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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

1 and 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

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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