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MATERIALS AND PROCESSES

Aircraft Materials and Processes Quiz

Test your knowledge and skills in materials and processes used in aviation with our comprehensive quiz. This quiz features 85 questions that cover various aspects including inspections, heat-treating processes, and bolt specifications.

Ideal for aviation professionals and students alike, this quiz will challenge you on:

Precision measuring tools
Nondestructive testing methods
Welding and bolt specifications

85 Questions21 MinutesCreated by InspectingSky452

1. Which statement regarding aircraft bolts is correct?

A. 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

B. In general, bolt grip lengths should equal the material thickness

C. Alloy steel bolts smaller than ¼ -inch diameter should not be used in primary structure

A. One

B. Three

C. Four

3. What precision measuring tool is used for measuring crankpin and main bearing journals for out-of-round wear?

A. Dial gauge

B. Micrometer caliper

C. Depth gauge

4. On a fillet weld, the penetration requirement includes what percentage(s) of the base metal thickness?

A. 100 percent

B. 25 – 50 percent

C. 60 – 80 percent

5. What is descriptive of the annealing process of steel during after it has been annealed?

A. Rapid cooling; high strength

B. Slow cooling; low strength

C. Slow cooling; increased resistance to wear

6. Which tool can be used to determine piston pin out- of-round wear?

A. Telescopic gauge

B. Micrometer caliper

C. Dial indicator

7. Which of the following is a main determinant of the dwell time to use when conducting a dye r fluorescent penetrant inspection?

A. The size and shape of the discontinuities being looked for

B. The size and shape of the part being inspected

C. The type and/or density of the part material

8. Which statement relating to the residual magnetizing inspection method is true?

A. Subsurface discontinuities are made readily apparent

B. It is used in practically all circular and longitudinal magnetizing procedures

C. It may be used with steels which have been heat treated for stressed applications

9. In examining and evaluating a welded joint, a mechanic should be familiar with

A. Likely ambient exposure conditions and intended use of the part, along with type of weld and original part material composition

B. The welding technique, filler material, and temperature range used

C. The parts, proportions, and formation of a weld

10. Circular magnetization of a part can be used to detect which defects?

A. Defects parallel to the long axis of the part

B. Defects perpendicular to the long axis of the part

C. Defects perpendicular to the concentric circles of magnetic force within the part

(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,

A. Only No.1 is true

B. Only No.2 is true

C. Both No.1 and No.2 are true

12. In performing a dye penetrant inspection, the developer

A. Seeps into a surface crack to indicate the presence of a defect

B. Acts as a blotter to produce a visible indication

C. Thoroughly cleans the surface prior to inspection

13. If it is necessary to accurately measure the diameter of a hole approximately ¼ inch in diameter, the mechanic should use a

A. Telescoping gauge and determine the size of the hole by taking a micrometer reading of the adjustable end of the telescoping gauge

B. 0 - to 1-inch inside micrometer and read the measurement directly from the micrometer

C. Small-hole gauge and determine the size of the hole by taking a micrometer reading of the ball end of the gauge

14. What method of magnetic particle inspection is used most often to inspect aircraft parts for invisible cracks and other defects?

A. Residual

B. Inductance

C. Continuous

15. What two types of indicating mediums are available for magnetic particle inspection?

A. Iron and ferric oxides

B. Wet and dry process materials

C. High retentivity and low permeability material

16. If dye penetrant inspection indications are not sharp and clear, the most cause is that part

A. Was not correctly degaussed before the developer was applied

B. Has no appreciable damage

C. Was not thoroughly washed before the developer was applied

17. What aluminum alloy designations indicate that the metal has received no hardening or tempering treatment

A. 3003-F

B. 5052-H36

C. 6061-O

18. Which heat-treating operation would be performed when the surface of the metal is changed chemically by introducing a high carbide or nitride content?

A. Tempering

B. Normalizing

C. Case hardening

19. Unless otherwise specified, torque values for tightening aircraft nuts and bolts relate to

A. Clean, dry threads

B. Clean, lightly oiled threads

C. Both dry and lightly oiled threads

20. 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?

