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Sheet metal Flashcards

1
Q

Select the alternative which best describes the function of the flute section of a twist drill

A

Forms the cutting edges of the drill point

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2
Q

Rivet gauge, or transverse pitch is the distance between the

A

Centers of rivets in adjacent rows.

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3
Q

Clad aluminum alloys are used in aircraft because they

A

Have surface layers of pure aluminum or aluminum alloy bonded to the core material to inhibit corrosion.

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4
Q

MS20426AD-6-5 indicates a countersunk rivet which has

A

An overall length of 5/16 inch.

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5
Q

Which rivet is used for riveting nickel-steel alloys?

A

Monel

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6
Q

What should be the included angle of a twist drill for soft metals?

A

90 degrees

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7
Q

The monocoque fuselage relies largely on the strength of

A

skin or covering

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8
Q

The length of a rivet to be used to join a sheet of .032 inch and .064 inch aluminum alloy should be equal to

A

One and one half times the rivet diameter plus .096 inch

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9
Q

A piece of stuck that is to be bent to a closed angle of 15 degrees must be bent through an angle of

A

165 degrees

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10
Q 
(Refer to figure 7.) What is dimension F?
Setback at D = .095
Setback at E = .068
Bend allowance at D = .150
Bend allowance at E = .112
A

5.936

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11
Q

What reference tool is used to determine how the fiber is to be oriented for a particular ply of fabric?

A

Warp clock (or compass)

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12
Q

Cabin upholstery materials installed in current standard category airplanes must

A

Be at least flame resistant.

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13
Q

When an MS20470D rivet is installed, its full shear strength is obtained

A

Only after a period of age hardening.

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14
Q

When conducting a tap test on a composite panel, which of the following sounds would indicate delamination?

A

Dull thud

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15
Q

(Refer Figure 1.) Which of the rivets shown will accurately fit the conical depression made by a 100 degree countersink?

A

1

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16
Q

Which of the following drill bit types work best when drilling an aramid fiber (kevlar) composite laminate?

A

Carbide W-point

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17
Q

The primary alloying agent of 2024-T3 is indicated by the number

A

2

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18
Q

A well-designed rivet joint will subject the rivets to

A

Shear loads

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19
Q

What is the material layer used within the vacuum bag pressure system to absorb excess resin during curing called?

A

Bleader

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20
Q

A category of plastic material that is capable of softening or flowing when reheated is described as a

A

Thermoplastic

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21
Q

A main difference between lockbolt/huckbolt tension and shear fasteners (other than their application) is in the

A

Number of locking collar grooves

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22
Q

Mild steel rivets are used for riveting

A

steel parts

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23
Q

Which of the following are generally characteristics of carbon/graphite fiber composites?

1) Flexibility
2) Stiffness
3) High Compression Strength
4) Corrosive effect in contact with aluminum
5) Ability to conduct electricity

A

2,3, and 4

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24
Q

One of the best ways to assure that a properly prepared batch of matrix resin has been achieved is to

A

Have mixed enough for a test sample

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25
Q

If it is necessary to compute a bend allowance tables are not available, the neutral axis of the bend can be

A

Found by adding approximately one-half of the stock thickness to the bend radius.

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26
Q

What type of bit should be used to drill holes in plexiglass?

A

A specifically modified twist drill

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27
Q

Repairing advanced composites using materials and techniques traditionally used for fiberglass repairs is likely to result in

A

An unairworthy repair

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28
Q

Which of the following, when added to wet resins, provide strength for the repair of damaged fastener holes in composite panels?

1) Microballoons
2) Flux
3) Chopped Fibers

A

2 and 3

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29
Q

Which is an identifying characteristic of acrylic plastics?

A

Zinc chloride will have no effect

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30
Q

Fiberglass damage that extends completely through a laminated sandwich structure

A

May be repaired

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31
Q

What is indicated by a black “smoky” residue streaming back from some of the rivets on an aircraft?

A

Fretting corrosion is occurring between the rivets and the skin.

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32
Q

The general rule for finding the proper rivet diameter is

A

Three times the thickness of the thickest sheet

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33
Q

What type loads cause the most rivet failures?

A

Shear

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34
Q

Under certain conditions, type A rivets are not used because of their

A

low strength characteristics

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35
Q

If a new safety belt is to be installed in an aircraft, the belt must conform to the strength requirements in which document?

A

TSO C22

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36
Q

When inspecting a composite panel using the ring test/tapping method, a dull thud may indicate

A

Separation of the laminates

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37
Q

What is the purpose of refrigerating 2017 and 2024 aluminum alloy rivets after heat treatment?

A

To retard age hardening

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38
Q

Which of these methods may be used to inspect fiberglass/honeycomb structures of entrapped water?

