Ew2 LS06

DWM40414:ENGINEERING WORKSHOP 2 / M06: MATERIALS AND HARDWARE
OBJECTIVES:
Upon completion of this laboratory, students should be able to:
1. Explain purpose, techniques and various types of locking devices and quick release fasteners
2. Recognize locking devices:
a) Split / cotter pins
b) Spring washers
c) Shake proof washers
d) Tab washers
e) Locking plate
f) Circlips
3. Explain characteristics and properties dzus quick release fasteners
4. Construct the correct installation and removal of above mention fastener and locking devices
TOOLS/EQUIPMENT (DP1):
1. Split Pin or Cotter Pin

2. Clip locking
3. Pliers (long nose, diagonal cut)
4. Turnbuckle
5. Bolt and Castellated nut
6. Training Kit
SAFETY PRECAUTION (DP5):
The Following safety precautions should be taken when using hand tool and equipment.
Precautions are most important for safety from accident
1. Lock pin and cotter pin should fit snugly in the hole provided
2. Cotter pin, lock wire and tab washer are should only use once only
3. Lock washers should never be used under the following conditions:
i. With fasteners to primary or secondary structures
ii. With fasteners on any part of the aircraft where failure might result in damage or
danger to the aircraft or personnel
iii. Where failure would permit the opening of a joint to the airflow
iv. Where the screw is subject to frequent removal
v. Where the washers are exposed to the airflow
vi. Where the washers are subject to corrosive conditions
vii. Where the washer is against soft material without a plain washer underneath to
prevent gouging the surface
EW2/LS-06/REV02/15JANUARY2024 Page 2 of 6
THEORY (DP1):
1. EXPLAIN THE USE OF LOCKING DEVICES
In some cases, locking devices may require additional evaluation to ensure that they comply with safety
regulations. It is the responsibility of the aircraft owner to establish whether the locking device complies
with safety regulations and standards prior to deploying such locks, either directly by way of certification
from the locking device supplier, or by contacting your aircraft maintenance engineer.
A positive locking device is a device used in conjunction with a fastener in order to positively lock the
fastener. This means that the fastener cannot work loose from vibrations.
2. IDENTIFY VARIOUS TYPES OF LOCKING DEVICES
Boots Self-Locking Nut

The Boots self-locking nut is of one piece, all-metal construction, designed to hold tight in spite of
severe vibration. It has two sections and is essentially two nuts in one, a locking nut and a load-
carrying nut. The two sections relate to a spring which is an integral part of the nut.
Stainless Steel Self-Locking Nut

The stainless-steel self-locking nut may be spun on and off with the fingers, as its locking action
takes place only when the nut is seated against a solid surface and tightened. The nut consists of
two parts: a case with a beveled locking shoulder and key, and a threaded insert with a locking
shoulder and slotted keyway.
Plain Washers
Plain washers both the AN960 and AN970, are used under hex nuts. They provide a smooth bearing
surface and act as a shim in obtaining correct grip length for a bolt and nut assembly. They are used
to adjust the position of castellated nuts in respect to drilled cotter pin holes in bolts. Use plain
washers under lock washers to prevent damage to the surface material.
Shake proof Lock washers

Shake proof lock washers are round washers designed with tabs or lips that are bent upward across
the sides of a hex nut or bolt to lock the nut in place. There are various methods of securing the lock
washer to prevent it from turning, such as an external tab bent downward 90° into a small hole in
the face of.
Cotter Pin
A split pin, also known in the United States as a cotter pin or cotter key, is a metal fastener with two
tines that are bent during installation, like a staple or rivet. Typically made of thick wire with a half-
circular cross section, split pins come in multiple sizes and types. There are 2 methods of
installing cotter pin: Preferred Method and Optional Method.
3. IDENTIFY LOCKING DEVICES PARTS
PROCEDURE (DP7):
Cotter Pin Installation on the training kit
1. Select the correct cotter pin size and material

2. The pin should be the largest size possible for the hole to ensure that the pin will not wiggle in
the bolt.
3. Insert the cotter pin into the hole of the bolt until the head of the pin rests against the bolt.
4. Secure the cotter pin by spreading the prongs in opposite directions, using pliers if desired.
5. Use diagonal cutters to cut excess length from either prong, according to application standards.
6. Cutting the prongs to the correct length helps when it is time to replace the pin.
7. The prongs must be long enough to prevent the pin from slipping back out through the bolt.
8. Repeat the cotter pin installation procedure for Optional Method and Preferred Method.
Clip Locking Installation
1. The clip-locking method of safetying uses an NAS lock clip.

