CH. 4 AIRCRAFT METAL STRUCTURAL REPAIR

4-69 AMA094 If it is necessary to compute a bend allowance problem and 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. B. represented by the actual length of the required material for the bend. C. found by subtracting the stock thickness from the bend radius.

A

4-79 AMA016 What type of damage repair consists of removing the damaged portion from the structure and replacing it with a member identical in material and shape? A. damage repairable by insertion B. damage necessitating replacement of parts C. negligible damage

A

4-81 AMA016 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. B. Exfoliation corrosion is occurring inside the structure. C. The rivets were excessively work hardened during installation.

A

4-54 AMA016 The form of dimpling that should only be used when the regular male die is broken or not available in A. hot dimpling. B. radius dimpling. C. coin dimpling.

C

4-84 AMA016 When riveting dissimilar metal together, what precautions must be taken to prevent an electrolytic action? A. Avoid the use of dissimilar metals by redesigning the unit according to the recommendations outlined in AC43.13-2A. B. Treat the surfaces to be riveted together with a process called anodic treatment. C. Place a protective separator between areas of potential electrical difference.

C

4-19 AMA094 All the following are shrinking and stretching tools or devices, except 1. dollies and stakes 2. hardwood form blocks 3. sandbags 4. c-clamp A. 4 B. 3 C. 1

A

4-26 AMA016 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. B. Drill through the manufactured head and shank with a drill one size smaller than the rivet and remove the rivet with a punch. C. Drill through the manufactured head and shank with a shank size drill and remove the rivet with a punch.

A

4-29 AMA017 MS20426AD-6-5 indicates a countersink rivet which has A. an overall length of 5/16 inch. B. a shank length of 5/16 inch (excluding head). C. a shank length of 5/32 inch (excluding head).

A

4-30 AMA058 A DD rivet is heat treated before use to A. soften to facilitate riveting. B. harden and increase strength. C. relieve internal stresses.

A

4-47 AMA094 A factor which determines the minimum space between rivets is the A. diameter of the rivets being used. B. length of the rivets being used. C. thickness of the material being riveted.

A

4-8 AMA017 To polish surfaces, which is the best tool or tools to use? 1. disk sander 2. belt sander 3. wet or dry grinder 4. grinding wheels A. 1 and 4 B. All of the above C. 2 and 3

A

4-85 AMA017 The dimensions of an MS20430AD-4-8 rivet are A. 1/8 inch in diameter and 1/2 inch long. B. 1/8 inch in diameter and 1/4 inch long. C. 4/16 inch in diameter and 8/32 inch long.

A

4-86 AMA016 Aircraft structural units, such as spars, engine supports, etc., which have been built up from sheet metal, are normally? A. Repairable, using approved methods B. not repairable, but must be replaced when damaged or deteriorated C. repairable, except when subjected to compressive loads

A

4-2 AMA017 Which is the force that tries to pull two sheets apart A. bearing B. torsion C. bending

A

4-67 AMA094 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. B. bend allowance. C. maximum radius of bend.

A

4-35 AMA017 Most rivets used in aircraft repair have A. a raised dot. B. smooth heads without markings. C. dimples.

C

4-12 AMA029 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. B. Apply considerable pressure on the reamer when starting the cut and reduce the pressure when finishing the cut. C. Turn the reamer in the cutting direction when enlarging the hole and in the opposite direction to remove from the hole.

A

4-16 AMA094 A ____________ is used on cylindrical and flat sheet metal to shape the edge or to form a bead along the edge. A. rotary machine B. slip roll former C. piccolo former

A

4-22 AMA017 Under certain conditions, type A rivets are not used because of their A. low strength characteristics. B. tendency toward embrittlement when subjected to vibration. C. high alloy content.

A

4-24 AMA058 The aluminum alloys used in aircraft construction are usually hardened by which method A. heat treatment. B. aging. C. cold working.

A

4-25 AMA017 What is the purpose of refrigerating 2017 and 2024 aluminum alloy rivets after heat treatment? A. to retard age hardening B. to relieve internal stresses C. to accelerate age hardening

A

4-31 AMA094 The general rule for finding the proper rivet diameter is A. 3 times the thickness of the thickest sheet. B. 1/3rd the edge distance from the rivet line. C. 3 times the thickness of the combined sheets.