1) Acoustic emission monitoring
2) x-ray
3) backlighting

A

2 and 3

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39
Q

On a sheet metal fitting layout with a single bend, allow for stretching by

A

Subtracting the setback from both legs

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40
Q

Which part of the 2017-T36 aluminum alloy designation indicates the primary alloying agent used in its manufacture

A

2

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41
Q

What is the minimum spacing for a single row of aircraft rivets

A

Three times the diameter of the rivet shank

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42
Q

When drilling stainless steel, the drill used should have an included angle of

A

140 degrees and turn at a low speed

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43
Q

(Refer to figure 4.) The amount of material required to make the 90 degree bend is

A

0.3436 inch

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44
Q

Sandwich panels made of metal honeycomb construction are used on modern aircraft because this type of construction

A

Has a high strength to weight ratio.

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45
Q

Rivet pitch is the distance between the

A

Centers of adjacent rivets in the same row

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46
Q

What is the purpose of a gusset or gusset plate used in the constitution and repair of aircraft structures?

A

To join and reinforce intersecting structural members

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47
Q

When necessary, what type of cutting fluid is usually acceptable for machining composite laminates?

A

Water only

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48
Q

Which of the following need not be considered when determining minimum rivet spacing?

A

Rivet length

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49
Q

Alloy 2117 rivets are heat treated

A

By the manufacturer and do not require heat treatment before being driven.

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50
Q

When making repairs to fiberglass, cleaning of the area to be repairs is essential for a good bond. The final cleaning should be made using

A

MEK (methyl ethyl ketone)

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51
Q

The Dzus turnlock fastener consists of a stud, grommet, and receptacle. The stud diameter is measured in

A

sixteenths of an inch

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52
Q

The coefficient of expansion of most plastic enclosure materials is

A

Greater than both steel and aluminum

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53
Q

What precaution, if any, should be taken to prevent corrosion inside a repaired metal honeycomb structure?

A

Prime the repair with a corrosion inhibitor and seal form the atmosphere

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54
Q

A single-loop sheet splice is to be used to repair a section of damaged aluminum skin. If a double row of 1/8 inch rivets is used, the minimum allowable overlap will be

A

13/16 inch

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55
Q

When comparing the machining techniques for stainless steel sheet material to those for aluminum alloy sheet, it is normally considered considered good practice to drill the stainless steel at a

A

Lower speed with more pressure applied to the drill

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56
Q

The length of rivet to be chosen when making a structural repair that involves the joining of 0.032 inch and 0.064 inch aluminum sheet, drilled with a No.30 drill is

A

5/16 inch

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57
Q

Fiberglass laminate damage that extends completely through one facing and into the core

A

Requires the replacement of the damaged core and facing

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58
Q

Joggles in removed rivet shanks would indicate partial

A

Shear failure

59
Q

The preferred way to make permanent repairs on composites is by

A

Laminating on new repair plies

60
Q

A sheet metal repair is to be made using two pieces of 0.040 inch aluminum riveted together. All rivet holes are drilled for 3/32 inch rivets. The length of the

A

1/4 inch

61
Q

Composite fabric material is considered to be the strongest in what direction?

A

Warp

62
Q

A sheet metal repair is to be made using two pieces of 0.0625 inch aluminum riveted together. All rivet holes are drilled for 1/8 inch rivets. The length of the rivets to be used will be

A

5/16 inch

63
Q

(Refer to Figure 6.) What is dimension D?
Setback = .252
Bend allowance = .345

A

4.182

64
Q

The flat layout or blank length of a piece of metal from which a simple L-shaped bracket 3 inches by inch is to be bent depends upon the radius of the desired bend. The bracket which will require the greatest amount of material is one which has a bend radius of

A

1/8 inch

65
Q

The most important factors needed to make a flat pattern layout are

A

Radius, thickness, and degree of bend

66
Q

Which rivet is used for riveting magnesium alloy structures

A

5056 aluminum

67
Q

Metal fasteners used with carbon/graphite composite structures

A

Must be constructed of material such as titanium or corrosion resistant steel

68
Q

The strength and stiffness of a properly constructed composite buildup depends primarily on

A

The orientation of the plies to the load direction.

69
Q

How many of the following are benefits of using microballoons when making repairs to laiminated honeycomb panels?

1) Greater concentrations of resin in edges and corners
2) Improved strength to weight ratio
3) Less density
4) Lower stress concentrations

A

2,3, and 4

70
Q

If an aircraft’s transparent plastic enclosures exhibit fine cracks which may extend in a network over or under the surface or through the plastic, the plastic is said to be

A

Crazing

71
Q

When repairing a small hole on a metal stressed skin, the major consideration in the design of the patch should be

A

The shear strength of the riveted joint

72
Q

If no scratches are visible after transparent plastic enclosure materials have been cleaned, their surfaces should be

A

Covered with a thin coat of wax

73
Q

The length of time that a catalyzed resin will remain in a workable state is called the

A

Pot life

74
Q

Repairs or splices involving stringers on the lower surface of stressed skin metal wings are usually

A

Permitted but are normally more critical in reference to strength in tension that similar repairs to the upper surface.

