Sheet metal FAA questions

B- only No.1 is true

(1) When reforming a ring (coin tap) test on composite structures, a change in sound may be due to damage or 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. A- both No.1 and No.2 are true B- only No.1 is true C- only No.2 is true

A- 1

(Refer to figure 1.) Which of the rivets shown will accurately fit the conical depression made by a 100 degree countersink? A- 1 B- 2 C-3

A- thermoplastic

A category of plastic material that is capable of softening or flowing when reheated is described as a A- thermoplastic. B- thermocure. C- thermoset

A- number of locking collar groves

A main difference between Lockbolt/Huckbolt tension and shear fasteners (other than their application) is the: A- number of locking collar grooves. B- shape of the head C- method of installation

C- 1 inch in diameter.

A potted compound repair on honeycomb can usually be made on damages less than: A- 4 inches in diameter. B- 2 inches in diameter. C- 1 inch in diameter

C-13/16 inch

A single-lap 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- 1/2 inch B- 3/4 inch C- 13/16 inch

B- shear loads

A well-designed rivet joint will subject the rivets to: A- compressive loads B- shear loads C- tension loads

A- by the manufacturer and do not require reheat treatment before being driven.

Alloy 2117 rivets are heat treated A- by the manufacturer and do not require heat treatment before being driven. B- by the manufacturer but require reheat treatment before being driven. C- to a temperature of 910 to 930 F and quenched in cold water.

B- be at least flame resistant

Cabin upholstery materials installed in current standard category airplanes must A- be fireproof B- be at least flame resistant C- meet the requirements prescribed in Part 43

B- have surface layers of pure aluminum or aluminum alloy bonded to the core material to inhibit corrosion.

Clad aluminum alloys are used in aircraft because they: A- are naturally corrosion resistant, so they do not require corrosion resistant materials for protection. B- have surface layers of pure aluminum or aluminum alloy bonded to the core material to inhibit corrosion. C- are highly corrosion resistant because of an oxide film forms on their surfaces upon contact with air.

B- Warp.

Composite fabric material is considered to be the strongest in what direction? A- Fill. B- Warp. C- Bias.

A- may be repaired

Fiberglass damage that extends completely through a laminated sandwich structure A- may be repaired B- must be filled with resin to eliminate dangerous stress concentrations C- may be filled with a putt which is compatible with resin

A- filling with a putty consisting of a compatible resin and clean, short glass fibers.

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 B- sanding the damaged area until an aerodynamic smoothness is obtained. C- trimming the rough edges and sealing with paint.

B- requires the replacement of the damaged core and facing

Fiberglass laminate damage that extends completely through one facing and into the core: A- cannot be repaired B- requires the replacement of the damaged core and facing C- can be repaired by using a typical metal facing patch

A- possibility of causing delamination

Hole filling fasteners (for example, MS20470 rivets) should not be used in composite structures primarily because of the: A- possibility of causing delamination B- increased possibility of fretting corrosion in the fastener C- difficulty in forming a proper shop head

A- By picking up the ''noise'' of any deterioration that may be present.

How does acoustic emission testing detect defects in composite materials: A- By picking up the ''noise'' of any deterioration that may be present. B- By analyzing ultrasonic signals transmitted into the parts being inspected. C- By creating sonogram pictures of the areas being inspected.

A- 56.

How many MS20470 AD-4-6 rivets will be required to attach a 10 x 5 inch plate, using a single row of rivets, minimum edge distance, and 4D spacing? A- 56. B-54. C-52.

A- 2,3, and 4

How many of the following are benefits of using micro balloons when making repairs to laminated honeycomb panels? 1. Greater concentration of resin in edges and corners. 2. Improved strength to weight ratio. 3. Less density. 4. Lower stress concentrations A- 2,3, and 4. B- 1,2, and 4 C- All of the above.

C- TSO C22

If a new safety belt is to be installed in an aircraft, the belt must conform to the strength requirements in which document? A- STC 1282 B- FAR Part 39 C- TSO C22

C- crazing

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- Hazing B- brinelling C- crazing

C- covered with a thin coat of wax.

If no scratches are visible after transparent plastic enclosure materials have been cleaned, their surfaces should be A- polished with rubbing compound applied with a damp cloth B- buffed with a clean, soft, dry cloth. C- covered with a thin coat of wax

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

Metal fasteners used with carbon/graphite composite structures: A- may be constructed of any of the metals commonly used in aircraft fasteners. B- must be constructed of material such as titanium or corrosion resistant steel. C- must be constructed of high strength aluminum-lithium alloy.

