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Aircraft System > 1205 Materials Prelim 1 > Flashcards

1205 Materials Prelim 1 Flashcards

1
Q

Aircraft Metal Structural Repair/ FAMILIARIZE

A

The satisfactory performance of an aircraft requires continuous maintenance
of aircraft structural integrity. It is important that metal structural repairs be
made according to the best available techniques because improper repair
techniques can pose an immediate or potential danger.

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2
Q

Aircraft Metal Structural Repair/ EXAMPLE FAMILIARIZE

A

In actual practice, repairs must be strong enough to carry all of the loads with
the required factor of safety, but they must not have too much extra
strength. For example, a joint that is too weak cannot be tolerated, but a
joint that is too strong can create stress risers that may cause cracks in other
locations.

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3
Q

made of aluminum alloys is used in airframe
sections that serve as both the structure and outer aircraft covering, with the
metal parts joined with _____ or other types of fasteners.

A

SHEET METAL ; RIVETS

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4
Q

it may also appear as part of a composite

airplane, such as in an instrument panel.

A

SHEET METAL

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5
Q

is used extensively in many types of aircraft from airliners to single-engine airplanes,

A

SHEET METAL

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6
Q

is obtained by rolling
metal into flat sheets of various thicknesses ranging from thin (leaf) to plate
(pieces thicker than 6 mm or 0.25 inch).

A

SHEET METAL

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7
Q

READ UNTIL THE END AND UNDERSTAND

A

Sheet metal can be cut and bent into a variety of shapes. During their career,
nearly all aviation maintenance technicians are involved to some degree in
the fabrication or repair of sheet metal aircraft structures. To fully
understand the theories and procedures used in sheet metal work, a
technician must recognize the construction techniques incorporated into the
design of an airframe that allow it to handle different types of structural
loads and stresses.

In addition, a technician must also be aware of how different physical
properties of sheet metal materials increase the durability and strength of an
aircraft. With an understanding of these items, a technician can maintain an
aircraft to its original condition, or properly alter its design to improve
aircraft performance or safety.

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8
Q

Whether the technician prepares a new drawing or transfers dimensions from
a drawing for a pattern, __________ are necessary to accurately determine
dimensions.

A

LAYOUT TOOLS.

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9
Q

One of the most commonly used measuring devices for sheet metal layout

A

FLEXIBLE STEEL SCALE OR SCALE

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10
Q

These handy tools usually have four sets of graduations on

them.

A

SCALES

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11
Q

For aircraft work, a scale with __nds and __ths of an inch on one side,
and increments of __ths and ths of an inch on the other, are most useful.
For the greatest accuracy when using a scale.

A

32, 64. 50, 100

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12
Q

Note for scales? FAMILIARIZE

A

do not measure from its end. Instead, start with one of the inch marks.
This is recommended because it is quite possible for a scale-end to have been
dam- aged, resulting in an inaccurate measurement.

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13
Q

The blade in this square is removable and is available with many different
types of graduations.

A

COMBINATION SQUARE

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14
Q

The blade with graduations of 50ths and lOOths of an

inch is the most useful for aircraft layout work.

A

COMBINATION SQUARE

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15
Q

The head of the square has a
45-degree bevel on one side and a 90-degree face on the other, with a spirit
level and a steel scribe in the head.

A

COMBINATION SQUARE

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16
Q

These
tools are handy for spacing rivets in a row and for transferring distances when
duplicating parts.

A

DIVIDERS

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17
Q

They may also be used to transfer measurements from a full-scale drawing to a layout on an actual metal part.

A

DIVIDERS

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18
Q

Layout tools?

A

scale, combination square, dividers

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19
Q

Once a drawing has been selected, dimensions must be transferred to the
surface of the metal for cutting, drilling, shaping, and forming. The ___________
device will vary according to the surface being marked and the operation to
be performed on the sheet metal.

A

marking tools

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20
Q

When using a _____ for marking sheet metal, a colored dye is usually applied
to the metal beforehand, then it is used to scratch through the dye.

A

scribes

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21
Q

should be used in sheet metal work only for marking the cut-off lines
of a part. They should never be used for marking dimension lines for bending
metal.

A

scribes

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22
Q

Any mark on a piece of sheet aluminum or magnesium that is
scratched into the metal with a scribe can cause the part to _______ when it is
bent.

A

crack

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23
Q

Most of the layout marks made on sheet metal can be made with a sharp, soft
lead ______.

A

pencil

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24
Q

Pencil marks can be more easily seen if the metal is wiped clean
with ______ or toluol and then sprayed with a light coat of zinc
chromate primer.

A

lacquer thinner

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25
Q

are becoming widely used by sheet metal technicians

because their marks are more visible than those of other marking tools.

A

felt marking pens

26
Q

To obtain sharp and clear lines, it is best to use a felt marking pen with _____

A

a fresh sharp tip

27
Q

Once a part is fabricated, the lines made by a felt marking pen can be easily
removed by _____ them with a rag_______.

A

wiping; soak with alcohol

28
Q

Marking tools?

A

scribes, pencil, felt marking pen

29
Q

The lines drawn on sheet metal indicate where different operations such as
bending and drilling are to be performed. This is not always sufficient for
some operations. Drilling, for instance, requires some physical indentation on
the surface in order to keep the drill from wandering when first starting.

READ 3 TIMES

A

PUNCHES

30
Q

Once layout marks have been made with a soft pencil, permanent marks can
be made in locations for holes with a sharp?

