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WorksheetsModule 6
Total questions: 141
Worksheet time: 1hrs 11mins
What temperature would steel be tempered at?
At the annealing temperature.
Above the annealing temperature.
Below the annealing temperature.
Chromium added to plain carbon steel.
Increases its resistance to corrosion.
Turns it into a non-ferrous alloy.
Makes the metal softer
Purpose of case hardening is to.
Produce a hard case over a tough core.
Reduce the carbon in the steel.
Introduce carbon into the steel
Tempering entails.
Heating under the UCP and slow cooling.
Heating over the UCP and fast cooling.
Heating over the UCP and slow cooling.
Nitriding is.
Tempering.
Anodizing.
Case hardening
A ferrous metal contains.
Aluminium.
Iron.
Magnesium.
With respect to ferrous metals which of the following is true?
Iron is not any element of ferrous metals.
Iron is a main element and most ferrous metal are magnetic.
Iron is a main element and ferrous metals are not magnetic.
The normalizing process on steel is required sometimes as it
Provides a corrosion resistant layer that prevents oxidation.
Allows the material a greater stress per unit area.
Relieves internal stress suffered after engineering processes
The hardness of steel depends upon.
Formation of pearlite into austenite.
Formation of cementite. (iron carbide)
The iron austenite grain structure
The difference between annealing and normalizing is.
Both are heated above the UCT, cool slowly to anneal, cool in air to normalize
Both are heated below the UCT, cool in air to anneal, cool slowly to normalize.
Both are heated above the UCT, cool in air to anneal, cool slowly to normalize.
Normalizing of steel is done to.
Remove residual stress of the manufacturing process.
Make steel softer.
Restore the fatigue life of steel.
When normalizing the material is.
Quenched immediately.
Left to cool in room temperature.
Cooled slowly
Cast iron is.
Very malleable.
Tough.
Brittle.
Case hardening can be carried out on.
Titanium.
Any ferrous metal.
Duralumin.
Steel is tempered.
After hardening.
Before hardening.
To increase hardening
A low carbon steel would normally be case hardened using.
The nitriding process.
Flame or induction hardening.
Pack or gas carburizing
Normalizing steels.
Increases toughness.
Increases the hardness.
Relieves the stresses
When metal is first heated slightly above its critical temperature and then cooled rapidly it is common that the metal will increase in.
Brittleness.
Hardness
Both of the above
Annealing steels.
Toughens the metal.
Makes the metal malleable.
Makes the metal brittle
Tempering of hardened steel is carried out to.
Retain surface hardness, but soften the core.
Retain core hardness, but soften the surface.
Significantly reduce the brittleness without suffering a major drop in its strength
Malleable materials are.
Easy to forge.
Easy to cast.
Highly ductile.
If a material has to undergo deep cold forming operation. The essential property would be.
Ductility.
Malleability.
Elasticity.
Ductility is the property of a metal which permits it
To be permanently drawn, bent, or twisted but is subject to breaking
To be permanently drawn, bent, or twisted
Not to be used for fuselage and wing skin
Non-heat treatable materials.
Cannot be hardened.
Can be hardened by strain hardening or cold working.
Can be hardened by annealing.
The ease with which a material can be forged, rolled and extruded without fracture is an indication of a material's.
malleability.
ductility.
brittleness.
e is an indication of a material's.
malleability.
ductility.
brittleness.
Wrought alloys are used most widely in aircraft construction for
Stringers, bulkheads
Skin, rivets, and extruded sections
Stringers, bulkheads, skin, rivets, and extruded sections
The metal, which must not be heated in a salt bath, is.
Magnesium alloy.
Duralumin.
Rivets made of alclad
The critical process of heat treatment is.
Temperature, method of heating and cooling.
Temperature and method of heating only.
Method of heating only
What is the effect of precipitation heat treatment on aluminium?
It speeds up age hardening process.
It delays the age hardening process.
It softens the material to allow it to be worked
If caustic soda turns a material black what is it?
Aluminium alloy.
Alclad.
Aluminium.
What chemical is used to identify aluminium alloys?
Caustic soda.
