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A&P - Airframe > Sheet Metal and Non-Metallic Structures > Flashcards

Sheet Metal and Non-Metallic Structures Flashcards

1
Q

A well-designed rivet joint will subject the rivets to

A

shear loads

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2
Q

A main difference between Lockbolt/Huckbolt tension and shear fasteners is in the

A

number of locking collar grooves

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3
Q

Alloy 2117 rivets are heat treated

A

by the manufacture and do not require heat treatment before being driven

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4
Q

The general rule for finding the proper rivet diameter

A

three times the thickness of the thickest sheet

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5
Q

The shop head of a rivet should be

A

one and a half times the diameter of the rivet shank

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6
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

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7
Q

Which of the following is on advantage of Hi-Lok fasteners?

A

Inability to be over torqued

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8
Q

The markings on the head of a Dzus fastener identify the

A

body diameter, type of head and length of fastener

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9
Q

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

A

Hundredths of a inch

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10
Q

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

A

Sixteenths of a inch

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11
Q

Threaded rivets (Rivnuts) are commonly used to

A

attach parts or components with screws to sheet metal

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12
Q

The installation of Cherry-max and Olympic-lok rivets is accomplished by utilizing

A

a pulling tool

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13
Q

Hole filling fasteners (for example, MS20470 rivets) should not be used in composite structures primarily because of the

A

possibility of causing delamination

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14
Q

Metal fasteners used with carbon/graphite composite structures

A

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

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15
Q

Sandwich panels made of metal honeycomb construction are used in high speed on aircraft because this type of construction

A

saves weight while not compromising on strength

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16
Q

No.1 When performing a ring tap (coin tap) test on composite structures, a change in sound may be due to damage or to transition to a different internal structure

A

No.1 is only true

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17
Q

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

A

X-ray and backlighting

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18
Q

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

A

the grain in perpendicular to the skin

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19
Q

When preparing a wood surface for bonding, what should NOT be used?

A

Sandpaper

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20
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

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21
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 of a test sample

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22
Q

How does acoustic emission testing detect defects in composite materials?

A

by picking up the ‘noise’ of any deterioration that may be present

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23
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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24
Q

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

A

Prime the repair with a corrosion inhibitor and seal from atmosphere

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25
Q

One method of inspecting a laminated fibreglass 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

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26
Q

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

A

seperation of the laminates

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27
Q

Which of the following are benefits of using micro balloons when making repairs to laminated honeycomb panels?

A

Improved strength to weight ratio, less density and lower stress concentrations

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28
Q

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

A

pot life

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29
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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30
Q

The classification for high tensile strength fibreglass used in aircraft structure is

A

S-glass

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31
Q

Which is a identifying characteristic of acrylic plastics?

A

Zinc chloride will have no effect

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32
Q

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

A

one or more coats of suitable resin (room temp catalyzed) to the surface

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33
Q

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

A

E-glass

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34
Q

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

A

1 inch in diameter

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35
Q

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

A

Warp

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36
Q

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

A

Warp clock

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37
Q

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

A

the orientation of the plies to the load direction

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38
Q

Which fibre to resin (percent) ratio for advanced composite wet lay ups is generally considered the best for strength?

A

60:40

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39
Q

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

A

Bleeder

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40
Q

Proper prepreg composite lay-up curing is generally accomplished by

A

applying external heat and pressure

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41
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 fibreglass in the bonded repair

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42
Q

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

A

MEK (methyl ethyl ketone)

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43
Q

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

A

Water only

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44
Q

Fibreglass 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 fibres

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45
Q

Fibreglass damage that extends completely through a laminated sandwich structure

A

may be repaired

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46
Q

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

A

an unairworthy repair

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47
Q

The preferred way to make permanent repairs on composites is by

A

laminating on new repair plies

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48
Q

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

A

flox and chopped fibres

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49
Q

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

A

ribbon direction

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50
Q

Which of the following are generally characteristics of aramid fibre (Kevlar) composite?

A

High tensile strength and flexibility

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51
Q

Which of the following are generally characteristic of carbon/graphite fibre composite?

A

Stiffness, high compressive strength and the corrosive effect in contact with aluminium

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52
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

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53
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

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54
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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55
Q

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

A

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

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56
Q

The coefficient of expansion of most plastic enclosure materials is

A

greater than both steel and aluminum

57
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

58
Q

Cabin upholstery material installed in current standard category airplanes must

A

be at least flame resistant

59
Q

Which regulation provides the airworthiness standards for an airplane certificated in the normal category?

A

14 CFR Part 23

60
Q

What is the most common method of cementing transparent plastics?

A

soak method

61
Q

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

A

a specially modified twist drill

62
Q

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

A

Carbide W-Point or Tapered carbide point

63
Q

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

A

To join and reinforce intersecting structural members

64
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

65
Q

How many MS20470 AD-4-6 rivets will be required to attach a 10” x 5” plate, using a single row of rivets, min edge distance and 4D spacing?

A

56

66
Q

On a semi-monocoque fuselage, the skin is reinforced by longitudinal structural members called

A

longerons and stringers

67
Q

Shallow scratches in sheet metal may be repaired by

A

burnishing

68
Q

Which maintenance action is an airframe major repair?

A

The repair of portions of skin sheets by making additional seams

69
Q

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

A

90 degrees

70
Q

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

A

lower speed with more pressure applied to the drill

71
Q

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

A

13/16 inch

72
Q

What is the minimum edge distance allowed for aluminum alloy single lap sheet splices containing a single row of rivets as compared to join with multiple rows, all rivets being equal in diameter?