A

4-37 AMA017 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. B. 3/16 inch. C. 5/32 inch.

A

4-38 AMA017 The length of a rivet to be used to join a sheet of .32 inch and .064 inch aluminum alloy should be equal to A. one and one half times the rivet diameter plus .096 inch. B. three times the rivet diameter plus .096 inch. C. two times the rivet diameter plus .064 inch.

A

4-40 AMA094 The shop head of a rivet should be A. one and one-half times the diameter of the rivet shank. B. one and one-half times the diameter of the manufactured head of the rivet. C. one-half times the diameter of the rivet shank.

A

4-43 AMA017 Which of the following need not be considered when determining minimum rivet spacing? A. rivet length B. type of material being riveted C. rivet diameter

A

4-49 AMA094 Rivet pitch is the distance between the A. centers of adjacent rivets in the same row. B. heads of rivets in the same row. C. centers of rivets in adjacent rows.

A

4-75 AMA094 If a streamline cover plate is to be hand formed 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 center. B. distributed evenly over the face of the aluminum at all times rather than being started at the edges or center. C. started by tapping the aluminum in the center until it touches the bottom of the mold and then working out in all directions.

A

4-1 AMA094 A well designed rivet joint will subject the rivets to A. compressive loads. B. tension loads. C. shear loads.

C

4-60 AMA011 A main difference between Lockbolt/Huckbolt tension and shear fasteners (other than their application) is in the A. method of installation. B. number of locking collar grooves. C. shape of the head.

B

4-62 AMA011 Which of the following rivets is not a nonstructural blind fastener? A. pop rivet B. mechanical lock blind rivet C. pull through nutplate blind rivet

B

4-63 AMA094 Which forming operation involves shaping and forming malleable metal by hammering or tapping with a rubber, plastic or rawhide mallet? A. Shrinking B. Bumping C. Crimping

B

4-51 AMA017 _____________ is/are used if the smoothness of the material, such as skin, requires that all countersunk rivets be driven within a specific tolerance. A. Rivet sets/headers B. Compression riveting C. Microshavers

C

4-52 AMA017 When comparing the machining techniques for stainless steel sheet material to those for aluminum alloy sheet, it is normally considered good practice to drill the stainless steel at a A. higher speed with less pressure applied to the drill. B. lower speed with less pressure applied to the drill. C. lower speed with more pressure applied to the drill.

C

4-34 AMA017 Which rivet may be used as received without further treatment? A. 2117-T3 B. 2017-T3 C. 2024-T4

A

4-56 AMA016 What type of loads cause the most rivet failures? A. shear B. head C. bearing

A

4-65 AMA094 A piece of sheet metal is bent to a certain radius. The curvature of the bend is referred to as the A. bend radius. B. bend allowance. C. neutral line.

A

4-77 AMA017 Which rivet is used for riveting magnesium alloy structures? A. 5056 aluminum B. Monel C. mild steel

A

4-11 AMA029 When drilling in tough metals like corrosion-resistant steel and titanium, which drill bit would be used? A. step drill bits B. cobalt alloy drill bits C. twist drill bits

B

4-13 AMA029 Which drill accessory or accessories aid in holding the drill perpendicular to the part? 1. drill stop 2. drill bushing 3. drill holder A. 1 B. 2 and 3 C. 1, 2, and 3

B

4-18 AMA094 The forming tool that stretches and thins the metal before forming into the desired shape is the A. piccolo former. B. english wheel. C. spin former.

B

4-41 AMA016 Alloy 2117 rivets are heat treated A. to a temperature of 910 to 930°f and quenched in cold water. B. by the manufacturer and do not require heat treatment before being driven. C. by the manufacturer and require reheat treatment before being driven.

B

4-42 AMA016 When repairing a small hole on a piece of metal, the major consideration in the design of the patch should be A. that the bond between the patch and the skin is sufficient to prevent dissimilar metal corrosion. B. the shear strength of the riveted joint. C. to use rivet spacing similar to a seam in the skin.

