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WorksheetsBLOCK 7 REVIEW FINAL QUESTIONS
Total questions: 75
Worksheet time: 38mins
The threads that run from one side to the other on a roll of fabric are called"
Warp threads
Bias threads
Fill fibers
The threads that run from one end of a roll of fabric to the other are called.
Warp threads
Bias threads
Woof threads
When the woof fibers run to the side of the cloth and turn around and god back, it is called?
The selvedge edge
Bias edge
Weft fibers
A fold or cut 45 degrees from the warp is called
Warp
Weft
Bias
Two types of fiberglass cloth are?
S glass and E glass
C glass and D glass
S glass and D glass
What is normally the material of choice for structural fiberglass?
C glass
S glass
E glass
What is S glass made from?
Borosilicate glass
Magnesia borosilicate glass
Magnesia-alumina-silicate glass
The purpose of resin is:
To give fiberglass form and to transfer loads from on fiber to the next
To provide the strength of the composite
To help transfer electric current through the panel
Two types of thermosetting resin are?
Polyester and thermoplastic
Epoxy and polyester
Epoxy and thermosetting
The primary load carrying component in a composite material are?
The resin
The core
The fibers
The resin that has the advantage of high strength, excellent adhesion and ease of processing is?
Epoxy resin
Polyester resin
Polyurethane resin
The most common fabric weaves used in composites are?
Plain weave and satin weave
Crowsfoot weave and satin weave
Plain weave and crowsfoot weave
The optimum ratio by weight of fibers to resin is:
40:60
60:40
60:50
Potting compounds are usually made up of epoxy resin filled with
Bondo
Microballons or chopped glass fibers
Flox or shredded cardboard
Methods for enabling composite materials to conduct electricity for protection from lightning strikes include bonding to the surface
Wire mesh, aluminum foll, conductive paint
Is not necessary as carbon fiber conducts electricity
A layer if Kevlar fibers
Name three different types of core used in sandwich panels
Microballoons, Fiberglass, Epoxy
Honeycomb, foam, balsa wood
Sitka spruce, foam, honeycomb
A warp clock is used to:
Time the epoxy pot life
Determine which fibers are the warp fibers
Describe the warp fiber direction on a spec sheet or diagram
When replacing a section of honeycomb core material it is important to:
Align the ribbon direction with the part being repaired
Doing a wetting test before applying the adhesive
Use a suitable foam plug to replace the damaged honeycomb
Repair patches should be?
Round or oval
Slightly larger than the damage
Square or rectangular
Carbon fiber skin panels should not be used with:
Aluminum honeycomb core
Pheonolic honeycomb core
Nomex honeycomb core
List the names of the fibers used to reinforce composites:
Carbon fiber, glass fiber, ceramic, Kevlar, boron
Polyurthane foam, Balsa, Honeycomb, Thermoplastic
Thermosetting resin, glass fibers, balsa, Kevlar
Which one of the above fibers can be utilized in high heat areas?
Kevlar
Carbon fiber
Ceramic
Curing of the matrix (resin) is accomplished with:
Time
Pressure
Time, heat and pressure
What is the minimum vacuum pressure required in a vacuum bag?
14.7 PSI
22" hg
20" hg
The best way to remove paint from a composite panel that is to be repaired, is
Pyrolytic paint removal
Hand sanding
Sand blasting
What FAR covers aircraft registration numbers?
FAR Part 43
FAR Part 45
FAR Part 65
The two types of spray guns used for aircraft finishing are:
The airless feed type and MLVP
High pressure and airless feed
Suction feed and pressure feed
The purpose of a zahn cup is:
To measure the viscosity of paint
To measure the thinner
To mix the paint thoroughly
Turning the fluid adjusting control on a spray gun in a counter-clockwise direction will:
Widen the spray pattern
Increase the paint flow
Increase the airflow
To decrease the amount of paint applied to an area, turn:
The fluid adjustment control counter-clockwise
The air adjustment control clockwise
The fluid adjustment control clockwise
The minimum width of letter “N” should be:
6”
8"
10"
The minimum width of a number “1” should be:
2”
3"
4"
A simple chemical treatment for all aluminum alloys to increase their corrosion resistance, before primer application:
Anodizing
Chemical Etching
Alodining
Wash primer is a water thin coating of:.
Phosphoric acid and alcohol.
Phosphorus alkaline
Sulphuric acid and alcohol
The viscosity of paint is significant:
During high temperatures
At all temperatures
At low temperatures
A cup with a controlled orifice at the bottom is used:
To add thinner to the paint
To measure paint to thinner ratios
To measure paint viscosity
The safety items that should be worn when mixing or using thinners and solvents and during painting operations include
Rubber gloves, goggles, respirator
Safety glasses, welding shield, cotton lab coat
Rubber boots, respirator, rubber hat
Common paint defects include.
Blushing, pin holes, orange peel
Runs, drips and errors
Sags, brushing, fish scales
The primer that contains phosphoric acid is
Epoxy primer
Wash Primer
Urethane primer
The air supply to a spray gun must be
No more than 10 PSI
100 to 120 PSI
Free of oil or water
Metal fasteners used with carbon/graphite composite structures
May be constructed of any of the metals commonly used in aircraft fasteners
Have a high potential for causing galvanic corrosion
Must be constructed of high strength aluminum-lithium alloy
Sandwich panel construction is used because this type of construction
is lighter than single sheet skin of the same strength and is more corrosion resistant
May be repaired by gluing replacement skin to the inner core material with thermoplastic resin
Has high bending stiffness at minimal weight compared to aluminum or solid composite construction
Which of these methods may be used to inspect fiberglass/honeycomb structures for entrapped water?