Copper sulphate.
Nitric acid
Precipitation treating makes the metal.
Precipitation treating makes the metal.
Less strong and hard.
Harder, stronger and less ductile
Clad aluminium alloy (alclad) has a pure aluminium coating of.
0.002.
1% of alloy thickness.
5% of alloy thickness.
Titanium can be identified by placing it on a grinding wheel and looking for.
Red Sparks.
Yellow Sparks.
White Sparks.
Pure aluminium is.
Highly resistant to corrosion.
Not resistant to corrosion.
Reasonably resistant to corrosion.
The main metal in monel is.
Aluminium.
Nickel.
Stainless steel.
The time between removal from heat treatment furnace and quenching must be not more than.
3 seconds.
10 seconds.
7 seconds
Monel metal consists of approximately.
66% Chromium and 33% Copper.
66% Copper and 33% Nickel.
66% Nickel and 33% Copper.
The aluminum code number 1100 identifies what type of aluminum?
Aluminum alloy containing 11 percent copper.
Aluminum alloy containing zinc.
99 percent commercially pure aluminum. . Aluminum identified by the code number 1100 is 99 percent commercially pure aluminum.
In the four-digit aluminium index system number 2024, the first digit indicates
The major alloying element.
The number of major alloying elements used in the Metal.
The percent of alloying metal added
A material containing approximately 66% nickel and 33% copper is known as.
Nimonic.
Monel metal.
Invar
The extrusion process
Involves the forcing of metal through an opening in a die
Of metals such as lead, tin, and aluminum may be extruded cold
Both A and B are correct
Fibre weave strength is greatest in the direction of the.
Weft.
Warp.
Bias.
Why are Electric motors not recommended for use with composite materials?
Carbon dust wears the bearings.
Carbon is conductive and can cause an electrical short circuit.
They are not as strong as air driven tools.
A mechanic has completed a bonded honeycomb repair using the potted compound repair technique. What non-destructive testing method can be used to determine the soundness of the repair after the repair has cured?.
Eddy current test.
Metallic ring test. ( Tap test)
Ultrasonic test.
How do you reduce or remove electrostatic charges which may build up on composite surfaces?.
No special treatment is necessary because fibre glass is an ins
The surface is treated with a special conductive paint.
The surface is impregnated with copper strips.
Useful method for the detection of internal delamination's, voids, or inconsistencies in composite components not otherwise discernible using visual or tap methodology is
X-ray
Ultrasonic
Eddy current
Storage temperature of prepreg, film adhesive, and foaming adhesives is
Between -18°C to 0°C
Near 4°C
Below -18°C
What available NDE techniques are used to defect water ingression in radomes?
Radiography, thermography, moisture meter
Radiography, thermography, tap test, dye penetrant
Radiography, thermography, eddy current, ultrasonic
Delamination, resin starved areas, resin rich areas, blisters, air bubbles, wrinkles, voids, thermal decomposition are included in
Manufacturing defects
In-service defects
Manufacturing defects and In-service defects
Environmental degradation, impact damage, fatigue, cracks from local overload, de-bonding, delamination, fiber fracturing, erosion are included in
Manufacturing defects
In-service defects
Manufacturing defects and In-service defects
Which types of damages cannot be found during visual inspections?
Resin starvation, resin richness, wrinkles, ply bridging, discoloration (due to overheating, lightning strike, etc.)
Impact damage by any cause, foreign matter, blisters, and dis-bondin
Internal flaws in the composite, such as delamination's, dis-bonds, and matrix crazing
Peel plies are used to
Seal the vacuum bag to the part or tool
Create a clean surface for bonding purposes.
Creates a path for the air and volatiles to escape from the repair
Which vacuum bagging technique is frequently used for removable aircraft parts, such as flight controls, access panels, etc., and when a part's geometry and/or the repair location makes it very difficult to properly vacuum bag and seal the area in a vacuum?
Single Side Vacuum Bagging
Envelope Bagging.
Impregnation Using a Vacuum Bag
Replacement of a wooden spar is.
Only permitted by the manufacturer.
A minor repair.
A major repair.