A

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

73
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

74
Q

What is the minimum edge distance for aircraft rivets

A

Two times the diameter of the rivet shank

75
Q

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

A

140 degrees and turn at a low speed

76
Q

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

A

Three times the diameter of the rivet shank

77
Q

What 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 aluminium

78
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

79
Q

What is one of the determining factors that requires the use of dimpling instead of countersinking?

A

Thickness of the material is less than the thickness of the rivet head`

80
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

81
Q

Which procedure is correct when using a reamer to finish a drilled hole to the correct size?

A

Turn the reamer only in the cutting direction

82
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 than similar repairs to the upper surface

83
Q

When straightening members made of 2024-T4, you should

A

straighten cold and reinforce

84
Q

Clad aluminium 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

85
Q

Which statement is true regarding a cantilever wing?

A

No external bracing is needed

86
Q

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

A

repairable using approved methods

87
Q

A factor which determines the minimum space between rivets is

A

diameter of the rivets being used

88
Q

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

A

118 degrees

89
Q

When fabricated parts from Alclad 2024-T3 aluminium sheet stock, all

A

scratches, kink, tool marks, nicks etc must be held to a minimum

90
Q

Monocoque fuselage relies largely on the strength of

A

skin or coverings

91
Q

Which part of a semi monocoqoue fuselage prevents tension and compression from bending the fuselage?

A

Longerons and stringers

92
Q

Rivet gauge or transverse pitch is the distance between

A

centre of rivets in adjacent rows

93
Q

Rivet pitch is the distance between the

A

centre of adjacent rivets in the same row

94
Q

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

A

Fretting corrosion is occuring between the rivets and the skin

95
Q

The identifying marks on the heads of aluminium alloy rivets indicate the

A

specific alloy used in manufacture of the rivets

96
Q

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

A

only after a period of age hardening

97
Q

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

A

Rivet length

98
Q

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

A

to retard age hardening

99
Q

Rivets can be stored below 32 degrees for how long after heat treatment to retard hardening?

A

24 hours

100
Q

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

A

low strength characteristics

101
Q

A rivet set used to drive MS20470 rivets should

A

have a slightly greater radius than the rivet head

102
Q

Heat treated rivets in the D and DD series that are not driven with in the prescribed time after heat treatment or removal from refrigeration

A

must be reheat treated before use

103
Q

The dimension of an MS20430AD-4-8 are

A

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

104
Q

The primary alloying agent of 2024-T36 is indicated by the number

A

2 (First number)

105
Q

Which part of 2024-T3 indicated the temper designation?

A

T3

106
Q

Which part of 2017-T36 aluminum alloy designation indicates the primarily alloying agent used in it manufacture?

A

2

107
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 rivets. The length of the rivets to be used will be

A

1/4 inch

108
Q

Most rivets used in aircraft construction have

A

dimples

109
Q

MS20426AD-6-5 indicated a counter sink rivet which has

A

an overall length of 5/16 inch

110
Q

Which rivet may be used as received without further treatment?

A

2117-T3

111
Q

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

A

MS20470AD-4-4

112
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

113
Q

Mild steel rivets are used for riveting

A

steel parts

114
Q

A DD rivet is heat treated before use to

A

soften to facilitate riveting

115
Q

When riveting dissimilar metals together, what precautions must be taken to prevent an electrolytic action?

A

Place a protective separator between areas of potential electrical difference

116
Q

The length of a rivet to be used to join a sheet of 0.032-inch and .064-inch aluminium alloy should be equal to

A

one and half times the rivet diameter plus .096 inch

117
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 head one size smaller than the rivet shank and remove the rivet with a punch

118
Q

Joggles in removed rivet shank would indicate partial

A

shear failure

119
Q

Joggles in rivet shanks due to shear failure would get replaced by which of the following?

A

A larger solid replacement rivet

120
Q

What types of loads cause the most rivet failures?

A

Shear

121
Q

Which rivet is used for riveting magnesium alloy structure?

A

5056 aluminium

122
Q

Which rivet is used for riveting nickel-steel alloys?

A

Monel

123
Q

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

A

5/16 inch

124
Q

If a streamline cover plate is to be hand formed by using a form block, 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 centre

125
Q

A piece of flat stock that is to be bent to closed angle of 15 degrees must be bent through an angle of

A

165 degrees

126
Q

When a piece of aluminum alloy is to be bent using a minimum bend 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

127
Q

The flat layout or blank length of a piece of metal from which a simple L-shaped bracket 3 inches by 1 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

128
Q

If it is necessary to compute a bend allowance problem and bend allowance table 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

129
Q

Unless otherwise specified, the radius of a bend is the

A

inside radius of the metal being formed

130
Q

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

A

minimum radius of bend

131
Q

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

A

radius, thickness and degree of bend

132
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

133
Q

You can distinguish between aluminum and aluminum alloy by

A

testing with a 10 percent solution of caustic soda

134
Q

The purpose of a joggle is to

A

allow clearance for a sheet or extrusion

135
Q

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

A

neutral line

136
Q

The sight line on a sheet metal flat layout to be bent is measured and marked

A

one radius from the bend tangent line that is placed under the brake

137
Q

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

A

by subtracting the setback from both legs

138
Q

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

A

heat treatment

A&P - Airframe (18 decks)

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