B

4-44 AMA094 How many MS20470 AD-4-6 rivets will be required to attach a 10 × 5 inch plate, using a single row of rivets, minimum edge distance, and 4D spacing? A. 54 B. 56 C. 52

B

4-45 AMA094 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. 3/4 inch. B. 13/16 inch. C. 1/2 inch

B

4-46 AMA094 What is the minimum spacing for a single row of aircraft rivets? A. three times the length of the rivet shank B. three times the diameter of the rivet shank C. two times the diameter of the river shank

B

4-48 AMA094 Rivet gauge, or transverse pitch is the distance between the A. head of the rivets in the same row. B. centers of the rivets in adjacent rows. C. centers of adjacent rivets in the same row.

B

4-20 AMA016 Clad aluminum alloys are used in aircraft because they A. are stronger than unclad aluminum alloys. B. are less subject to corrosion than uncoated aluminum alloys. C. can be heat treated much easier than the other forms of aluminum.

B

4-27 AMA017 What is the angle of the standard countersunk head rivet? A. 105° B. 100° C. 88°

B

4-28 AMA017 Heat treated rivets in the D and DD series that are not driven within the prescribed time after heat treatment or removal from refrigeration A. may be returned to refrigeration and used later without reheat treatment. B. must be reheat treated before use. C. must be discarded.

B

4-3 AMA029 In the list below, which one(s) is not a layout tools used to make the repair part? 1. scales 2. rivet spacers 3. combination square 4. scribes 5. dividers A. 2 and 4 B. 4 C. 4 and 5

B

4-33 AMA011 The identifying marks on the heads of aluminum alloy rivets indicate the A. degree of dimensional and process control observed during manufacture. B. specific alloy used in the manufacture of the rivets. C. head shape, shank size, material used, and specifications adhered to during manufacture.

B

4-36 AMA017 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 rivets to be used will be A. 5/16 inch. B. 1/4 inch. C. 1/8 inch.

B

4-5 AMA017 When removing a damaged section on a stringer, the best saw to use is A. reciprocating saw. B. kett saw. C. circular cutting saw

B

4-50 AMA017 A rivet set used to drive MS20470 rivets should A. be nearly flat on the end, with a light radius on the edge to prevent damage to the sheet being riveted. B. have a slightly greater radius than the rivet head and contact the center two thirds of the rivet head. C. have the same radius as the rivet head.

B

4-53 AMA016 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 greater than the thickness of the rivet head. C. Thickness of the material is less than the thickness of the rivet head.

B

4-57 AMA011 Which blind rivet was designed to prevent the problem of losing the center stem due to vibration? A. friction- locked blind rivet B. mechanical-lock blind rivet C. high-shear fastener

B

4-58 AMA011 CherryMAX and Olympic-Lok rivets A. may be installed with ordinary hand tools. B. utilize a pulling tool for installation. C. utilize a rivet gun, special rivet set, and bucking bar for installation.

B

4-6 AMA017 Which shears have an upper cutting blade that is stationary while the lower blade is moveable? A. throatless shears B. scroll shears C. squaring shears

B

4-64 AMA094 Unless otherwise specified, the radius of a bend is the A. radius of the neutral axis plus one half the thickness of the metal being formed. B. inside radius of the metal being formed. C. inside radius plus one half the thickness of the metal being formed.

B

4-73 AMA094 ___________________ can be curved and not bent sharply by stretching or shrinking either of the flanges. A. Straight line bends B. Formed or extruded angles C. Flanged angles

B

4-80 AMA016 Which statement is true regarding the 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 genuine rivet tipping has occurred, groups of consecutive rivet heads will be tipped in the same direction. C. If bearing failure has occurred, the rivet shanks will be joggled.

B

4-7 AMA017 When needing to quickly remove corners from sheet metal, the best tool to use is a A. band saw B. rotary punch press C. notcher

C

4-70 AMA094 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. mold line. B. bend tangent line. C. neutral line.

C

4-71 AMA094 Which of the following list of steps for using a sheet metal brake to fold metal are correct? Step 1: adjustment of bend radius Step 2: adjusting clamping pressure Step 3: adjusting the nose gap A. 1 and 2 B. 2 and 3 C. All of the above

C

4-72 AMA094 The sight line on a sheet metal flat layout to be bent in a cornice or box brake is measured and marked A. one radius from either bend tangent line. B. one-half radius from either bend tangent line. C. one radius from the bend tangent line that is placed under the brake.

