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Aircraft mechanics > Structures > Flashcards

Structures Flashcards

1
Q

Best way to prevent the formation of corrosion

A

Eliminate one of more of the basic requirements

  • remove the electrical potential difference within the metals
  • prevent the introduction of an electrolyte
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2
Q

Types of metallic coatings

A

Cladding: pure aluminium rolled onto aluminium alloy

Electroplating: plating cadmium, chromium, nickel or zinc on steel

Metal spraying: aluminium or zinc on steel

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3
Q

Surface conversion coatings

A

Anodising of al alloys

Alodine 1200, 1120 pens

Chromating of magnesium alloys

Phosphating of steel

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4
Q

Organic coatings

A

Paint
Jointing compound
Sealant
Cpcs

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5
Q

What are cpcs

A

Used as a secondary protective coating to the primary protection. Provided by paint, chromate primer, alodine anodising and plating

Oil/wax Base as a means of retarding and preventing corrosion

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6
Q

Types of cpcs

A

Type a- short term. Water displacing. Thin film. Base

Type b- medium term. Soft film. Common. Good penetrating properties

Type c- long term. Hard film. Low penetrating properties. Top coat.

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7
Q

Handling practices and husbandry

A
  • Maintain adequate cleaning/preservation programme.
  • Wear approved footwear and ensure soles are free from embedded abrasive material
  • Treat corrosion and failure of protective coatings as often as possible
  • Lubricate exposed mechanical parts regularly
  • Store removed panels/cooking’s safely to prevent them being blown and scratched
  • handle fuel hoses/ equipment carefully to avoid scratching Ac
  • drain/ventilation holes are free from obstructions
  • fit protective covers
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8
Q

Handling of al alloys

A

1) wear ppe
Gloves, overalls, steel toe/suitable footwear
2) seeks assistance if handling large sheets
3) clean work area

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9
Q

Storage of al alloys

A

1) store on edge to avoid damage to surface. But avoid damage to edge
2) take care of protecrivecoating
3) cut from one edge only. Take care to avoid removing identification markings
4) mark out in the most economical way prior to cutting
5) take particular care when inserting sheets into racks. Avoid scratching other sheets

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10
Q

Repair manuals and references

A

Specific Ac structural repair manual 13,-98
General Ac structural repair manual
General engineering manual
Manufacturers material and fastener data handbooks

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11
Q

Procedure for corrosion removal

A 
Ref:srm 
1) remove surface coating
2) consult srm for damage limits 
Measure corroded area
Discuss with supervisor 
Remove
3) measure damage after removal, repair if necessary
4) apply appropriate treatment to area affected
5) reapply surface coating
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12
Q

Types of surface coating removals

A

Chemical

Mechanical

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13
Q

Surface coating removal. Non powered mechanical

A 
Abrasive mats(scotch rite) 
Abrasive paper
Abrasive cloth
Wire brush 
Tube brush
Pumice powder 
Metallic wool 
scrapers
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14
Q

Surface coating removal. Powered mechanical

A 
Al oxide discs 
Scotchbrite discs
3m radial bristle discs 
Mediablasters 
Rotary file (burrs) 
Linisher (dynafile) 
Flapper wheel
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15
Q

Ways to measure damage for corrosion removal

A 
Depth garage 
Optical depth gauge 
Ndt 
Fluerscent dye penetrant 
Eddy current 
Ultrasonic
Radiographic 
Straight edge feeler gauge
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16
Q

Repair manuals

A

Specific aircraft structural repair manuals
general aircraft structural repair manual
General engineering manuals
Manufacturers material and fastener data handbooks

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17
Q

To- 1-1a series

A

To1-1a-1 general manual of structural repair
To1-1a-8 aircraft structural hardware
To 1-1a-9 aerospace metals general data/usage

