. Before being installed a rivet consists
of a smooth cylindrical shaft with a head on one end. The end opposite the head is called
the buck-tail. On installation the rivet is placed in a punched or drilled hole, and the tail is
upset, or bucked (i.e., deformed), so that it expands to about 1.5 times the original shaft
diameter, holding the rivet in place. To distinguish between the two ends of the rivet, the
original head is called the factory head and the deformed end is called the shop head or
buck-tail.
Because there is effectively a head on each end of an installed rivet, it can support
tension loads (loads parallel to the axis of the shaft); however, it is much more capable of
supporting shear loads (loads perpendicular to the axis of the shaft). Bolts and screws are
better suited for tension applications.
Fastenings used in traditional wooden boat building, such as copper nails and clinch
bolts, work on the same principle as the rivet but were in use long before the term rivet
was introduced and, where they are remembered, are usually classified among nails and
bolts respectively.
TOOLS REQUIRED:

Steel ruler
Hammer
Chisel
Tri square
Scribber
Snap and file
Hand vice

APPARATUS REQUIRED:

Bench vice
Electrical drilling machine
Hand riveting tool

REQUIREMENT:
1. Aluminium sheet of 60 X 60mm
2. Aluminium rivets of 3mm diameter(blind and solid head)
PROCEDURE:

1. Size the given plate accurately with the smooth file.

2. Mark the given workpiece according to the given dimension.
3. Punch the workpiece with centre punch and hammer.
4. Drill the holes with electric drill.
5. Rivet using Hand riveting gun and Air riveting hammer.

RESULT:
The repair on an aircraft metallic skin by making a lap and butt joint is carried out
Successfully.

PIPE BENDING
EXPT. NO:

DATE:

AIM:
To carryout bending of aluminum tube with the help of bending machines.
REQUIREMENT:
1. Aluminium pipe of 10mm diameter.
2. Filler material.
TOOLS REQUIRED:
1.
2.
3.
4.

Radius bend bar.

Bench vice.
Smooth file
Hack saw

PROCEDURE:
1. Size the pipe to correct length.
2. Clean the pipe and check if for any obstruction.
3. Fill the pipe with filler material.
4. Hold the pipe in the radius bend as per the procedure given in the manual.
5. Select the former, guides, adjustable shop as per the diameter of pipe.
6.Apply pressure gently, should not be given jerk while applying pressure and bend
it to correct angle.
7.Check the locking before bending.

RESULT:
Pipe bending is carried out successfully as per requirements.
VIVA-VOCE QUESTIONS:
1. What are the types of bend?
2. What are the different methods of tube bending?
UNIVERSITY QUESTIONS:
1. Make the tube bending in the given work piece.

PIPE FLARING
EXPT. NO:

DATE:

AIM:
To renew the damaged tube length with necessary end fittings and flaring
to prevent fluid damage.
THEORY:
Flare fittings are a type of compression fitting used with metal tubing, usually soft
steel and ductile (soft) copper, though other materials are also used. Tube flaring is
considered to be a type of forging operation and is usually a cold working procedure.
During assembly, a flare nut is used to secure the flared tubing's tapered end to the also
tapered fitting, producing a pressure-resistant, leak-tight seal. Flared connections offer a
high degree of long-term reliability and for this reason are often used in mission-critical
and inaccessible locations.
The tool used to flare tubing consists of a die that grips the tube and a mandrel
that is forced into the end of the tube to form the flare by cold working. The most
common flare fitting standards in use today are the 45-degree SAE style, and the 37degree AN style, also used with the JIC system. The AN/JIC style generally has a higher
pressure rating for a given size tubing. SAE and AN/JIC fittings are completely
incompatible due to the different flare angle. Further, AN fittings (or those complying
with subsequent standards) and JIC fittings are not interchangeable for design-controlled
applications due to differing quality standards.
MATERIALS REQUIRED:
Document Aircraft Maintenance Manual
Aluminum pipe of 10mm diameter.