75
Q

The monocoque fuselage relies largely on the strength of

A

Skin or covering

76
Q

Threaded rivets (rivnuts) are commonly used to

A

Attach parts or components with screws to sheet metal

77
Q

Fiberglass laminate damage not exceeding the first layer or ply can be repaired by

A

Filling with a putty consisting of a compatible resin and clean, short glass fibers

78
Q

What is the minimum edge distance allowed for aluminum alloy sing lap sheet splices containing

A

The minimum edge distance for the single row is equal to that for the multiple row.

79
Q

When repairing puncture-type damage of a metal faced laminated honeycomb panel, the edges of the doubler should be tapered to

A

100 times the thickness of the metal

80
Q

A potted compound repair on honeycomb can usually be made on damages less than

A

1 inch diameter

81
Q

What precaution, if any, should be taken to prevent corrosion inside a repaired metal honeycomb structure?

A

Prime the repair with a corrosion inhibitor and seal from the atmosphere

82
Q

The aluminum alloys used in aircraft construction are usually hardened by which method?

A

Heat treatment

83
Q

Which is considered good practice concerning the installation of acrylic plastics?

A

When rivets are used, adequate space or other satisfactory means to prevent excessive tightening of the frame to the plastic should be provided.

84
Q

Which rivet is used for riveting nickel-steel alloys?

A

Monel

85
Q

What is generally the best procedure to use when removing a solid shank rivet?

A

Drill to the base of the manufactured rivet head with a drill one size smaller than the rivet shank and remove the rivet with a punch.

86
Q

What type of bit should be used to drill holes in plexiglas?

A

A specifically modified twist drill

87
Q

A factor which determines the minimum space between rivets is

A

The diameter of the rivets being used

88
Q

Select the alternative which best describes the function of the flute section of a twist drill

A

Forms the cutting edges of the drill point

89
Q

(Refer to Figure 3.) Which is the grip length of the flush rivet?

A

3

90
Q

When bending metal, the material on the outside of the curve stretches while the material on the inside of the curve compresses. That part of the material which is not affected by either stress is the

A

Neutral line

91
Q

When repairing large, flat surfaces with polyester resins, warping of the surface is likely to occur. One method of reducing the amount of warpage is to

A

Use short strips of fiberglass in the bonded repair.

92
Q

When straightening members made of 2024-T4, you should

A

Straighten cold and reinforce

93
Q

If a streamline cover plate is to be hand formed using a form bock, a piece of dead soft aluminum should first be placed over the hollow portion of the mold and securely fastened in place. The bumping operation should be

A

Started by tapping the aluminum lightly around the edges and gradually working down into the center.

94
Q

(Refer to Figure 6.) Determine the dimensions of A, B, and C in the flat layout.
Setback = .252
Bend allowance = .345

A

A = .748, B = 1.496, C = 1.248

95
Q

The sharpest bend that can be placed in apiece of metal without critically weakening the part is called the

A

Minimum radius of the bend

96
Q

The shop head of a rivet should be

A

One and one-half times the diameter of the rivet shank.

97
Q

Which is correct concerning the use of a file?

A

Apply pressure on the forward stroke, only, except when filing very soft metals such as lead or aluminum.

98
Q

Which part of 2024-T3 aluminum alloy indicates the temper designation?

A

T3

99
Q

A DD rivet is heat treated before use to

A

Soften to facilitate riveting

100
Q

On a semimonocoque fuselage, the skin is reinforced by longitudinal structural members called

A

Longerons and stringers

101
Q

Proper pre-preg composite lay-up curing is generally accomplished by

1) Applying external heat
2) Room temperature exposure
3) Adding a catalyst or curing agent to the resin
4) Applying pressure

A

1 and 4

102
Q

A rivet set used to drive MS20470 rivets should

A

Have a slightly greater radius than the rivet head

103
Q

The dimensions of an MS20430AD-4-8 rivet are

A

1/8 inch in diameter and 1/2 inch long

104
Q

Most rivets used in aircraft construction have

A

Dimples

105
Q

What is one of the determining factors which permits machine countersinking when flush riveting?

A

Thickness of the material is greater than the thickness of the rivet head.

106
Q

How does acoustic emission testing detect detetcs in composite materials?

A

By picking up the “noise” of any deterioration that may be present.

107
Q

(Refer to Figure 5.) What is the flat layout dimension?

A

6.8 inches

108
Q

Shallow scratches on sheet metal may be required by

A

Burnishing

109
Q

The length of a rivet to be used to join a sheet of .032 inch inch and .064 inch aluminum alloy should be equal to

A

One and one-half times the rivet diameter plus .096 inch.

