Aircraft Engineering Reviewer (MATERIALS AND PROCESSES)
Which statement relating to the residual magnetizing inspection method is true?
Subsurface discontinuities are made readily apparent
It is used in practically all circular and longitudinal magnetizing procedures
It may be used with steels which have been heat treated for stressed applications
If it is necessary to accurately measure the diameter of a hole approximately ¼ inch in diameter, the mechanic should use a
Telescoping gauge and determine the size of the hole by taking a micrometer reading of the adjustable end of the telescoping gauge
Small-hole gauge and determine the size of the hole by taking a micrometer reading of the ball end of the gauge
0 - to 1-inch inside micrometer and read the measurement directly from the micrometer
What two types of indicating mediums are available for magnetic particle inspection?
High retentivity and low permeability material
Iron and ferric oxides
Wet and dry process materials
What precision measuring tool is used for measuring crankpin and main bearing journals for out-of-round wear?
Depth gauge
Dial gauge
Micrometer caliper
Which statement regarding aircraft bolts is correct?
In general, bolt grip lengths should equal the material thickness
Alloy steel bolts smaller than ¼-inch diameter should not be used in primarv structure
When tightening castellated nuts on drilled bolts, if the cotter pin holes do not line up, it is permissible to overtighten the nut to permit alignment of the next slot with the cotter pin hole
How many of these factors are considered essential knowledge for x-ray exposure?
- Processing of the film
- Material thickness and density
- Exposure distance and angle
- Film characteristics
One
Four
Three
On a fillet weld, the penetration requirement includes what percentage(s) of the base metal thickness?
25-50 percent
100 percent
60-80 percent
What is descriptive of the annealing process of steel during after it has been annealed?
Slow cooling; low strength
Rapid cooling; high strength
Slow cooling; increased resistance to wear
Aircraft bolts are usually manufactured with a
Class 1 fit for the threads
Class 2 fit for the threads
Class 3 fit for the threads
Which tool can be used to determine piston pin out-of-round wear?
Dial indicator
Telescopic gauge
Micrometer caliper
In examining and evaluating a welded joint, a mechanic should be familiar with
The welding technique, filler material, and temperature range used
Likely ambient exposure conditions and intended use of the part, along with type of weld and original part material composition
The parts, proportions, and formation of a weld
What nondestructive testing method requires little or no part preparation, is used to detect surface or near-surface defects in most metals, and may also be used to separate metals or alloys and their heat-treat conditions?
Magnetic particle inspection
Eddy current inspection
Ultrasonic inspection
Which of the following is a main determinant of the dwell time to use when conducting a dyer fluorescent penetrant inspection?
The size and shape of the discontinuities being looked for
The size and shape of the part being inspected
The type and or density of the part material
Circular magnetization of a part can be used to detect which defects?
Defects perpendicular to the long axis of the part
Defects perpendicular to the concentric circles of magnetic force within the part
Defects parallel to the long axis of the part
Which of the following defects are not acceptable for metal lines?
1. Cracked flare
2. Seams
3. Dents in the heel of a bend less than 20% of the diameter
4. Scratches/nicks on the inside of a bend less than 10% of wall thickness
5. Dents in straight section that are 20% of tube diameter
1,2,3 and 5
1,2,3,4 and 5
1,2 and 3
If dye penetrant inspection indications are not sharp and clear, the most cause is that part
Has no appreciable damage
Was not correctly degaussed before the developer was applied
Was not thoroughly washed before the developer was applied
Which heat-tréating operation would be performed when the surface of the metal is changed chemically by introducing a high carbide or nitride content?
Case hardening
Tempering
Normalizing
(1) In nondestructive testing a discontinuity may be defined as an interruption in the normal physical structure or configuration of a part
(2) A discontinuity may or may not affect the usefulness of a part
Regarding the above statements,
Only No.1 is true
Only No.2 is true
Both No.1 and No.2 are true
Unless otherwise specified, torque values for tightening aircraft nuts and bolts relate to
Clean, lightly oiled threads
Both dry and lightly oiled threads
Clean, dry threads
How is the locking feature of the fiber-type locknut obtained?