A crack is found in a wooden spar, you.
Must replace the spar section.
Might be able to repair the spar.
Must replace the entire spar.
Kevlar and Nomex are types of.
Glass fiber composite.
Aramid fiber.
Aluminium alloy.
Intergranular corrosion is caused by.
Improperly assembled components.
Improper heat treatment.
Dissimilar metal contact
After a product has been manufactured and all heat treatment has been carried out the stress remaining if any is termed as.
Residual stress.
Working stress.
Applied stress.
When buffing surface of Aluminium Alloy, what material are you removing?
Oxide layer.
Aluminium.
Alloy
Galvanic corrosion caused by electrolytic action is the result of
Contact between two unlike metals.
Excessive anodization.
The wrong quenching agent
Corrosion may be regarded as the destruction of metal by.
Electrochemical action.
Hydroelectric action.
Electromechanical action
Which of these is a common cause of corrosion
Water in fuel.
Spilled battery acid
Untreated metal.
What is stress corrosion?
Corrosion in an area under cyclic loading.
Corrosion due to fretting.
Corrosion in an area under continuous loading.
Chemical attack is a direct result of.
Intergranular corrosion.
Cathodic & anodic changes in the material.
Filiform corrosion.
Galvanic corrosion is caused by.
Incorrect heat treatments or incorrect alloying.
Cyclic stressing and a decrease in cross sectional area.
The joining of 2 dissimilar metals.
Corrosion will spread more rapidly when metals are exposed to
Cold climates.
Higher temperature
Dry climates
Corrosion control begins at the.
Production stage.
Manufacturing stage.
Design stage.
When galvanic corrosion takes place, which part corrodes?
Anode.
Oxide film coating.
Cathode
Corrosion caused by galvanic action is the result of.
Contact between two unlike metals.
Excessive anodization.
Excessive etching
When dissimilar metals are brought together, or the same metal in different states, one metal forms the anode and the other the cathode. Which will suffer from corrosion?
Both will corrode equally
The cathode
The anode.
Black streaks back from a rivet hole signify.
Galvanic corrosion.
Intergranular corrosion.
Fretting
The lifting or flaking of the metal at the surface due to delamination of grain boundaries caused by the pressure of corrosion is.
Exfoliation.
Electrolysis.
Trans granulation
Aluminium is.
Not resistant to corrosion.
Highly resistant to corrosion.
Reasonably resistant to corrosion
In the galvanic series, the most noble metal will, if joined to another metal.
Always be at the top of the table
Corrode before the less noble metal.
Allow the less noble metal to corrode first.
What is the indication of fretting corrosion on aluminium alloy?
Black powder.
Brown powder
White powder
What action is taken to protect integral tanks from corrosion due to micro-biological growth?
The inside of the tank is coated with yellow chromate.
Rubber liners are installed in the tank.
A biocidal additive is used in the fuel
What type of corrosion attacks grain boundaries of aluminium alloys which are improperly or inadequately heat treated?
Stress corrosion.
Intergranular corrosion
Surface corrosion.
Intergranular corrosion in structural aluminium alloy parts.
Are not likely to occur in parts fabricated from heat-treated sheet aluminium.
May be detected by the white, powdery deposit formed on the surface of the metal.
Cannot always be detected by surface indications
Corrosion under the surface coating can be detected by
Frosted appearance
Roughening of the surface
Paint or plating is lifted off the surface in small blisters
Corrosion at the grain boundaries is called.
Intergranular.
Fretting.
Filiform
Fretting corrosion occurs where?
Two material are subject to very slight movement between the two.
A deep scratch increases to become fretting corrosion.
Pitting corrosion is allowed to become more pronounced
What are the signs of fretting corrosion?
Black stain around a rivet
Intergranular cracking.
Flaking
Surface corrosion on stainless steel is identified by.
Uniform red, brown, stain.
White film.
Black pitting
The usual manufacturer's anti-corrosion process to be applied to Fe aircraft parts is.
Cadmium plating.
Anodizing.
Metal spraying.
Corrosion on copper is identified by.
Red/brown rust.
Black powder.