B- longerons and stingers

On a semimonocoque fuselage, the skin is reinforced by longitudinal structural members called? A- beams and struts B- longerons and stingers C- formers and bulkheads

A- strip the damaged area of all paint and shine a strong light through the structure.

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. B- use dye-penetrant inspection procedures, exposing the entire damaged area to the penetrant solution. C- use an eddy current robe on both sides of the damaged area.

B- have a mixed enough for a test sample.

One of the best ways to assure that a properly prepared batch of matrix resin has been achieved is to: A- perform a chemical composition analysis B- have a mixed enough for a test sample C- test the viscosity of the resin immediately after mixing

C- they can be installed with ordinary tools.

One of the main advantages of Hi-Lok type fasteners over earlier generations is that: A- they can be removed and reused again. B- the squeezed on collar installation provides a more secure, tighter fit. C- they can be installed with ordinary tools.

B- 1 and 4

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- 2 and 3 B- 1 and 4 C- 1,3, and 4

C- an unairworthy repair

Repairing advanced composites using materials and techniques traditionally used for fiberglass repairs is likely to result in: A- restored strength and flexibility B- slightly stronger strength to weight ratio C- an unairworthy repair

C- permitted but are normally more critical in reference to strength in tension than similar repairs to the upper surface.

Repairs or splices involving stringers on the lower surface of stressed skin metal wings are usually: A- not permitted. B- permitted only if the damage does not exceed 6 inches In any direction. C permitted but are normally more critical in reference to strength in tension than similar repairs to the upper surface.

A- has a high strength to weight ratio

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. B- may be repaired by gluing replacement skin to the inner core material with thermoplastic skin. C- is lighter than a single sheet skin of the same strength and is more corrosion resistant.

C- Forms the cutting edges of the drill point.

Select the alternative which best describes the function of the flute section of a twist drill. A- Provides a method for cooling oil to be delivered to the cutting surface. B- Forms the area where the drill bit attaches to the drill motor. C- Forms the cutting edges of the drill point.

A- burnishing

Shallow scratches in sheet metal may be repaired by A- burnishing B- buffing C- stop drilling

B- one ore or more coats of a suitable resin (room temperature catalyzed) to the surface.

Superficial scars, scratches, surface abrasion, or rain erosion on fiberglass laminates can generally be repaired by applying: A- a piece of resin-impregnated glass fabric facing B- one or more coasts of a suitable resin (room temperature catalyzed) to the surface C- a sheet of polyethylene over the abraded surface and one or more coats of resin cured with infared heat lamps.

C- sixteenths of an inch

The Dzus turnlock fastener consists of a stud, grommet, and receptacle. The stud diameter is measured in: A- tenths of an inch B- hundredths of an inch C- Sixteenths of an inch

A- hundredths of an inch

The Dzus turnlock fastener consists of a stud, grommet, and receptacle. The stud length is measured in: A- hundredths of an inch B- tenths of an inch C- sixteenths of an inch

A- E-glass

The classification for fiberglass reinforcement material that has a resistivity and is the most common is A- E-glass B- S-glass C- C-glass

B- S-glass

The classification for high tensile strength fiberglass used in aircraft structures is A- E-glass B- S-glass C- C-glass

A- greater than both steel and aluminum

The coefficient of expansion of most plastic enclosure materials is A- greater than both steel and aluminum B- greater than steel but less than aluminum C- less than either steel or aluminum

C- three times the thickness of the thickest sheet.

The general rule for finding proper rivet diameter is: A- three times the thickness of the materials to be joined. B- two times the rivet length. C- three times the thickness of the thickest sheet.

B- a pulling tool

The installation of Cherrymax or Olympic-Lok rivets is accomplished by utilizing : A- rivet gun, special rivet set, and bucking bar. B- a pulling tool C- ordinary hand tools

A- pot life

The length of time that a catalyzed resin will remain in a workable state is called the A- pot life. B- work life. C- pliable life.

A-body diameter, type of head, and length of the fastener.

The markings on the head of a Dzus fastener identify the: A- body diameter, type of head, and length of the fastener. B- body type, head diameter, and type of material C- manufacturer and type of material

B- ribbon direction

The part of a replacement honeycomb core that must line up with the adjacent original is the: A-cell side B- ribbon direction C- cell edge

C- laminating on new repair plies.