By a fiber insert held firmly in place at the base of the load carrying section
By making the threads in the fiber insert slightly smaller than those in the load carrying section
By the use of an unthreaded fiber locking insert
When the specific torque value for nuts is not given, where can the recommended torque value be found?
AC 43. 13-1B
AC43. 13-2A
Technical Standard Order
Which of the following occurs when a mechanical force is repeatedly applied to most metals at room temperature, such as rolling, hammering, or bending?
1. The metals become artificially aged.
2. The metals become stress corrosion cracked
3. The metals become cold worked, strain or work hardened
2
1 and 3
3
In performing a dye penetrant inspection, the developer
Thoroughly cleans the surface prior to inspection
Acts as a blotter to produce a visible indication
Seeps into a surface crack to indicate the presence of a defect
A bolt with an X inside a triangle on the head is classified as an
NAS close tolerance bolt
NAS standard aircraft bolt
AN corrosion-resistant steel bolt
Which heat-treating process of metal produces a hard, wear-resistant surface over a strong, tough core?
Case hardening
Annealing
Tempering
Alclad is a metal consisting of
Aluminum alloy surface layers and a pure aluminum core
A homogeneous mixture of pure aluminum and aluminum alloy
Pure aluminum surface layers on an aluminum alloy core
Unless otherwise specified or required, aircraft bolts should be installed so that the bolthead is
Upward, or in a forward direction
Upward, or in rearward direction
Downward, or in a forward direction
The society of Automotive Engineers (SAE) and the American Iron and Steel Institute use a numerical index system to identify the composition of various steels. In the number '4130' designating chromium molybdenum steel, the first digit indicates the
Percentage of carbon in the alloy in hundredths of a percent
Percentage of the basic element in the alloy
Basic alloying element
Which of the following describe the effects of annealing steel and aluminum alloys?
1. Decrease in internal stress
2. Softening of the metal
3. Improved corrosion resistance
1,2
1,3
2,3
What method of magnetic particle inspection is used most often to inspect aircraft parts for invisible cracks and other defects?
Inductance
Continuous
Residual
(1) An aircraft part may be demagnetized by subjecting it to a magnetizing force from alternating current that is gradually reduced in strength
(2) An aircraft part may be demagnetized by subjecting it to a magnetizing force from direct current that is alternately reversed in direction and gradually reduced in strength
Regarding the above statements,
Only No.2 is true
Only No.1 is true
Both No. 1 and No. 2 are true
What aluminum alloy designations indicate that the metal has received no hardening or tempering treatment
5052-H36
3003-F
6061-0
What is steel tempered after being hardened
To relieve its internal stresses and reduce its brittleness
To increase its hardness and ductility
To increase its strength and decrease its internal stresses
Identify the correct statement
Tools used on certificated aircraft must be an approved type
Dividers do not provide a reading when used as measuring device
An outside micrometer is limited to measuring diameters
Which condition indicates a part has cooled too quickly after being welded?
Cracking adjacent to the weld
Gas pockets , porosity, and slag inclusions
Discoloration of the base metal
How is the locking feature of the fiber-type locknut obtained?
By making the threads in the fiber insert slightly smaller than those in the load carrying section
By a fiber insert held firmly in place at the base of the load carrying section
By the use of an unthreaded fiber locking insert
Which number represents the Vernier scale graduation of a micrometer?
.0001
.001
.00001
One characteristics of a good weld is that no oxide should be formed on the base metal at a distance from the weld of more than
1 inch
½ inch
¼ inch
Which material cannot be heat treated repeatedly without harmful effects?
Clad aluminum alloy
A. Unclad aluminum alloy in sheet form b.
6061-T9
Aircraft bolts are usually manufactured with a
Class 1 fit for the threads
Class 2 fit for the threads
Class 3 fit for the threads
Generally speaking, bolt grip lengths should be
Equal to the thickness of the material which is fastened together, plus approximately one diameter
Equal to the thickness of the material which is fastened together
One and one half times the thickness of the material which is fastened together
Which statement regarding aircraft bolts is correct?