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18
Q

Ap 101a series

A

Ap101a-1401-1 reverting process used on Ac

Ap101a-1402-1 aerospace sheet metals and fasteners

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19
Q

General engineering manuals

A

591
6003-1, Ac and aeronautical equipment maintenance- general orders and procedures
6000-1, Air Force maintenance orders
6005.042-1.1-3 engineering practices and procedures- ac and avionic systems cleaning and corrosion prevention

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20
Q

Identifying American al alloy

A 
Four digit designation
Clad bare
Temper
Thickness
Fed specification number
Manufacturers name
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21
Q

4 digit designations al alloys

A 
1-99% or higher pure al 
2-copper
3-manganese 
4-silicon
5-magnesium
6-magnesium and silicon
7-zinc
8-others
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22
Q

Methods of harden ing al alloy

A

Cold work
Rolling, forging, extrusions

Heat treatments
Solution heat, natural age, artificial age or precipitation heat treated

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23
Q

Hardness designators

A 
Cold- h1- strain hardened 
H2- strain hardened and partially annealed
H3- strain harder and stabilised
Heat- 0- annealed
W-solution heat treated (unstable) 
T3-solution HT then cold worked
T4 SHT then naturally age hardened 
T6 SHT then artificially age hardened
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24
Q

Go do we know which sheet to use?

A

Stated in drawing

Stated in srm/ repair scheme

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25
Q

Characteristics of al alloy sheets

A 
Large
Expensive
Difficult to handle
Sharp edges
Easy damaged
Major load carrying member
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26
Q

Storage of al alloy sheets

A

Store on edge to prevent damage to surface, but avoid damage to edge
Take care of protective coating
Cut from one edge only- don’t cut off identification markings
Mark sheet in most economical way
Take care when inserting sheets into racks to avoid scratching other sheets

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27
Q

Handling precautions for al alloy sheets

A

Ppe to be worn. Gloves, boots, overalls
Seek assistance if handling large sheets
Clean work area

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28
Q

Sphere of influence is what

A

5d

The area effected by the clamping force of each installed rivet

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29
Q

Edge distance?

A

2d minimum, specific limits in srm.

Distance between the centre of a fastener and a edge of the structure

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30
Q

What’s the pitch?

A

Distance between adjacent rivers centres in the same row. Commonly 4d

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31
Q

Transverse pitch of spacing?

A

Distance between the centres of rivets in rows. Commonly 4d

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32
Q

Clearence still does what

A

Allow for river expansion in the hole
Prevents burrs
Prevents hold damage and skin by killing
Prevents the protective coatings being removed on rivet installation

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33
Q

Drilling aids

A

Drill blocks

Bushings

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34
Q

Types of reams

A

Hand

Machine

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35
Q

Pilot holes-

Pre drill-

A

Used to locate new holes

Used prior to drilling final or clearance

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36
Q

Flush fasteners used where

A

Aerodynamically smooth skin surface is required

The fastener head may interfere with adjacent structure

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37
Q

Methods of flush fasteners

A

Countersinking

Dumpling

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38
Q

Why would u use countersinking

A 
Used on thicker material
Quick and easy 
Cheap
Used where dimpling is impractical or not possible 
Cons-weakens material strength
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39
Q

Factors effecting countersinking

A

Diameter of fastener head

Height of the fastener head

Angle of fastener head

Dimensions of fastener head can be found in Ac srm, 6005.001-1 or manufacturers fastner handbook

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40
Q

Common countersinking cutting bits

A

Multi fluted, un piloted

Piloted

Microstop

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41
Q

Things to note about multiflute not and piloted csk bit

A

Mfb-less likely to chatter because of the many cutting faces

Piloted- uses the pilot to guide the cutter, helps to keep concentric

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42
Q

Things to note about microstop countersink

A

Adjustable to depth increments of 0.001”