C

4-74 AMA094 In regards to hand forming curved flanged parts, which of the following is true? 1. The concave flange is formed by stretching. 2. The convex flange is form by shrinking. 3. Bend the flange on the concave first. 4. Convex surfaces are formed by shrinking the material over a form block. A. 1, 2, and 4 B. 1 and 2 C. All of the above

C

4-76 AMA094 The purpose of a joggle is to A. decrease the weight of the part and still retain the necessary strength. B. increase obstruction for a sheet or an extrusion. C. allow clearance for a sheet or an extrusion.

C

4-78 AMA016 In regards to the basic principles of sheet metal repair, which of the following statements are not true? 1. Ensure that the cross-sectional area of a splice or patch is at least equal to or greater than that of the damaged part. 2. The joint is critical in sheer if more than the optimum number of fasteners of a given sized are installed. 3. The joint is critical in bearing if less than the optimum number of fasteners of a given size are installed. 4. Form all repairs in such a manner to fit the 5. original contour perfectly. 6. Keep the weight of all repairs to a minimum. 7. The importance of retaining the proper balance and rigidity of aircraft control surfaces cannot be overemphasized. A. 5 B. 1 and 6 C. 2 and 3

C

4-82 AMA016 Which patch may be utilized in repairing skin where aerodynamic smoothness is not important? A. flush patch B. open and closed skin area repair C. lap or scab patch

C

4-83 AMA094 What is the minimum edge distance for aircraft rivets? A. three times the diameter of the rivet shank B. two times the diameter of the rivet head C. two times the diameter of the river shank

C

4-9 AMA029 The hand cutting tools that has colored handles to identify the direction of the cuts are A. straight snips. B. files. C. aviation snips.

C

4-10 AMA029 Which drill would be used for the installation of nutplates? A. pneumatic drill B. right angle drill C. two hole drill

C

4-14 AMA058 Annealing of aluminum A. increases the tensile strength. B. makes the material brittle. C. removes stresses caused by forming.

C

4-15 AMA094 Any bend formed on a bar folder can also be made on the 1. press brake. 2. cornice brake. 3. box and pan brake. A. 2 and 3 B. 1 and 2 C. 1, 2, and 3

C

4-17 AMA029 Which forming technique is usually limited to relatively flat parts with flanges, beads, and lightening holes? A. stretch forming B. drop hammer C. hydropress forming

C

4-21 AMA016 When fabricating parts from Alclad™ 2024-T3 aluminum sheet stock A. bends should be made with a small radius to develop maximum strength. B. all bends must be 90° to the grain. C. all scratches, kinks, tool marks, nicks, etc., must be held to a minimum.

C

4-23 AMA017 Mild steel rivets are used for riveting A. nickel steel parts. B. magnesium parts. C. steel parts.

C

4-32 AMA017 Which rivets should be selected to join two sheets of .032-inch aluminum A. MS20455DD-5-3. B. MS20425D-4-3. C. MS20470AD-4-4.

C

4-39 AMA017 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. 1/4 inch. B. 7/16 inch. C. 5/16 inch.

C

4-4 AMA029 When driving out a pin or bolt, the use of these two punches together may be necessary. Please select from the list below: 1. prick punch 2. awl 3. center punch 4. chassis punch 5. automatic center punch 6. pin punch 7. transfer punch 8. drive punch A. 3 and 8 B. 3 and 7 C. 6 and 8

C

4-55 AMA016 Joggles in removed rivet shanks would indicate partial A. bearing failure. B. torsion failure. C. shear failure.

C

4-59 AMA011 One of the main advantages of Hi-Lok type fasteners over earlier generations is that A. the squeezed on collar installation provides a more secure, tighter fit. B. they can be removed and reused again. C. they can be installed with ordinary hand tools.

C

4-61 AMA011 Threaded rivets (Rivnuts® or rivet nuts) are commonly used to A. join two or more pieces of sheet metal where shear strength is desired. B. join two or more pieces of sheet metal where bearing strength is desired. C. attach parts or components with screws to sheet metal.

C

4-66 AMA094 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. 1/2 inch. B. 1/4 inch. C. 1/8 inch.

C

4-68 AMA094 On a sheet metal fitting layout with a single bend, allow for stretching by A. adding the setback to each leg. B. subtracting the setback from one leg. C. subtracting the setback from both legs.

C