Alloy steel bolts smaller than ¼-inch diameter should not be used in primary structure
In general, bolt grip lengths should equal the material thickness
When tightening castellated nuts on drilled bolts, if the cotter pin holes do not line up, it is permissible to overtighten the nut to permit alignment of the next slot with the cotter pin hole
A mechanic has completed a bonded honeycomb repair using the potted compound repair technique. What nondestructive testing method is used to determine the soundness of the repair after the repair has cured?
Ultrasonic test
Eddy current test
Metallic ring test
Which of the following materials may be inspected using the magnetic particle inspection method?
1. Magnesium alloys
2. Aluminum alloys
3. Iron allovs
4. Copper alloys
5. Zinc alloys
1,2,3,4
1,2,3
3
Why is it considered good practice to normalize a part after welding?
To increase the hardness of the weld
To relieve internal stresses developed within the base metal
To remove the surface scale formed during welding
What is generally used in the construction of aircraft engine firewalls?
Stainless steel
Titanium nickel alloy
Chrome-molybdenum alloy steel
The aluminum code number 1100 identifies what type of aluminum
Aluminum alloy containing 11 percent copper
99 percent commercially pure aluminum
Aluminum alloy containing zinc
What tool is generally used to set a divider to an exact dimension?
Surface gauge
Dial indicator
Machinist scale
The core material of Alclad 2024-T4 is
Commercially pure aluminum, and the surface material is heat-treated aluminum alloy
Heat-treated aluminum alloy, and the surface material is commercially pure aluminum
Strain- hardened aluminum alloy, and the surface material is commercially pure aluminum
The clearance between the piston rings and the ring lands is measured with a
Thickness gauge
Depth gauge
Micrometer caliper
To detect a minute crack using dye penetrant inspection usually requires
That the developer be applied to a flat surface
The surface to be highly polished
A longer-than-normal penetrating time
Magnetic particle inspection is used primarily to detect
Flaws on or near the surface
Distortion
Deep surface flaws
Aircraft bolts with a cross or asterisk marked on the bolthead are
Made of aluminum alloy
Close tolerance bolts
Standard steel bolts
Select a characteristics of a good gas weld
The height of the weld bead should be 1/8 inch above the base metal
The weld should taper off smoothly into the base metal
The depth of penetration shall be sufficient to ensure fusion of the filler rod
What defects will be detected by magnetizing a part using continuous longitudinal magnetization with a cable?
Defects parallel to the concentric circles of magnetic force within the part
Defects parallel to the long axis of the part
Defects perpendicular to the axis of the part b.
Where is an AN clevis bolt used in an airplane?
For tension and shear load conditions
Only for shear load applications
Where external tension loads are applied
When checking an item with the magnetic particle inspection method, circular and longitudinal magnetization should be used to
Reveal all possible defects
Ensure uniform current flow
Evenly magnetize the entire part
One way a part may be demagnetized after magnetic particle inspection is by
Subjecting the part to high voltage, low amperage ac
Slowly moving the part out of an ac magnetic field of sufficient strength
Slowly moving the part into an ac magnetic field of sufficient strength
How is a clevis bolt used with a fork-end cable terminal secured?
With a castle nut tightened until slight binding occurs between the fork and the fitting to which it is being attached
With a shear nut and cotter pin or thin self-locking nut tightened enough to prevent rotation of the bolt in the fork
With a shear nut tightened to a snug fit, but with no strain imposed on the fork and safe tied with a cotter pin
A fiber-type, self-locking nut must never be used on an aircraft if the bolt is
Subject to rotation
Under tension loading
Under shear loading
Why should an aircraft maintenance technician be familiar with weld nomenclature?
So that accurate visual (pictorial) comparisons can be made
In order to compare welds with written (non-pictorial) description standards
In order to gain familiarity with the welding technique, filler material and temperature range used
Which type crack can be detected by magnetic particle inspection using either circular or longitudinal magnetization
Longitudinal
Transverse
45*
A particular component is attached to the aircraft structure by the use of an aircraft bolt and a castle tension nut combination. If the cotter pin hole does not align within the recommended torque range, the acceptable practice is to
Exceed the recommended torque range by no more than 10 percent
Change washers and try again
Tighten below the torque range
In magnetic particle inspection, a flaw that is perpendicular to the magnetic field flux lines generaly causes
A large disruption in the magnetic field
A minimal disruption in the magnetic field
No disruption in the magnetic field
Which of the following methods may be suitable to use to detect cracks open to the surface in aluminum forgings and castings?