Gives accurate depth control

Negates requirement for frequent stops to check countersink depth

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43
Q

Material thickness limits for countersinking can be found where

A

Ac srm

Snap 6005.001-1

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44
Q

Dumpling used when

Also known as what

A

Form countersinking

Thinner material

Used where cut countersinking is impractical or not possible

Gives greater shear strength at fastner joint

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45
Q

Things to be aware of when dumpling a piece of material

A

Male and female dies match and are the correct size

Dumpling pressure is correct, otherwise causes warpages

Dumpling pilot hole is correct dimension. Critical to ensure the simple is concentric to the hole

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46
Q

Types of dimpling

A

Coin

Radius

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47
Q

Formed rivet terms

A

Manufacturers head
Shank
Shop head or tail

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48
Q

Grip=

Allowance=

A

GL= same as the material thickness
A=protruding length of the unformed rivet required before forming. Normally 1-1.5d
D=rivet shank dia

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49
Q

Total rivet length =

A

Grip + allowance

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50
Q

Shop head dimensions after riveting

A

0.5d

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51
Q

Head shapes

A

Countersink

Universal

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52
Q

Solid rivet identifications

A

A dimple- ad 2117

Dd-double dashes 2024

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53
Q

Solid rivet part numbers

An 426 ad 4-5

Ms20470 ad4-5

A 
Catalogue method 
Headstyle -426 countersink, 470 universal 
Alloy designation
Diameter in 1/32
Length in 1/16
54
Q

Methods of forming

A

Hand rivet
Squeeze rivet
Reaction rivet

55
Q

Reaction rivet

A

Rolling
Pneumatic air hammer
Snaps
Dollies or bucking bar

56
Q

Solid rivet faults

A 
Cut head 
Sheared head 
Open head 
Damaged skin
Snap damage
Cracked shop head 
Formed between skins-0.003” or less is ok 
Cocked head-0.002
Opened edge-0.010
Under/over formed shophead 
Offset shophead
57
Q

Servicae shophead dimensions

A
  1. 3-0.5d

1. 4-1.5d

58
Q

Safety precautions when operating a snap

A

Don’t operate fun without safety spring fitted on snap
Disconnect air supply when removing or replacing snap
Wear ear protection
Prior to riveting shout a warning to inform others of hazard
Always have a snap on rivet or wood when operating the gun

59
Q

What is a blind rivet
When is it used
Advantages

A

Rivet that can be fitted when access from only one side is possible

  • when access is no longer available due to further construction
  • when it would not be cost or time effective to gain access to use conventional fasteners
  • fitted blind or from one side
  • fitted by one person
60
Q

Blind rivet substitution.

A

Not a direct shbsititute forsolid rivets. Used only iaw ac srm(-3) and 6003-1 substitution chart

61
Q

Blind rivet terminology

A 
Mandrel or stem 
Driving anvil
Locking ring 
Tail or bulb 
Body or sleeve
62
Q

Generations of blind rivets

A

Pull thru-cherry pull thru
Friction locked-self plugging. Tucker pop
Mechanically locked, self plugging- huchloks, cherryloks, Olympicloks.
Self plugging mechanically locking mandrel bulged type- cherry max, huck clinch, huck max

63
Q

RNZAF blind rivet policy

A 
Laid out in NZ ap 6003-1 leaflet d1 
Tuckerpop
Olympic lok 
Cherry max 
Cherry pull thru 
Huckclinch/huck max
Huck blind bolt & jo bolt (heavy duty structural fastner)
64
Q

How to get correct length for grip length for blind bolt

A

Grip length gauges

Grip length chart

65
Q

Cherrymax/ huck clinch nominal and oversize indicators

A

Gold driving anvil-nominal

Silver driving anvil- oversize. Oversize is 1/64” bigger than the actual shank dia stated

66
Q

Tuckerpop identification

AGS2051630BS

A

Ags2051-rivet type, material headshape
6-dia in 1/32”
30-rivet length in 1/100”
Bs-breakstem