Green to blue copper salts on the corroded part
Fretting corrosion occurs when
Water is trapped between moving parts.
Two mating surfaces are subject to slight relative motion.
Improperly heat treated.
Intergranular corrosion is also known as what?
Stress corrosion.
Exfoliation.
Galvanic.
Corrosion of metals in a metal to metal joint or corrosion at the edge of a joint is
Filiform corrosion.
Fretting corrosion.
Crevice corrosion.
Lead acid battery fluid has been found to be leaking on the surface of the aircraft structure. What substance would you use to neutralize the acid?
Sulphur and Lime
Hot distilled water.
Sodium bicarbonate of soda.
A primary cause of intergranular corrosion is.
Improper heat treatment.
Improper application of primer.
Dissimilar metal contact
Aircraft bolts are almost always manufactured in
Class 2, free fit
Class 3, medium fit
Class 4, close fit
Most commonly used thread form in aviation is
Unified or metric threads
Round thread.
Buttress.
Pitch of a screw thread is defined as.
Distance from the centre of one crest to the next.
Difference between major diameter and minor diameter.
Distance between the crest and the root of the thread.
A metric screw thread angle is.
7 °
57 °
60 °
Aircraft bolts with a cross or asterisk marked on the bolt head are
Made of aluminum alloy.
Close tolerance bolts.
Standard steel bolts.
A particular component is attached to the aircraft structure by the use of an aircraft bolt and a castle tension nut combination. If the cotter pin hole does not align within the recommended torque range, the acceptable practice is to
The nut may not be over torque
Tighten below the torque range.
Change washers and try again.
A bolt with a single raised dash on the head is classified as an
AN corrosion-resistant steel bolt.
NAS standard aircraft bolt.
NAS close tolerance bolt.
Where is an AN clevis bolt used in an airplane?
For tension and shear load conditions.
Where external tension loads are applied.
Only for shear load applications.
A bolt with an X inside a triangle on the head is classified as an
NAS standard aircraft bolt.
NAS close tolerance bolt.
AN corrosion-resistant steel bolt.
Aircraft bolts are usually manufactured with a
Class 1 fit for the threads.
Class 2 fit for the threads.
Class 3 fit for the threads.
How is the locking feature of the fiber-type locknut Obtained?
By the use of an unthreaded fiber locking insert.
By a fiber insert held firmly in place at the base of the load carrying section.
By making the threads in the fiber insert slightly smaller than those in the load carrying section.
Which type of pin is used with tie rod terminals and in secondary controls which are not subject to continuous operation?
Flathead pin
Taper pin
Cotter pin.
Plain washers, both the AN960 and AN970,
Are used under hex nuts
Are used with machine screws or bolts where the self locking or castellated type nut is not appropriate
Are used where a bolt is installed at an angle to a surface, or where perfect alignment with a surface is required.
Lock washers, both the AN935 and AN936,
Are used under hex nuts
Are used with machine screws or bolts where the self-locking or castellated type nut is not appropriate
Are used where a bolt is installed at an angle to a surface, or where perfect alignment with a surface is required.
The ball socket and seat washers, AC950 and AC955,
Are used under hex nuts
Are used with machine screws or bolts where the selflocking or castellated type nut is not appropriate.
Are used where a bolt is installed at an angle to a surface, or where perfect alignment with a surface is required.
What method is used on most modern aircraft to safety turn buckles?
The double wrap method
Clip locking method
Single wrap spiral method
The AN-3 and the AN-73 series bolts are
Interchangeable for all practical purposes
Tension and shear strengths are different.
Are non-drilled head bolts
What metal is suitable for riveting magnesium alloy?
Monel metal
5606 aluminium alloy
2024 aluminium alloy
If D or DD rivets are not broached in time, or removed from the freezer in time, they
Must be re-heat treated before use
Can be re-heat treated once then discarded
Must be discarded
An aluminium alloy rivet identification is
D embossed
X embossed
Embossed
D and DD rivets are refrigerated to
Retard age hardening
Increase age hardening
Precipitation harden
What do you do to 2017 and 2024 rivets after heat treatment?