A. Eddy current inspection

B. Ultrasonic inspection

C. Magnetic particle inspection

21. How is the locking feature of the fiber-type locknut obtained?

A. By the use of an unthreaded fiber locking insert

B. By a fiber insert held firmly in place at the base of the load carrying section

C. By making the threads in the fiber insert slightly smaller than those in the load carrying section

22. When the specific torque value for nuts is not given, where can the recommended torque value be found?

A. AC 43. 13-1B

B. Technical Standard Order

C. AC43. 13-2A

23. Alclad is a metal consisting of

A. Aluminum alloy surface layers and a pure aluminum core

B. Pure aluminum surface layers on an aluminum alloy core

c. A homogeneous mixture of pure aluminum and aluminum alloy

24. 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

A. 1,2,3,4 and 5

B. 1,2 and 3

C. 1,2,3 and 5

25. Which heat-treating process of metal produces a hard, wear-resistant surface over a strong, tough core?

A. Case hardening

B. Annealing

C. Tempering

26. Generally speaking, bolt grip lengths should be

A. Equal to the thickness of the material which is fastened together, plus approximately one diameter

B. Equal to the thickness of the material which is fastened together

C. One and one half times the thickness of the material which is fastened together

27. 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

A. 1,2

B. 1,3

C. 2,3

28. A bolt with an X inside a triangle on the head is classified as an

A. NAS standard aircraft bolt

B. NAS close tolerance bolt

C. AN corrosion-resistant steel bolt

29. When checking an item with the magnetic particle inspection method, circular and longitudinal magnetization should be used to

A. Reveal all possible defects

B. Evenly magnetize the entire part

C. Ensure uniform current flow

30. Unless otherwise specified or required, aircraft bolts should be installed so that the bolthead is

A. Upward, or in rearward direction

B. Upward, or in a forward direction

C. Downward, or in a forward direction

31. (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,

A. Both No. 1 and No. 2 are true

B. Only No.2 is true

C. Only No.1 is true

32. 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

A. Percentage of the basic element in the alloy

B. Percentage of carbon in the alloy in hundredths of a percent

C. Basic alloying element

33. 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

A. 2

B. 1 and 3

C. 3.

34. Which of the following materials may be inspected using the magnetic particle inspection method? 1. Magnesium alloys 2. Aluminum alloys 3. Iron alloys 4. Copper alloys 5. Zinc alloys