67
Q

Cherrymax identification

Cr3213-6-5

A

Cr-cherrymax rivet
3213-material, nom/over, headshape
-6-dia in 1/32”
-5-grip length in 1/16”

68
Q

Cherrymax tooling

A

Hand
Hydraulic hand
Pneumatic hydraulic

69
Q

Huck clinch identification

Hc3213-6-5

A

Hc-huck clinch rivet
3213-material nom/oversize
-6-dia in 1/32”
-5-GL 1/16”

70
Q

Headstyles for jo bolt

Made of what alloys

A

Hexagon protruding bead
100* flush head
100* flush billable head
Steel and titanium alloys

71
Q

Installation inspections for jo bolt

A

Looseness-checked with driving tool nose adapter, torque wrench

Head flushness- no more than 0.010”

Break off limits-go/no go gauge

Gaps under head-0.005” + reject, 0.004” around 40% of circumference or less=acceptable

Collar inspections-where possible

72
Q

Structural fasteners in rnzaf

A

Jo holy

Huck or cherry blind bolt

73
Q

Blind bolt identification

Ms90353-06-05

A

Ms90353-pn, head shape, material, nom/over
- -double action, S single action U unimatic
06-dia in 1/32”
05-GL in 1/16”

74
Q

What does the green dye on a blind bolt indicate

A

Single action installation

75
Q

Lock bolt identification
Pin- NAS1466-5

Collar-NAS1080-6

A

NAS146-pn, material, head shape, bom/over, stump/pull thru type
6-dia in 1/32”
5-GL in 1/16”

NAS1080-pn material
6-collar dia in 1/32”

76
Q

How do you inspect a lock bolt

A

With a go no go gauge

77
Q

Types of hi loc pins

A

Hi lox Pin

Hi tigue pin

78
Q

Hi tigue pin fatigue resistance benefits

A 
Burnishes the hole
Preloads the hold
Cold works the hole
Sizes the hole
Protects surface coatings
Lowers the installation loads
79
Q

Hi loc pn identification-part numbers
Pin-
HL50-6-6

Collar-HL90-6

A

HL50-pn material bead shape nom,over HLT=hi tigue
6-dia in 1/32”
6-GL in 1/16”

HL90-PN material
-6-dia in 1/32”

80
Q

Hi loc identification-head markings
Pin-
HL18-6-6

CollarHL70-6

A

HL18-pn material, head shape, nom/over, HLT-hi tigue
6-dia in 1/32”
6-GL in 1/16”

hl70-pn material
6-dia in 1/32”

81
Q

What is the preferred pin fastner for general repair work in the RNZAF during design of modifications and repair schemes

A

Hi lock

82
Q

Ac loads

A

Aerodynamic loads
Inertial
Concentrated
Engine

83
Q

Types of composites

A

Ceramic

Fibre reinforced plastics

84
Q

Types of FRP

A

Glass fibre
Carbon
Aramid/Kevlar
Boron

85
Q

Alternatives to al alloy

A

High strength steel alloys
-carbon
Stainless
Molybdenum

Titanium alloys
Magnesium

86
Q

Types of bulkheads

A 
Structural
Pressure
Fuel
Fire
Cantered
87
Q

Typical damage to Ac structure

A 
Warpage 
Fatigues
Oil canning
Buckling 
Corrosion
Impact damage
88
Q

Typical damage to Ac composite structure

A 
Substructure damage
Voids
Ingress of water and absorbsion
Disbonding
Delaminatiln
Barely visible impact damage
Cracking/brittle fractures
89
Q

Methods of ndt

A 
Magnetic particle detection
Ultrasonic 
Fluescent dye penetrant 
Visual
Eddy current 
Radiography
90
Q

3 conditions needed for corrosion to exist

A

Electrical potential difference between anode and cathode

Metallic connection between anode and cathode

Continuous liquid path (electrolyte)