2. To safety the turnbuckle, align the slot in the barrel with the slot in the cable terminal.
3. Hold the lock clip between the thumb and forefinger at the end loop.
4. Insert the straight end of the clip into the aperture formed by the aligned slots.
5. Bring the hook end of the lock clip over the hole in the center of the turnbuckle barrel and seat
the hook loop into the hole.
6. Application of pressure to the hook shoulder at the hole will engage the hook lip in the turnbuckle
barrel and complete the safety locking of one end.
7. The above steps are then repeated on the opposite end of the turnbuckle barrel.
8. Both locking clips may be inserted in the same turnbuckle barrel hole, or they may be inserted in
opposite holes.
RESULT (DP4):
1. Provide 3 pictures of your product consisting of:

i. Clip Locking on turnbuckle,
ii. Cotter Pin Optional Method,
iii. Cotter Pin Preferred Method of your result.
Every picture must have title.
DISCUSSION (DP3):
1. From the practical, identify problems that you have encountered and how you solve them.
2. Discuss the importance of locking device.
3. Identify and explain REAL INCIDENT in aviation happened because of improper locking device
application.
CONCLUSION (DP2):
Conclusion based on objectives. Were your objectives achieved or not. If NOT, explain WHY.
REFERENCES:
State references used from any sources e.g books, internet, journal including Page Block/Maintenance
Manual.
Please follow IEEE reference format.
ASSESSMENT:
The course assessment consists of:
Coursework Assessment (CA) - 100%
Coursework assessments that measure knowledge, practical skills and generic skills are carried out in
the form of continuous assessment. Coursework assessments total score comprises the knowledge and
practical marks ONLY. It does not include the mark of generic skills.
Assessment Method Quantity Percentages Topic

Practical Report (Group) 5 10% Report 1: Topic 2 - Wire Locking
Report 2: Topic 3 - Bending
Report 3: Topic 3 - Patch Repair
Report 4: Topic 4 -Torque Loading
Report 5: Topic 4 - Locking Device
Practical Performance (A) 1 10% Topic 1 - 4
Practical Performance (P) 1 10% Topic 2 - 4
Oral Assessment 1 10% Topic 1 - 4
Practical Task 5 60%
i. Lock wire (15%) Topic 2: Wire Locking
ii. Aircraft Sheet Metal - (10%) Topic 3: Bending
Folding, Bending, Cutting
Stretching, Rolling And
Spinning
iii. Aircraft Sheet Metal – (25%) Topic 3: Patch Repair
Patch Repair And
Riveting
iv. Torque Loading (5%) Topic 4: Torque Loading
v. Locking Devices (5%) Topic 4: Locking Device

Total 100%

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DWM40414:ENGINEERING WORKSHOP 2 / M06: MATERIALS AND HARDWARE

1. Split Pin or Cotter Pin

SAFETY PRECAUTION (DP5):

1. EXPLAIN THE USE OF LOCKING DEVICES

2. IDENTIFY VARIOUS TYPES OF LOCKING DEVICES

Boots Self-Locking Nut

Stainless Steel Self-Locking Nut

Shake proof Lock washers

3. IDENTIFY LOCKING DEVICES PARTS

Cotter Pin Installation on the training kit

1. Select the correct cotter pin size and material

Clip Locking Installation

1. The clip-locking method of safetying uses an NAS lock clip.

1. Provide 3 pictures of your product consisting of:

Every picture must have title.

Please follow IEEE reference format.

The course assessment consists of:

Coursework Assessment (CA) - 100%

Assessment Method Quantity Percentages Topic

v. Locking Devices (5%) Topic 4: Locking Device

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