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AT 106 > Lecture 13 > Flashcards

Lecture 13 Flashcards

1
Q

What is an aluminum alloy?

A

A chemical composition where other elements are added to pure aluminum in order to enhance its properties
Primarily to increase its strength

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2
Q

What does 2024 mean when talking about aluminum alloys?

A

Copper can be found in the aluminum alloy

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3
Q

Sort T3, T351, and T4 from strongest temper to weakest temper

A

T351
T4
T3

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4
Q

What are some elements that can be added to aluminum?

How much of the weight of the alloy do these additions make up?

A

Iron, silicon, copper, magnesium, manganese and zinc

15% of the alloy by weight

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5
Q

How is AlClad aluminum created?

A

Cladding (covering) a aluminum alloy inner core with surface layers of pure aluminum
Pure aluminum for corrosion resistance
Produced by rolling

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6
Q

How much of AlClad aluminum is pure aluminum?

A

5.5% thickness per side

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7
Q

A metal’s strength is directly related to its _____ and _____, and _____.

A

grain size
orientation
heat treatment (temper)

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8
Q

How does the grain in sheet metal align itself?

A

The grains align themselves parallel with the rolling operation when the metal is rolled out to form a sheet

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9
Q

What is a composite material?

A

A material which is produced from two or more materials

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10
Q

In a typical jet today, how much of it is pure aluminum?

A

As little as 20%

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11
Q

A _____ sheet is a requirement via _____ and other workplace organizations for any workplace to provide to its _____.

A

Safety data sheet (SDS)
OSHA
employees

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12
Q

What is AC 43.13 1B?

A

Advisory circular (AC)
Contains methods, techniques, and practices “acceptable” for the inspection and repair of of civil aircraft
Only to be used when there are no manufacturer repair or maintenance instructions**

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13
Q

Sheet metal that is used for structure and outer aircraft covering is made from _____ and _____.

A

aluminum alloys
composites

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14
Q

How are parts of sheet metal formed and joined?

A

Rivets or other types of fasteners

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15
Q

What are the different types of specification to which aircraft hardware adheres to?

A

National Aerospace Standard (NAS)
Amy-Navy (AN)
Military Standard (MS)

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16
Q

What are the five different load types?

A

Compression (push together)
Tension (pull apart)
Shear (top pulls left, bottom pulls right)
Torsion (top and bottom spin in opposite directions)
Bending (pressure placed on middle)

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17
Q

What is the preferred construction method for metal aircraft?

Why?

A

Solid shank rivets

They fill up the hole, which results in good load transfer

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18
Q

What is yield strength?

A

Working load limit
The amount of stress a material can withstand without permanent deformation

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19
Q

What is tensile strength?

A

The maximum amount of axial stress that a material can take before breaking

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20
Q

How is the size and type of rivet to be used determined?

A

Loads imposed on the structure
Applications the parts will be in
Alloy of the material to be joined
Manufacturer
Information found in the manufacturer’s Structural Repair Manual (SRM)

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21
Q

Information in the advisory circular (AC) is _____ data NOT _____ data.*

A

acceptable
approved

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22
Q

How are drill bits sized?

What tool is used to size a drill bit?

A

Fractions, numbers, and letters

Drill gages

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23
Q

Aviation uses _____ drill bits for installing rivets

A

numbered

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24
Q

Larger drill bits are denoted by _____ numbers.
Smaller drill bits are denoted by _____ numbers.

A

smaller
larger

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25
Q

Drill bits are selected based on the _____.

A

rivet shank diameter

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26
Q

What is the process for drilling a hole?

A

Drill with a hand drill held perpendicular to the work
Apply medium pressure to prevent walks
Use a center punch to aid in drilling accurately

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27
Q

After drilling a hole, the material must be _____ on both sides.

A

deburred

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28
Q

What tools are used for countersinking?

A

Microstop countersink tool
Dimpler dies

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29
Q

What type of metal can you not countersink?

A

Thin sheetmetal

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30
Q

Aviation rivets have a _____ countersunk head.

A

100°

31
Q

When would a dimpler die be used?

A

When sheet metal is .032” or less when using an 1/8” rivet

32
Q

What is de-burring?

A

To remove the rough edges of a hole or sheet after it has been drilled or cut

33
Q

Why is de-burring important?

A

Removes stress risers that cause incorrect riveting and stress cracking

34
Q

What are clecos?

A

Hold sheet metal together in preparation for fasteners

35
Q

What are some common types of rivet installers?

A

Hand squeezers
Pneumatic air gun and bucking bar
Pneumatic squeezers

36
Q

What is considered the oldest and most reliable fastener?

When was it first used?

A

Solid rivets

During the bronze age

37
Q

What is the most common type of solid rivet?

A

Universal head (rounded)
100 ̊ countersunk heads (flat heads)

38
Q

How is a solid rivet installed?