91
Q

Factors influencing rate of corrosion

A 
Type of metal
Heat treated 
Grain direction
Anode and cathode surface area
Presence of electrolytes and degree of acidity
Salts
Temperature
Mechanical stress
Fatigue
92
Q

Corrosion prone areas-accessible

A 
External skin
Engine inlet
Engine exhaust
Wheel wells/landing gear
Battery compartments/cents
Lavatories/food service areas
93
Q

Types of forms for transparent plastic material

A

Simple curveformjng

Compound curve forming

94
Q

Types of compound curve forming

A 
Stretch forming
Mal and female die 
Vacuum forming without forms
Vacuum formwith a female 
Sawing
95
Q

What do you drink a plastic transparency with

A

Unibit for windshields and windows

96
Q

Repair of windows/windshields

A

Temporary-fly to a location where it can be replaced. Stop drill with no 30drill. No40 half inch from the edge

Permanent-stopdrill no30. Hypodermic syringe and needle to fill the crack with ethylene dichloride

97
Q

How are acrylic plastics joined together

A

Ethylene dichloride

98
Q

Types of construction

A 
Integral 
Bonded 
Sandwich
-honeycomb
-end grain bulsa
-plastic foam
99
Q

Defects for laminated glass

A

Scratches
Shattering
Delamination
Cracking

100
Q

Defects for plastics

A

Scratches
Crazing
Cracking
Distortion

101
Q

Ac locations using reference line sys

A

Fs-lengthways from a reference point along the fuselage
Ws-measured along the span of the wing with zero the centreline of the fuselage
Bl-left or right of the centreline of fuselage
Wl-measurement of height from horizontal line fixed below the bottom of the fuselage
XYZ-longitudinal,lateral,vertical axes as xyz and is identified by the manufacturer

102
Q 
Define skin
Frame 
Former 
Stringer
Bulkhead
A

Smooth outer covering of the af
-transverse structural member, provides aerodynamic shape and rigidity
Lighter than a frame
-a long continuous memberthat assists skin load carrying to other structural members
Major transverse membersin the fuselage or Wing and other structure

103
Q

Lightening hole. Define
Longeron
Stringer

A

A hole in a member to decrease weight with strength maintained by flagging around the hole
Main longitudinal structural member. Heavier than a stringer
A long continuous member hat assists skin load carrying to other structural members

104
Q

Stiffener

Doubler

A

Normally a strip or beam attached to a sheet to resist load normal to the surface. Short component used to stiffen a localised area
A piece of sheet or strip placed against Ac skin to provide stiffness it additional strength

105
Q

Cantilever construction
Spar
Cap
Boom

A

Supported internally by structural members assisted by the skin
The main structural span wise member of an aerofoil
The longitudinal member atthe top and bottom of a beam often called a boom
Longitudinal structural member

106
Q

Web

Rib

A

Vertical member of a beam, spar or other length of a wing or fuselage providing strength necessary to resist shear stress and keep upper and lower booms apart
-structural crosspieces combining with sparks and stringers to make the framework of wings, ailerons, elevators, riders and stabilisers

107
Q

Nacelle
Cowl panrl
Fairing

A

Any auxiliary structure that encloses the power plant or other equipment

  • surrounds the power plant or other equipment circumferentially and improves airflow
  • a smooth covering over a joint or a junction in an Ac structure providing a smooth surface for the airflow reducing drag
108
Q

Access panel

Structural/stressed panel

A

A seperate or distinct portion of the surface of an Ac structure earily removed
-similar to access panel but more substantial design and iaw mm or srm ay needyk Be fittedprior to Ac movement or jacking

109
Q

Fillet

Radome

A

Aerodynamic fairing giving radius atthe junction of two surfaces
-protective covering and aerodynamic fairing overtaxation antenna

110
Q

Impact damage to composite materials

A 
Substructure damage 
Voids
Water ingress and absorption
Disbonding / delamination
Barely visible impact damage
Cracking/brittle fractures
111
Q