110
Q

1) When performing a ring (coin tap) test on composite structures, a change in sound may be due to damage or to transition to a different internal structure.
2) The extent of separation damage in composite structures is most accurately measured by a ring (coin tap) test.
Regarding the above statements,

A

Only No.1 is true

111
Q

The classification for high tensile strength fiberglass used in aircraft structures is

A

S-glass

112
Q

The markings on the head of a Dzus fastener identify the

A

Body diameter, type of head, and length of the fastener.

113
Q

Which of the following are generally characteristic of aramid fiber (kevlar) composites?
1 - High tensile strength
2 - Flexibility
3 - Stiffness
4 - Corrosive effect in contact with aluminum
5 - Ability to conduct electricity

A

1 and 2

114
Q

Which rivets should be selected to join two sheets of .032 inch aluminum?

A

MS20470AD-4-4

115
Q

Which of the following drill bit types work best when drilling an aramid fiber (Kevlar) composite laminate?

A

Carbide W-point

116
Q

A piece of sheet metal is bent to a certain radius . The curvature of the bend is referred to as the

A

Bend radius

117
Q

(Refer to Figure 4.) The length of flat A is

A

3.750 inches

118
Q

The part of a replacement honeycomb core that must line up with the adjacent original is the

A

Ribbon direction

119
Q

A potted compound repair on honeycomb can usually be made on damages less than

A

1 inch in diameter

120
Q

One of the main advantages of Hi-lok type fasteners over earlier generations is that

A

They can be installed with ordinary hand tools.

121
Q

Cabin upholstery materials installed in current standard category airplanes must

A

Be at least flame resistant

122
Q

What is the most common method of cementing transport plastics

A

Soak method

123
Q

Aircraft structural units, such as spars, engine supports etc, which have been built up from sheet metal, are normally

A

Repairable, using approved methods.

124
Q

One method of inspecting a laminated fiberglass structure that has been subjected to damage is to

A

Strip the damaged area of all paint and shine a strong light through the structure.

125
Q

You can distinguish between aluminum and aluminum alloy by

A

Testing with a 10 percent solution of caustic soda.

126
Q

What is the minimum edge distance for aircraft rivets?

A

Two times the diameter of the rivet shank

127
Q

(Refer to Figure 2.) Select the preferred drawing for proper countersinking

A

1

128
Q

When balsa wood is used to replace a damaged honeycomb core, the plug should be cut so that

A

The grain is perpendicular to the skin.

129
Q

Which part(s) of a semi-monocoque fuselage prevent(s) tension and compression from bending the fuselage?

A

Longerons and stringers

130
Q

Heat-treated rivets in the D and DD series that are not driven within the prescribed time after treatment of removal from refrigeration

A

Must be reheat treated before use.

131
Q

Rivet gauge, or transverse pitch is the distance between the

A

Centers of rivets in adjacent rows.

132
Q

Which statement is true regarding the inspection of a stressed skin metal wing assembly known to have been critically loaded?

A

If genuine rivet tipping has occurred, groups of consecutive rivet heads will be tipped in the same direction.

133
Q

Superficial scars, scratches, surface abrasion, or rain erosion on fiberglass laminates can generally be repaired by applying

A

One or more coats of suitable resin (room temperature catalyzed) to the surface.

134
Q

What should be the included angle of a twist drill for hard metal?

A

118 degrees.

135
Q

When a piece of aluminum alloy is to be bent using a minimum radius for the type and thickness of material,

A

The layout should be made so that the bend will be 90 degrees to the grain of the sheet.

136
Q

The classification for fiberglass reinforcement material that has high resistivity and is the most common is

A

E-glass

137
Q

The general rule for finding the proper rivet diameter is

A

Three times the thickness of the thickest sheet

138
Q

How many MS20470 AD-4-6 rivets will be required to attach a 10x5 inch plate, using a single row of rivets, minimum edge distance, and 4D spacing?

A

56

139
Q

The installation of cherry mac and olympic-Lok rivets is accomplished by utilizing

A

A pulling tool

140
Q

When installing transparent plastic enclosures which are retained by bolts extending through the plastic material and self-locking nuts, the nuts should be

A

Tightened to a firm fit, then backed off one full turn.

141
Q

The strength and stiffness of a properly constructed composite buildup depends primarily on

A

The orientation of the plies to the load direction.

142
Q

Parts fabricated from Alclad 024-T3 aluminum sheet stock must have all

A

Scratches, kinks, tool marks, nicks, etc., must be held to a minimum.

143
Q

The Dzus turnlock fastener consists of a stud, grommet, and receptacle. The stud length is measured in

A

Hundredths of an inch.

Airframe (17 decks)

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