1 Aircraft arrives in S.A.L.

AircraWRun-u Test - Fuel to Local Aircraft Paint

only Disposal Company

I inspected I I Tech Wash I Parts removed to Shops I

I

I

I

Usin water on1 U Sheetmetal - I

Inspections and Maintenance Work

Defect Rectification Function Checks

Aircraft sealed PR1440 or PR1442

Anti Corrosion Treatment LPS3 or Dinitrol

- Non Destructive Testing i ) - Corn osites 4- U holst

Interiors & on Aircraft

I

To Maintenance Hangar for -n Final Ins ections & Testing

Engine Oil I Exterior Polishing

Using Buffers

I

En ineTestin - I

Aircraft leaves facility

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Aircraft Arrives in SAL

Mechanically Aircraft stripped - Mechanically or Chemically

Aircraft washed with Jet clean Waste Water to Clare County Council

Chemically

I j

I I I

I I Yellow (1st) Primer I

underneath aircraft. All waste stripperMudge gathered and

Chromate containing primer Waste Disposal Contractor takes all waste products away

I

I Grey (2nd) Primer Chromate Free

Aviox Hardeners Thinners

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in shop

I I

Disassembly

Inspection

i

Re-assembly and Act (Corrosion prevention)

and Lubrication

I Aircraft parts out I

Flight Controls

Parts are cleaned using water and white spirits. No Waste Products

Panels are removed and parts are disassembled to facilitate full inspections

Parts are thoroughly inspected and defects documented.

During overhaul and repair, Sealants and Corrosion Preventitive Compounds are used: PRC 1422/PRC 1436 Sealants. Mastinox - Corrosion Prevention No Waste from either product.

Parts are lubricated using grease 16,28,7. LPS 3 & AV30. A Corrosion Inhibiting Compound is applied to all parts before they are paneled up.

Epoxy Primer is also used to touch up parts and Alodine which is a Corrosion Inhibiting Solution for Aluminium.

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COMPOSITE WORKSHOP PARTS

Damage Assessment e Aluminium Assemblies \

I

I Damage Removal I

\ Repair Parts Fabrication

I

I Abrade Repair Area I Clean repair area with

Solvent (Acetone)

Alodine and prime repair area and repair

I y a i r parts and cure under Heat

".". and Vaccum - Seal repair area

k I Fibrous Components I

Clean repair area with Solvent after abrading

Lay-up repair plies (Carbon, glass fibre) using epoxy resin.

Vacuum bag repair and cure under heat.

i

Seal repair area after bonding.

Final Inspection after repair

[Parts routed to next workstation 1

/

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FLOW CHART ITEMS FOR N.D.T. INSPECTIONS

Shops: Composite Mechanical Sheetmetal 1 Sheetmetal 2

RADIOGRAPHIC INSPECTION Chemicals Used: DevelopedFixer

PENETRANT INSPECTION Chemicals Used:Developer, Cleaner, Penetrant

MAGNETIC PARTICLE INSPECTION Cleaner, Magnetic Particle Bath.

INSPECTION PERFORMED BOTH ON THE AIRCRAFT AND IN THE N.D.T. AREA

ITEMS USED IN N.D.T. PROCEDURES

41) X-Rays

42) Film Developer and Fixer

43) Solvent Cleaner Aerosol Can

44) Developer Aerosol Can

45) Penetrant Aerosol Can

Lines 1 - 5 I

46) Magnetic Particle Bath

MANUFACTURERS OF CHEMICALS USED N.D.T.

Product Manufacturer of Chemicals Fixer Kodak Developer Kodak Solvent Cleaner Penetrant Magnaflux Magnetic Particle Bath Magnaflux

Magnaflux (Cotter Marketing Cork)

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3 Mechanical Workshop Flowchart

or Part arrives from Line

I Material for Fabrication or repair ordered I

L

Cadmium Plate Parts Cleaned

v b by Approved Prepared

Part Fabricated or Method

Repaired as per Approved Data

carried out per

Fabricated Part issued

Work Order

4 Paperwork completed

and Certified b to stores with Internal e Repair part issued to Line Paperwork given to relevant

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Seat Shop 0 I

I Seats received from Aircraft

Cleaned and Inspected 3 I L

I I

Damaged Covers sent to Upholstry

Sheetmetal, Repaired covers Laminate repairs

carried out or parts

11 I I Unit Reassembled 3 1 Return to Aircraft or Shop

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* "

SHEETMETAL 1

Functions

Heat Treatment & Fabrication of N C

Material Used: Materials Used: Materials Used: Sealant - PR 142Z1440

Primer - Zinc Chromate

Mastinox

Alu Alloy Steel Argon gas, Titanium rods Alu rods Alodine 1200

Waste Materials No Waste Materials Burnt gases I

Main functions of the Sheetmetal Shop is to support line maintenance This is done by

.(I) Fabrication of new aircraft parts in accordance with Boeing and Doughas standards and with detailed drawings of the part to be Fabricated

Heat Treatment of Fabricated parts in accordance with Boeing standards S R M SI-20-02 or Douglas standards S R M SI-10-2A depending on aircraft part

Welding of aircraft parts e g ducts, pipes. brackets are welded in accordance with DPS 10-301 or BAC 7975 depending on Aircraft part

Repair and overhaul of aircraft doors Doors are sent from the line to the shop for repairs major or minor e g skin change and overhaul which can include complete strip down and reassembly of door mechanics in accordance with the relavant overhaul manual or S R M ChpSZ

.(2)

.(3)

.(4)

t

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I Upholstry Shop I I

I I Blankets Galley floor cover Dividers and /'e'\ Cleaned and Units cleaned

- No

fc - New carpet or floor cover cut

New Blanket Fabrication using fiberglass and foil ---El- cover

'I - Back of floor cover taped

Damaged decor removed using Heat guns and scrapers I

out using Blanket patch

Spray Adhesive

Unit returned

1 Aircraft or other Shop

e

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Interiors 0 Sidewall, Floor, Ceiling cargo

I and Cockpit panels

Units Cleaned and Inspected 1

Fault found v Unit Disassembly

c Decorative parts sent to Upholstiy

Fiberglass, Honeycomb Part returned from repair carried out or part Upholstry Shop

I

I I

)Unit Tested and returned 1

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1 Galleys Shop I

I Parts received from Aircraft or other Shop

I I I Faults No fault found found

1 Unit disassembled 1

sent to Upholstry Parts replaced or

Sheetmetal, Composite Plumming & Electrical

repairs carried out

e

I

I Lavs 3

Cleaned and Inspected

I , I I ' No Fault Fault found found I

Unit Disassembled

Decorative parts Composite, Plumming sent to Upholstry and Electrical repairs

carried out or parts

I to Aircraft I

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This page has been inserted to indicate that content has been extracted from this location-in the

document and has be.en stored in a, separate file. (This is due to file size issues.)

The extracted content can be found in the foll electronic pdf file:

Application Form-Drawing- 1

Licence: POO69-02

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