Classes of structural damage

A

Negligible
Repairable
Replacement

112
Q

Ac inspection types

A

Zvin
Gvin
Corrosion

113
Q

Inspection tooling equipment

A

Light
Magnification
Mirrors

114
Q

Function of ndt

A

Method we are able to use to detect flaws without affecting the serviceability of the material

115
Q

Define corrosion

A

Deterioration of metals that result from an electro chemical reaction between a metal and its environment. Corrosion occurs due to the tendency for metals to return to their natural state

116
Q

Three conditions that must exist for corrosion

A

Difference in electrical potential between anode and cathode

Metallic connection between anode and cathode

Continuous liquid path

117
Q

Factors that influence corrosion

A 
Type of metal
Heat treatment
Grain direction
Dissimilar metals
Anode/cathode surface area
Presence of electrolytes and concentration
Salts
Oxygen
Temperature 
Mechanical stress
Fatigue 
Length of exposure
118
Q 
Corrosion looks like-
Al and al alloys
Magnesium alloys
Iron/steel
Copper alloys
Cadmium
Stainless steel
Titanium
A 
White-grey powdery particles
White-grey powder fluffy particles
Reddish brown scale
Blue/green powdery particles
White powder deposite
Red brown or black stain
No visible corrosion at low temp
119
Q

Accessible forrosion prone areas

A 
External skin areas
Eng Inlet 
Eng outlet 
Wheel wells and landing gear
Battery compartments and vents
Lavatories and good service areas
120
Q

Why corrosion of lavatories and good service areas

A

Organic materials are highly corrosive
Food waste traps water
Disinfectences are corrosive

121
Q

Inaccessible areas corrosion prone

A 
Electronic equipment 
Welded areas
Fuel tanks
Control surface recess
Piano hinges
Bulge areas
Landing gear boxes
Eng mount structure
122
Q

Ac sealants do what

A

Aid structural integrity
Contain vital gases and liquids
Prevent the ingress of damaging liquids and gases

123
Q

Sealant type for each application is contained in what publication/s

A

Ac srm.

Authorised sealants are listen in the nzap 6005.009-1

124
Q

Sealant construction is made of what compound

A

Two part polysulphide rubber compound and made to various different specifications

125
Q

Sealant part number

PR1440GB2

A 
Product number
G-Increased soluble chromate content. Helps prevent corrosion
B-method of application
A-brushable
B-sealant gun/spatula 
C-faying surface sealant sprayable 
2-application time in hours
126
Q

Reliving sealants and adhesives?

A 
Condition of container
-leakage, corrosion, degradation
Condition in container
-separation,layering, settling 
Application of properties
-lumps, foreign matter, viscosity 
Drying or cure time 
Appearance

If yes, extend by one half of initial assigned shelf life. 591, 7.17

127
Q

Non extendable shelf life of sealants

A
  • Not been stored in a controlled temperature environment
  • Products marked with an “N” in their relief code column
  • Locally purchased products
  • Those is aerosol containers
  • Those with no DOM
128
Q

Surface preparation sealants

A

Remove old sealant using a specialist type scraper
Thoroughly clean and degrease area
Mask around area to be sealed

129
Q

Sealant CHeck prior to mixing

A
  • Self life
  • separation of contents that may prohibit a homogenous mixture being achieved
  • Degradation of container
  • discolouration of Base compound or accelerator
  • hardness or tackiness
  • leakage from container
130
Q

Sealant application methods

A

Nozzle
Polythene tune
Spatulas

131
Q

Two part sealants are mixedhow

A

Iaw instructions on the semkit cartiridge

General instructions

132
Q

Sealant handling precautions

A 
Avoid eye contact
Avoid skin contact
Avoid breathing vapour 
Ensure adequate ventilation 
Store sealants correctly

Aircraft mechanics (14 decks)

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