TOOLS REQUIRED:

Flaring tool
Rough file

DIAGRAM:

Fig.1 Tube flaring

Fig.2 Types of flaring

PROCEDURE:
1. Shape and size the pipe.
2. Slide in the sleeves and nuts as shown in drawings.
3. Open the damp screw of the flaring tool, insert the tube to flared clamping blocks
tighten the clamp screw.
4. Ensure 2mm protrusion of pipe above the clamping block and tighten the clamp
screw.
5. Give the required amount of flaring.
6. Repeat the same for flaring at the other end of pipe.
RESULT:
Thus the desired amount of flaring is made in the pipe.
VIVA-VOCE QUESTIONS:
1. What is flaring?
2. What is need of flaring?

UNIVERSITY QUESTIONS:
1. Make the tube flaring in the given work piece.

MAKING A CHANNEL SECTION BY BENDING ALUMINIUM STRIP

EXPT. NO:

AIM:
To learn hand forming process by bending a strip into channel section.
REQUIREMENTS:
1.
2.
3.
4.

Aluminum sheet of 1.2mm thickness

Operation hour 2
Man power 1
Aircraft repair manual

TOOLS REQUIRED:
1.
2.
3.
4.
5.
6.

File
Tri square
Steel ruler
Vernier caliper
Bench vice
Surface plate and Vee block

PROCEDURE :
1. Size the given piece accurately.
2. Mark in the metal sheet using scribber.
3. Bending the aluminium metal sheet by using Vee block.
4. Wooden mallet is used to beat aluminum sheet into C shape.

DATE :

RESULT:
The bending of aluminium strip is carried out successfully.

PREPARATION OF FIBRE GLASS EPOXY REINFORCED

COMPOSITE LAMINATES
EXPT. NO:

DATE :

AIM:
To prepare the fibre glass epoxy reinforced matrix composite laminate.
MATERIALS USED:
1.
2.
3.
4.
5.
6.

Steel ruler
Epoxy
Files
Fibre glass
Wax of mustard oil
Curing agent: hardener (polyamine)

PROCEDURE:
1. Spread the wax (or) mustard oil over the file.
2. Weight glass fibre and take the quantity of epoxy.
3. Prepare the entry by adding equal amount of hardness.
4. Pour the epoxy resin over the wax and spread it with steel ruler.
5. Place the glass fibre over the resin
6. Again powder the epoxy resin over the glass fibre and spread it with steel ruler.
7. Place another glass fibre over the spreading epoxy resin.
8. Repeat the same procedure for about the layer of glass fibre.
9. Place another board till above the wax and load it.
10. Allow the laminate to core.
DESCRIPTION OF PREPARATION OF GLASS FIBRE REINFORCED POLYMER HAND
LAY-UP METHOD:
The hand lay-up is one of the oldest and most commonly used methods for manufacturing
composite parts. Hand lay-up composite are a case of continuous fibre reinforced composites. Layers
of unidirectional or woven composite are combined to result in a material exhibiting desirable
properties in one or more directions. Each layer is oriented to achieve the maximum utilization of its
properties. Layers of different materials (dye fibre in different direction) can be combined to further
enhance the overall performance of the laminated composite material. Resins are impregnated by hand
into fibres which are in the form of woven, knitted, stretched or bonded fabrics. This is usually
accomplished by rollers or brushers with an increasing use of up roller type impregnated for forcing
resin into the fabrics by means of rotating rollers and a bath of resin. Laminates are left to cure under
standard atmospheric condition to typical hand lay- up method is shown.

ADVANTAGES:
1. Design flexibility.
2. Large and complex items cant be produced.
3. Tooling cost is low.
4. Design changes are easily affected.
5. Sandwich construction are possible.
6. Semi skilled workers are needed.
DISADVANTAGES:
1. Only one moulded surface is obtained.
2. Quality in related to the skill of operation.
3. Low volume process.
4. Longer cure time required.
5. Resin needed to be low in viscosity to be workable by hand. Then generally compromises their
mechanical/thermal property.
6. The waster factor can be high.
APPLICATION :
Standard wind turbine blades, productive boats, architectural moldings.

RESULT:
Thus the fibre glass epoxy reinforced matrix composite laminated has been prepared.