A

Driving (squeezing) the body with pneumatic or hand tools

39
Q

What are solid rivets made of?

A

A variety of aluminum alloys and specialty metals

40
Q

What are bolts?

A

Threaded fasteners used to assemble components, structures and assemblies

41
Q

For aircraft, what are bolts often made of?

Why?

A

Stainless steel or cadmium plated

Corrosion resistance

42
Q

What is a “grip” length?

How is grip determined?

A

The unthreaded section on the shank of a bolt

The grip should be equal to the thicknesses of the two pieces being held together

43
Q

What is different about aircraft bolts?

A

Drilled heads or drilled shanks for safety devices

44
Q

How are threads measured?

What are the two types of threads?

A

TPI gage (threads pre-inch)

Fine (UNF) or coarse (UNC)

45
Q

How do you identify bolts?

A

Different marks on the head of the bolt that denote alloy type, strength, and application

46
Q

What are the parts of a bolt?

A

Head
Shank
Grip
Threads

47
Q

How is bolt or screw length measured?

A

The bottom of the head to the end of the shank/threads

48
Q

What are nuts used for?

A

Secure bolts & screws in assemblies
Made for shear and tension applications

49
Q

Can nuts be drilled for safety wire?

A

Yes

50
Q

What is the purpose of aircraft washers?

A

Spread the load of a fastener
Protect the metal from galling

51
Q

How are aircraft washers sized?

A

The inside diameter and thickness

52
Q

How are aircraft washers different from automobile washers?

A

They cannot be interchanged

53
Q

What is torque?

A

A measure of how much a force acting on an object causes that object to rotate
Measured in inch pounds or foot pounds
12 in.lbs.= 1 ft.lb.

54
Q

What are the three types of torque wrenches?

A

Click type
Dial type
Beam type

55
Q

When would the torque wrench formula be used?

Why?

A

When an attachment (extension) is used which effectively changes the length of the wrench

The formula compensates for the additional length

56
Q

Bolts and fasteners are torqued (tightened) according to _____.

A

size

57
Q

Where are torque values found?

A

In torque charts

58
Q

When possible, where is torque applied?*

A

To the nut

59
Q

What is safety wire used to secure?

A

Anything that has the potential to loosen during normal operations
Nuts
Bolts
Oil filters
Cannon plugs

60
Q

How is safety wire twisted?

A

By hand or with duckbill pliers
Most often with safety wire pliers

61
Q

What safety wire pattern is used to prevent things from loosening?

A

S or Z pattern

62
Q

What are cotter pins used for?

What are they used in combination with to prevent spinning?

A

Secure bolts, screws, nuts and pins

Castle nut

63
Q

What are Hi-Lok Fasteners?

A

Simple two-part, structural fastener designed to achieve consistent torque on each fastener

64
Q

What happens when tightening a Hi-Lok fastener?

A

The fastener gets tightened onto the bolt until required torque amount and end piece breaks/shears off

65
Q

What is a blind fastener?

What is the process of inserting a blind rivet?

A

Used once the original solid fastener was removed and you only have access to one side of the fastener

Inserted into rivet hole, center piece is pulled out, crushing the end of the rivet against the surface until required torque is reached and the center piece shears off

66
Q

What is welding?

A

Joins metals by melting the work pieces (or a separate rod of material) until they are united together

67
Q

When was welding first used?

How has the process evolved?

A

The Bronze age, but modern welding developed in the 19th century

Lighter metals like aluminum, magnesium and titanium*

68
Q

What are the four types of welding?

A

Gas or oxy/act welding
TIG welding
MIG welding
Electric arc welding

69
Q

What is gas welding?

How is a gas weld done?

A

Fusion process in which heat is supplied by burning a mixture of oxygen and gas such as acetylene (oxyacetylene)

Done by heating the ends or edges of metal parts to a molten state with a high temperature flame

70
Q

How is a GMAW (MIG) weld done?

A

A spool of wire constantly moves through the gun then melts to form the weld
Argon, helium or carbon dioxide is used as the inert gas (not going to catch fire or poison you)
Shielding gas dispersed by gun shields weld from air to prevent oxidation

71
Q

What is a GTAW (TIG) weld?

How is a GTAW (TIG) weld done?

What materials does this type join together?

A

Weld produced by an electric arc (power supply)

Foot pedal starts the arc and the gas
Long rods to fuse two metals directly together
Gas shields the electrode to prevent contamination
Electrode doesn’t touch the work

Welds aluminum, copper, stainless, magnesium and titanium

72
Q

What is brazing?

What materials does brazing join together?

A

Filler metal is deposited in the joint other than by capillary attraction

Copper, bronze, nickel and other non-ferrous metals to stainless steel

73
Q

What is soldering?

What must be in place before soldering?

A

A relatively weak joint made by melting wire over a section

Must have flux to work properly (removes films on the surface being soldered)
Flux can be in the solder or in a separate container

AT 106 (13 decks)

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