Sheet Metal & Bonded Structures
Sheet Metal & Bonded Structures is a core knowledge area on the AMT — Airframe FAA written exam. This hub collects our 16 in-depth, ACS-aligned sheet metal & bonded structures articles — each written in plain English and grounded in the official FAA handbooks. Work through them below, then drill the topic with practice questions.
Aircraft Sheet Metal Alloy Designations and Temper Codes
Aircraft sheet metal is identified by standardized alloy and temper codes that define composition, strength, and heat-treatment state — knowledge essential for every airframe technician making structural repairs.
Rivet Types and Material Selection for Airframe Repair
Rivets are the backbone of metal airframe construction; selecting the correct type and material for each repair is critical to both structural integrity and airworthiness.
Rivet Spacing, Edge Distance, and Pitch Requirements
Proper rivet spacing, edge distance, and pitch are critical to sheet metal structural integrity; incorrect values cause stress concentrations, sheet tear-out, and failed FAA inspections.
Sheet Metal Layout and Bend Allowance Calculation
Sheet metal layout and bend allowance calculation are foundational AMT skills that ensure fabricated parts fit precisely and maintain structural integrity without cracking or distorting at bends.
Dimpling and Countersinking Techniques for Flush Rivets
Flush rivets require either dimpling or countersinking to seat the head below the skin surface; choosing the right method depends on material thickness, rivet size, and structural requirements.
K-Factor and Setback in Sheet Metal Brake Forming
The K-factor and setback are essential sheet metal calculations that tell technicians exactly where to mark bend lines so finished parts match blueprint dimensions precisely.
Rivet Hole Drilling, Deburring, and Reaming Procedures
Proper rivet hole drilling, deburring, and reaming are foundational sheet metal skills that directly affect joint strength and fatigue life in aircraft structures.
Solid Shank Rivet Installation and Bucking Bar Techniques
Solid shank rivets form the backbone of aircraft sheet metal construction; mastering installation technique and bucking bar selection ensures strong, airworthy joints every time.
Blind Rivet Types and Installation for Limited-Access Repairs
Blind rivets allow secure structural fastening where only one side of the work is accessible, making them essential for sheet metal repairs in enclosed or hard-to-reach aircraft structures.
Sheet Metal Damage Classification and Repair Eligibility
Learn how FAA-certificated airframe technicians classify sheet metal damage into four categories and determine whether a structure can be repaired or must be replaced, grounded in AC 43.13-1B and related handbooks.
Allowable Damage Limits and Repair Substantiation Using SRM
Structural Repair Manuals (SRMs) define allowable damage limits and approved repair procedures for aircraft sheet metal and bonded structures, guiding AMTs through substantiated, airworthy repairs.
Splice Plates and Doubler Design for Sheet Metal Structural Repair
Splice plates and doublers restore load-carrying ability to damaged sheet metal aircraft structure by distributing stress across a repaired joint; understanding their design rules is essential for AMT airframe certification and FAA knowledge tests.
Fretting Corrosion and Dissimilar Metal Considerations in Airframe Joints
Fretting corrosion and dissimilar metal galvanic reactions silently destroy airframe joints; understanding their causes, detection, and prevention is essential for every AMT working with sheet metal and bonded structures.
Detecting Disbonds and Delaminations in Bonded Panels
Disbonds and delaminations silently destroy composite and bonded metal panel strength; AMTs must recognize their causes, apply the correct inspection methods, and understand the FAA-accepted repair limits before returning aircraft to service.
Bonded Repair Procedures and Core Replacement in Honeycomb Sandwich Structures
Honeycomb sandwich structures combine light weight with exceptional strength, and proper bonded repair procedures—from damage assessment through core replacement and adhesive cure—are critical to restoring structural integrity safely.
Adhesive Bonded Structure Types and Construction Principles
Adhesive bonded structures join aircraft components using structural adhesives rather than mechanical fasteners, offering superior fatigue resistance and weight savings critical to modern airframe design.
More AMT — Airframe subjects
Articles are original summaries grounded in the public-domain FAA handbooks and cite their source. ACS-aligned study aids — not a substitute for the official handbooks or regulations.