The preferred way to make permanent repairs on composites is by: A- bonding on metal or cured composite patches. B- riveting on metal or cured composite patches. C- laminating on new repair plies.

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

The shop head of a rivet should be: A- one and one-half times the diameter of the rivet shank. B- one-half times the diameter of the rivet shank. C- one and one-half times the diameter of the manufactured head of the rivet.

B- the orientation of the plies to the load direction.

The strength and stiffness of a properly constructed composite buildup depends primarily on: A- a 60 percent matrix to 40 percent fabric ratio. B- the orientation of the plies to the load direction. C- the ability of the fibers to transfer stresses to the matrix.

B- attach parts or components with screws to sheet metal

Threaded rivets (Rivnuts) are commonly used to A- join two or more pieces of sheet metal where shear strength is desired. B- attach parts or components with screws to sheet metal C- join two or more pieces of sheet metal where bearing strength is desired

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

What is one of the determining factors which permits machine countersinking when flush riveting? A- Thickness of the material and rivet diameter are the same. B- Thickness of the material is less than the thickness of the rivet head. C- Thickness of the material is greater than the thickness of the rivet head.

A- Bleeder

What is the material layer used within a the vacuum bag pressure system to absorb excess resin during curing called? A- Bleeder. B- Breather C- Release

C- The minimum edge distance for the single row is equal

What is the minimum edge distance allowed for aluminum allow single lap splices containing a single row of rivets as compared to a joint with multiple rows, all rivets being equal in diameter. A- The minimum edge distance for the single row is greater than that for the multiple row. B- The minimum edge distance for the single row is less than that for the multiple row. C- The minimum edge distance for the single row is equal to that for the multiple row.

A- Two times the diameter of the rivet shank

What is the minimum edge distance for aircraft rivets? A- Two times the diameter of the rivet shank. B- Two times the diameter of the rivet head. c- Three times the diameter of the rivet shank.

C- Three times the diameter of the rivet shank

What is the minimum spacing for a single row of aircraft rivets? A- Two times the diameter of the rivet shank. B- Three times the length of the rivet shank. C- Three times the diameter of the rivet shank

B- Soak method

What is the most common method of cementing transparent plastics? A- Heat method B- Soak method C- Bevel method

C- To join a reinforce intersecting structural members

What is the purpose of a gusset or gusset plate used in the construction and repair of aircraft structures? A- To hold structural members in position temporarily until the permanent attachment has been made. B- To provide access for inspection of structural attachments. C- To join and reinforce intersecting structural members.

A- Prime the repair with a corrosion inhibitor and seal from the atmosphere.

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. B- Paint the outside area with several coats of exterior paint. C- None. Honeycomb is usually made form manmade or fibrous material which is not susceptible to corrosion.

C- Warp clock (or compass)

What reference tool is used to determine how the fiber is to be oriented for a particular ply of fabric? A- Fill clock (or compass). B- Bias clock (or compass). C- Warp clock (or compass).

B- 90 degrees

What should be the included angle of a twist drill for soft metals? A- 118 degrees B- 90 degrees C- 65 degrees

B- A specially modified twist drill.

What type of bit should be used to drill holes in Plexiglas? A- A standard twist drill. B- A specially modified twist drill. C- A dulled twist drill.

C- the grain is perpendicular to the skin

When balsa wood is used to replace a damaged honeycomb core, the plug should be cut so that: A- the grain is parallel to the skin. B- it is about 1/8 inch undersize to allow sufficient bonding material is applied. C- the grain is perpendicular to the skin

B-lower sped with more pressure applied to the drill.

When comparing the machining techniques for stainless steel sheet material to those for aluminum alloy sheet, it is normally considered good practice to drill stainless steel at a A- higher speed with less pressure applied to the drill. B- lower speed with more pressure applied o the drill. C- lower speed with less pressure applied to the drill.

B-Dull thud

When conducting a tap test on a composite panel, which of the following sounds would indicate delamination? A- Sharp ringing B- Dull thud C- Sharp thud

C- 140 degrees and turn at a low speed

When drilling stainless steel, the drill used should have an included angle of A- 90 degrees and turn at a low speed B- 118 degrees and turn at a high speed. C- 140 degrees and turn at a low seed.

B- separation of the laminates

When inspecting a composite panel using the ring test/tapping method, a dull thud may indicate: A- less than full strength curing of the matrix. B- separation of the laminates. C- an area of too much matrix between fiber layers

B- tightened to a firm fit, the backed off one full turn

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, plus one fill turn B- tightened to a firm fit, then backed off one full turn. C- tightened to a firm fit.