Pulse echo ultrasonic inspection, radiography and thermography
visual inspection
tap testing
When balsa wood is used as a core material in a sandwich panel:
it can only be used with fiberglass skins
it has a considerably higher density than other core materials
it will be lighter than other core materials
When repairing puncture-type damage of a sandwich honeycomb panel, the Damaged skin scarf should be tapered
Two times the thickness of the metal
At a slop of 1:40
to whatever is desired for appearance
Thermosetting resins cure in three stages, which statement is accurate:
State A - The resin is fully cured
Stage B - The resin has been mixed and the chemical reaction has started
Stage C - The resin is mixed but the chemical reaction has not started
Composite inspections conducted by audible sonic testing is known as
Tap or coin testing
Ultrasonic testing
Sonogram testing
Carbon fiber structures
Conduct electricity so they do not need additional lighting protection
Fiberglass structures are non-metallic so they do not get struck by lightning
Are lightning protected by coating with a conductive material
One method of inspecting a solid laminated fiberglass structure that has been subjected to damage is to
Use ultrasonic inspection
Use dye-penetrant inspection procedures, exposing the entire damaged area to the penetrant solution
Use an eddy current probe on both sides of the damaged area
When inspecting a composite panel using the ring test/tapping method, a dull thud may indicate
Less than full strength curing of the matrix
separation of the laminates
an area of too much matrix between the fiber layers
The advantage of polyester resin is
Its structural strength
low price and fast processing
it can be softened by reheating and its shape reformed
Satin weave fabric
Uses fewer fibers in the woof direction than in the warp direction
Has all fibers running in the same direction
Has less crimp and is easier to distort than plain weave
A category of plastic material that is capable of softening or flowing when reheated is describe as a
Thermoplastic
Thermocure
Thermoset
The classification for high tensile strength fiberglass used in aircraft structures is
E
S
G
Acrylic plastic
Is a thermosetting plastic ideal for aircraft windows
Should be cold formed to the desired shape
Can be heated to forming temperature, molded then cooled
Prepreg material consists of
Resin-impregnated fabric kept in the B stage of cure by storing at low temperatures
Fiberglass fabric pre-impregnated with thermoplastic resin
Fiberglass fabric impregnated with precured resin
A potted compound repair on honeycomb can usually be made on damages less than
4 inches in diameter
2 inches in diameter
0.5 inch in diameter
The strength and stiffness of a properly constructed composite buildup depends primarily
a 60 percent matrix to 40 precent fiber ratio
the orientation of the plies to the load direction
the ability of the fibers to transfer stress to the matrix
Which fiber to resin (percent) ratio for advanced composite wet lay-ups is generally considered the be for strength?
40:60
50:60
60:40
What is the material layer used within the vacuum bag pressure system absorb excess resin during curing called?
Bleeder
Breather
Release
Isotropic materials have strength:
90* apart
In one direction only
equally in all directions
What reference tool is used to determine how the fiber is to be oriented for a particular ply of fabric?
Fill clock (or compass)
Bias clock (or compass)
Warp clock (or compass)
Proper pre-preg composite lay-up curing is generally accomplished by
applying external heat and pressure
room temperature exposure
adding a catalyst or curing agent to the resin
Kevlar is DuPonts name for
Carbon fiber
Aramid fiber
Boron fiber
The most common core material for a sandwich composite panel
Is hexagonal cells
Balsa wood
Aluminum foil cells
Fiberglass damage that extends completely through a laminated sandwich structure
may be repaired
must be filled with resin to eliminate dangerous stress concentrations
may be filled with putty, which is compatible with resin
Fiberglass laminate damage that extends completely through one facing and into the core
cannot be repaired
requires the placement of the damaged core and facing
can be repaired by using typical metal facing patch
The part of a replacement honeycomb core that must line up with the adjacent original is the
Cell side
Direction of core cells
Cell edge
A caul plate is often used during the cure cycle
On top of the repair to distribute pressure and provide more uniform heat distribution
To keep the bag from applying too much pressure on the part
As the primary heat source
If a new safety belt is to be installed in an aircraft, the belt must conform to the strength requirements in which of the following documents?
STC 1282
FAR part 65
TSO C22
The coefficient of expansion of most plastic enclosure materials is
greater than both steel or aluminum
greater than steel but less than aluminum
less than either steel or aluminum
If an aircraft's transparent plastic enclosure exhibits tiny fissures or cracks which may extend in a network over or under the surface of the plastic, the plastic is said to be
hazing
brinelling
crazing
Which of the following are generally characteristic of carbon/graphite fiber composites
High strength and corrosive effect in contact with aluminum
Flexibility
Low electrical resistance
Cabin upholstery materials installed in normal category airplanes must
be fireproof
be at least flame resistant
meet the requirements prescribed in "FAR" part 43
The simplest and most common damage inspection methods for composites is:
Visual inspection
Dye penetrant inspection
Ultrasonic inspection