1. Dye penetrant inspection
2. Magnetic particle inspection
3. Metallic ring (coin tap) inspection
4. Eddy current inspection
5. Ultrasonic inspection
6. Visual inspection
1,2,3,4,5,6
1,2,4,5,6
1,4,5,6
Which tool is used to find the center of a shaft or other cylindrical work
Dial indicator
Combination set
Micrometer caliper
A part which is being prepared for dye penetrant inspection should be clean with
The penetrant developer
Water-base solvents only
A volatile petroleum-based solvent
A bolt with a single raised dash on the head is classified as an
NAS standard aircraft bolt
NAS close tolerance bolt
AN corrosion-resistant steel bolt
Liquid penetrant inspection methods may be used on which of the following?
1. Porous plastics
2. Ferrous metals
3. Nonferrous metals
4. Smooth primer-sealed wood
5. Nonporous plastics
1,2,3
2,3,5
2,3,4
What tool is generally used to calibrate a micrometer or check its accuracy?
Gauge block
Machinist scale
Dial indicator
In the four-digit aluminum index number 2004 the first digit indicates
The number of major alloying elements used in the metal
The major alloying element
The percent of alloying metal added
Select a characteristics of a good gas weld
The height of the weld bead should be 1/8 inch above the base metal
The depth of penetration shall be sufficient to ensure fusion off the filler rod
The weld should taper off smoothly into the base metal
The twist of a connecting rod is checked by installing push-fit arbors in both ends, supported by parallel steel bars on a surface plate.
Measurements are taken between the arbor and the parallel bar with a
Thickness gauge
Height gauge
Dial gauge
The pattern for an inclusion is a magnetic particle build up forming
A single line
A fernlike pattern
Parallel lines
Which tool can be used to measure the alignment of a rotor shaft or the plane of rotation of a disk?
Protractor
Shaft gauge
Dial indicator
What type of corrosion may attack the grain boundaries of aluminum alloys when the heat treatment process has been improperly accomplished
Concentration cell
Intergranular
Fretting
Which tool is used to measure the clearance between a surface plate and a relatively narrow surface being checked for flatness?
Depth gauge
Dial indicator
Thickness gauge
Under magnetic particle inspection, a part will be identified as having a fatigue crack under which condition?
The discontinuity is found in a non stressed area of the part
The discontinuity pattern is straight
The discontinuity is found in a highly stressed area of the part
What may be used to check the stem on a poppet-type valve for stretch?
Telescoping gauge
Micrometer
Dial indicator
Which of these nondestructive testing methods is suitable for the inspection of most metals, plastics and ceramics for surface and subsurface defects?
Ultrasonic inspection
Magnetic particle inspection
Eddy current inspection
What metal has special short-time heat properties and is used in the construction of aircraft firewalls?
Stainless steel
Titanium alloy
Chrome molybdenum alloy steel
How can the dimensional inspection of a bearing in a rocker arm be accomplished?
Telescopic gauge and micrometer
Depth gauge and micrometer
Thickness gauge and push-fit arbor
The reheating of het treated metal, such as with a welding torch
Has a cumulative enhancement effect on the original heat treatment
Has little or no effect on a metal's heat treated characteristics
Can significantly alter a metal's properties in the reheated area
Holes and a few projecting globules are found in a weld.
What action should be taken?
Reweld the defective portions
Remove all the old weld, and Reweld the joint
Grind the rough surface smooth, inspect, and Reweld all gaps/holes
Normalizing is a process of heat treating
Aluminum alloys only
Both aluminum alloys and iron-base metals
Normalizing is a process of heat treating
Aluminum alloys only
Both aluminum alloys and iron-base metals
Iron-base metal only
The testing medium that is generally used in magnetic particle inspection utilizes a ferromagnetic material that has
High permeability and high retentivity
High permeability and low retentivity
The testing medium that is generally used in magnetic particle inspection utilizes a ferromagnetic material that has
High permeability and high retentivity
High permeability and low retentivity
Low permeability and high retentivity
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