A

prick punch

31
Q

It takes only a light
___ of the prick punch with a small hammer to mark these locations, which can be enlarged later
with a center punch.

A

tap

32
Q

Enlarging a prick punch mark with a ______ allows a drill to be centered
so that it will start cutting the metal in the proper location.

A

center punch

33
Q

It has a blunt point, ground to an angle of about 60 degrees, which
approximates the tip angle of a twist drill. The marks should be deep enough
for the drill to start cutting, but the blow used on the punch must not be hard
enough to distort the metal.

A

center punch

34
Q

Much sheet metal repair work consists of replacing damaged skin with new skins.

If the old metal is an insufficient condition, layout marks can be
transferred directly to the new material by the use of a _____ punch

A

transfer punch

35
Q

This punch is used to locate the exact center of drilled holes, such as
those used for rivets.

A

transfer punch

36
Q

This punch has a shank the diameter of the hardware
that will be installed in the hole and has a sharp point in its exact center.
The point will make a mark similar to a prick punch mark in the center of the
hole. These punches are made as both solid steel, and automatic punches.

A

transfer punch

37
Q

One of the most useful punches for a sheet metal worker is the ____ punch
because it is ideal for removing rivets.

A

pin punch

38
Q

To do this, begin by drilling through
the rivet head down to the base. Then, by using a pin punch of the same
diameter as the rivet shank, snap the head off by prying sideways. Once the
rivet head is removed, the rivet shank is then punched out of its hole with the
pin punch, leaving the original-size rivet hole. When punching the rivet shanks
out of thin materials, back up the metal before tapping the pin punch to help
prevent distorting the metal.

PLEASE READ 3 TIMES

A

PIN PUNCH

39
Q

PUNCHES?

A

prick punch, center punch, transfer punch, pin punch

40
Q

Metal cutting tools can be divided into two types.

A

hand-operated or floor-mounted types.

41
Q

CUTTING TOOLS | READ ANSWER 3 TIMES

A

Again, when
using any fabrication equipment, always consult the tool manufacturer’s
information for use and care instructions.

42
Q

> The electrically operated portable circular-cutting

>uses blades of various diameters.

A

KETTS SAW

43
Q

The head of this saw can be turned to any desired angle,
which makes it very useful for removing damaged sections on stringers and
other intricately designed parts.

A

KETTS SAW

43
Q

The head of this saw can be turned to any desired angle,
which makes it very useful for removing damaged sections on stringers and
other intricately designed parts.

A

KETTS SAW

44
Q

Advantages of a Ketts saw include:

A
  • The ability to cut metal up to 3/16 inch thick.
  • A starting hole is not required.
  • A cut can be started anywhere on a sheet of metal.
  • The saw provides the capability to cut an inside or outside radius.
45
Q

KETTS SAW | READ ANSWER 5 TIMES

A

Although the tool is fairly easy to operate, some basic operating precautions
are required. To prevent the blade from grabbing and kicking back, keep a
firm grip on the saw handle at all times. In addition, before installing any
cutting blade on the tool, the blade should be checked carefully for cracks. A
crack could cause the blade to fail during operation, thereby causing parts to
fly out, possibly causing serious injury to the operator or bystanders.

46
Q

is an electrically-powered tool used for rough cutting of

large damaged sections such as portions of spars or stringers.

A

RECIPROCATING SAW

47
Q

With these
saws, a variety of cutting blades is available to be used on different types and
thickness of materials. The cutting blades used to cut through metal are
primarily made of good quality steel and are available with different numbers
of teeth per inch of blade.

A

RECIPROCATING SAW

48
Q

RECIPROCATING SAW
For metal .250 inch or thicker, use a coarse cutting blade. However, if a
coarse blade is used on thin metal, the blade can hang up, dull rapidly, or
break.

READ 4 TIMES

A

RECIPROCATING SAW

49
Q

is a tool used for rough cutting small- to medium-size holes in skins,
radio chassis, and instrument panels.

These tools may be electrically or
pneumatically powered, but are also available in a non-powered hand version.
Regardless of the operating power, each tool produces a similar style cut.

A

NIBBLERS

50
Q

are compound action shears which have a serrated cutting edge
that holds the metal that is being cut.

A

AVIATION SNIPS

51
Q

come in sets of three
and are manufactured to perform different cuts as indicated by a color-code
on the handles.

A

AVIATION SNIPS

52
Q

The use of Snips with yellow handles

A

cut straight

53
Q

The use of aviation snips with green handles cut to the?

A

RIGHT

54
Q

snips with red handles CUT TO THE?

A

LEFT

55
Q

NAME METAL-CUTTING POWER TOOLS? (4)

A

ketts saw, reciprocating saws, nibblers, aviation snip

56
Q

When aircraft sheet metal skins or other parts with close tolerances need to
fit together, a ____ is often used to provide a finished edge or surface.

A

file

57
Q

When aircraft sheet metal skins or other parts with close tolerances need to
fit together, a ____ is often used to provide a finished edge or surface.

A

file

58
Q

The _____ tool should be used to remove
burrs and to smooth edges. If too much pressure is applied while deburring, it
is possible the hole will become undesirably countersunk.

A

deburring

59
Q

Once a hole is drilled in sheet metal, it is not uncommon to find that a sharp
edge or burrs, is left around the circumference of the hole.

However, a common mistake made by inexperienced technicians is to remove
too much material. Remember, a deburring tool should be used to remove
burrs and to smooth edges. If too much pressure is applied while deburring, it
is possible the hole will become undesirably countersunk.

A

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Aircraft System (11 decks)

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