Use immediately or refrigerate
Leave for a minimum of 2 hours before using
Refrigerate for a minimum of 2 hours before using
An American rivet with a cross on the head is
2117 aluminium alloy
5056t aluminium alloy
2124 aluminium alloy
A countersunk rivet of the 'SP' series has a head style of
90o
100o
20o
When a solid rivet is formed it only holds 75% of its shear strength, the other 25% comes from
Heating the completed assembly
Cooling completed assembly
Leaving assembly for 4 days to age harden
One of the main advantages of the Hi-Lok type fasteners over earlier generations is that.
They can be installed with ordinary hand-tools.
They can be removed and reused again.
The squeezed on collar installation provides a more secure, tighter fit.
Deutsch rivet consists of
An aluminium sleeve and the hardened steel drive pin
A stainless steel sleeve and the hardened steel drive pin
The stainless steel sleeve and the aluminium drive pin
Which thread form is compatible with the unified or metric forms?
Obsolete British Standard thread forms
Whitworth thread forms.
Neither A nor B is correct
Lock plates are used
Where positive retention of a nut is required
Are used where positive retention of a nut is required.
Both A and B are correct
Jo-bolts
Consists of three parts
Are resistance to
Both A and B are correct
A fluid line marker with a skull & crossbones is.
Fluid line carries toilet waste.
Warning symbol.
Radioactive symbol.
The international marking for a fire protection pipe line is a series
Circles.
Squares
Diamonds.
The end of the fitting that passes through the bulkhead is
Shorter than the other end(s), which allows a locknut to be installed, securing the fitting to the bulkhead
Equal to the other end(s), which allows a locknut to be installed, securing the fitting to the bulkhead.
Longer than the other end(s), which allows a locknut to be installed, securing the fitting to the bulkhead.
Size of MS flareless tube fittings MS 21900 –4D is
4/8 inch
4/16 inch
4/32 inch
MS flareless tube fittings MS 21900 –4D is made from
Aluminum Alloy
Brass
Steel
Ball and roller bearings are made from a combination of low carbon steel and a percentage of.
Chromium.
Nickel.
Nickel chrome
Thrust bearings transmit.
Thrust loads, thus limiting axial movement.
Radial loads, thus limiting axial movement.
Thrust loads, thus limiting radial movement.
Backlash is a type of wear associated with.
Gears.
Rivets.
Bearings
A gear with teeth twisted at an angle from the gear center line is a
Helical Worm Gear
Rack and pinion.
Bevel gears
Rack and pinion gears
Are used in changing rotary motion into linear motion or the reverse.
Has multiple uses.
Has less precision than most other options.
Control cable pulleys should be lubricated
Every C check.
When stiffness is felt in the control column.
Not required bearings are sealed lubricated at the factory
If the turnbuckles are in a control system to
Enable quick disconnect of cables.
Enable cable tension to be adjusted.
Enable cable ends to be joined without swaging
A 7x7 cable has seven strands each of.
Fourteen wires.
Seven wires.
One wire.
In a Teleflex flexible control system, the Teleflex cable consists of.
multi strand steel wires and is used primarily as a single one way device operated from a control lever
a high tensile steel wire with a right or left hand helix wire wound on to it. The system can operate in two directions.
a flexible seven or nineteen strand steel cable used for the operation of manual flying controls.
A cable tension regulator will be installed in a flying control system to.
automatically compensate for low cable tension caused by worn cables.
compensate for rapid movement of the controls by taking up the slack.
allow for variations in temperature which will vary the cable tension.
How are changes in direction of a control cable accomplished?
Bell cranks.
Fairleads.
Pulleys.
. A cable loom should be protected by conduit when fed through the
Main equipment center
Wheel wells
Cargo compartment ceiling
Why are copper wires used in electrical systems?
They have high permeability
They do not give off a magnetic field.
Copper has a higher conductivity
The main advantage of Coaxial cables is
they are shielded against electrostatic and magnetic fields and they will not pick up any energy, or be
influenced by other strong fields
The outer sheathing is damage proof
They do not require secure cable clamping.