A-MEK

When making repairs to fiberglass, cleaning of the area to be repaired is essential for a good bond. The final cleaning should be made using: A- MEK (methyl ethyl ketone) B- soap, water, and a scrub brush C- A thixotropic agent

C- Water only

When necessary, what type of cutting fluid is usually acceptable for machining composite laminates? A- Water soluble oil B- Water displacing oil C- Water only

A- the shear strength of the riveted joint.

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. B- to use rivet spacing similar to a seam in the skin. C- that the bond between the patch and the skin is sufficient to prevent dissimilar metal corrosion.

B- use short strips of fiberglass in the bonded repair

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- add an extra amount of catalyst to the resin B- use short strips of fiberglass in the bonded repair C- use less catalyst than normal so the repair will be more flexible

B- 100 times the thickness of the metal

When repairing puncture-type damage of a metal faced laminated honeycomb panel, the edges of the doubler should be tapered to: A- two times the thickness of the metal B- 100 times the thickness of the metal C- whatever is desired for a neat, clean appearance

A- straighten cold and reinforce.

When straightening members made of 2024-T4, you should: A- straighten cold and reinforce. B- straighten cold and anneal to remove stress. C- apply heat to the inside of the bend.

C- 60 fiber:40 resin

Which fiber to the resin (percent) ratio for advanced composite wet lay-ups is generally considered the best for strength? A- 40:60 B-50:50 C- 60:40

A- Zinc chloride will have no effect

Which is an identifying characteristic of acrylic plastics? A- Zinc chloride will have no effect B- Acrylic has a yellowish tint when viewed from the edge C- Acetone will not soften plastic but will change its color

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

Which is considered good practice concerning the installation of acrylic plastics? A- When nuts and bolts are used, the plastic should be installed hot and tightened to a firm fit before the plastic cools. B- When rivets are used, adequate spacer or other satisfactory means to prevent excessive tightening of the frame to the plastic should be provided. C- When rivets or nuts and bolts are used, slotted holes are not recommended.

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

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. B- A smoother finish can be obtained by using a double-cut file than using a single cut. C- The terms "double-cut" and "single-cut" have the same meaning in reference to files.

A- 1 and 2

Which of the following are generally characteristics 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 B- 2, 3, and 4 C-1, 3, and 5

B- 2, 3, and 4

Which of the following are generally characteristics of carbon/graphite fiber composites? 1-Flexibility 2. Stiffness 3. High compressive strength 4. corrosive effect in contact with aluminum 5. Ability to conduct electricity A- 1 and 3 B- 2, 3, and 4 C- 1, 3, and 5

C- Carbide W-Point

Which of the following drill bit type work best when drilling an aramid fiber (Kevlar) composite laminate? A- Tool steel with standard grind. B- Diamond dust coated C- Carbide W-Point.

C- Inability to be over-torqued.

Which of the following is one advantages of Hi-Lok fasteners: A- Shorter transition area between the shank and thread. B- External counterbore at the base to accommodate material thickness. C- Inability to be over-torqued.

A- 2 and 3

Which of the following, when added to wet resins, provide strength for the repair of damaged fastener holes in composite panels? 1. Microballoons. 2. Flox 3. Chopped fibers A- 2 and 3 B- 1 and 3 C- 1, 2, and 3

C- 2 and 3

Which of these methods may be used to inspect fiberglass/honeycomb structures for entrapped water? 1. Acoustic emission monitoring 2. X-ray 3. Backlighting A- 1 and 2 B- 1 and 3 C- 2 and 3

B- Turn the reamer only in the cutting direction.

Which procedure is correct when using a reamer to finish a drilled hole to the correct size? A- Turn the reamer in the cutting direction when enlarging and in opposite direction to remove from the hole. B- Turn the reamer only in the cutting direction. C- Apply considerable pressure on the reamer when starting the cut and reduce the pressure when finishing the cut.

B- No external bracing is needed.

Which statement is true regarding a cantilever wing. A- It has nonadjustable lift struts. B- No external bracing is needed. C- It requires only one lift strut on each side.

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

Which statement is true regarding inspection of a stressed skin metal wing assembly known to have been critically loaded? a- If rivets show no visible distortion, further investigation is unnecessary. B- If bearing failure has occurred, the rivet shanks will be joggled. C-If genuine rivet tipping has occurred, groups of consecutive rivet heads will be tipped in the same direction.