1,2,3

B. 1,2,3,4

35. What is steel tempered after being hardened

A. To increase its hardness and ductility

B. To increase its strength and decrease its internal stresses

C. To relieve its internal stresses and reduce its brittleness

36. Which condition indicates a part has cooled too quickly after being welded?

A. Cracking adjacent to the weld

B. Discoloration of the base metal

C. Gas pockets, porosity, and slag inclusions

37. How is the locking feature of the fiber-type locknut obtained?

A. By the use of an unthreaded fiber locking insert

B. By a fiber insert held firmly in place at the base of the load carrying section

C. By making the threads in the fiber insert slightly smaller than those in the load carrying section

38. Which material cannot be heat treated repeatedly without harmful effects?

A. Unclad aluminum alloy in sheet form

B. 6061-T9

C. Clad aluminum alloy

39. Which number represents the Vernier scale graduation of a micrometer?

00001

001

0001

40. Identify the correct statement

A. An outside micrometer is limited to measuring diameters

B. Tools used on certificated aircraft must be an approved type

C. Dividers do not provide a reading when used as measuring device

41. 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

A. ½ inch

B. 1 inch

C. ¼ inch

42. Which statement regarding aircraft bolts is correct?

A. 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

B. In general, bolt grip lengths should equal the material thickness

C. Alloy steel bolts smaller than ¼-inch diameter should not be used in primary structure

43. What is generally used in the construction of aircraft engine firewalls?

A. Stainless steel

B. Chrome-molybdenum alloy steel

C. Titanium nickel alloy

44. Why is it considered good practice to normalize a part after welding?

A. To relieve internal stresses developed within the base metal

B. To increase the hardness of the weld

C. To remove the surface scale formed during welding

45. Aircraft bolts are usually manufactured with a

A. Class 1 fit for the threads

B. Class 2 fit for the threads

C. Class 3 fit for the threads

46. A fiber-type, self-locking nut must never be used on an aircraft if the bolt is

A. Under shear loading

B. Under tension loading

C. Subject to rotation

47. The aluminum code number 1100 identifies what type of aluminum

A. Aluminum alloy containing 11 percent copper

B. Aluminum alloy containing zinc

C. 99 percent commercially pure aluminum

48. Magnetic particle inspection is used primarily to detect

A. Distortion

B. Deep surface flaws

C. Flaws on or near the surface

49. The clearance between the piston rings and the ring lands is measured with a

A. Micrometer calliper

B. Thickness gauge

C. Depth gauge

50. Which type crack can be detected by magnetic particle inspection using either circular or longitudinal magnetization

A. 45°

B. Longitudinal

C. Transverse

51. Where is an AN clevis bolt used in an airplane

A. For tension and shear load conditions

B. Where external tension loads are applied

C. Only for shear load applications

52. In magnetic particle inspection, a flaw that is perpendicular to the magnetic field flux lines generally causes

A. A large disruption in the magnetic field

B. A minimal disruption in the magnetic field

C. No disruption in the magnetic field

53. What type of corrosion may attack the grain boundaries of aluminum alloys when the heat treatment process has been improperly accomplished?

A. Concentration cell

B. Intergranular

C. Fretting

54. Select a characteristics of a good gas weld

A. The depth of penetration shall be sufficient to ensure fusion off the filler rod

B. The height of the weld bead should be 1/8 inch above the base metal

C. The weld should taper off smoothly into the base metal

55. 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

A. Dial gauge

B. Height gauge

C. Thickness gauge

56. The core material of Alclad 2024-T4 is

A. Heat-treated aluminum alloy, and the surface material is commercially pure aluminum

B. Commercially pure aluminum, and the surface material is heat-treated aluminum alloy

C. Strain- hardened aluminum alloy, and the surface material is commercially pure aluminum

57. Which tool is used to measure the clearance between a surface plate and a relatively narrow surface being checked for flatness?

A. Depth gauge

B. Thickness gauge

C. Dial indicator

58. What tool is generally used to calibrate a micrometer or check its accuracy?

A. Gauge block

B. Dial indicator

C. Machinist scale

59. How is a clevis bolt used with a fork-end cable terminal secured?

A. With a shear nut tightened to a snug fit, but with no strain imposed on the fork and safe tied with a cotter pin

B. With a castle nut tightened until slight binding occurs between the fork and the fitting to which it is being attached

C. With a shear nut and cotter pin or thin self- locking nut tightened enough to prevent rotation of the bolt in the fork

60. The testing medium that is generally used in magnetic particle inspection utilizes a ferromagnetic material that has

A. High permeability and low retentivity

B. Low permeability and high retentivity

C. High permeability and high retentivity

61. To detect a minute crack using dye penetrant inspection usually requires

A. That the developer be applied to a flat surface

B. A longer-than-normal penetrating time

C. The surface to be highly polished

62. 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?

A. Eddy current test

B. Metallic ring test

C. Ultrasonic test

63. What may be used to check the stem on a poppet-type valve for stretch?

A. Dial indicator

B. Micrometer

C. Telescoping gauge

64. What defects will be detected by magnetizing a part using continuous longitudinal magnetization with a cable?

A. Defects perpendicular to the axis of the part

B. Defects parallel to the long axis of the part

C. Defects parallel to the concentric circles of magnetic force within the part

65. 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

A. 1,4,5,6

B. 1,2,4,5,6

C. 1,2,3,4,5,6

66. How can the dimensional inspection of a bearing in a rocker arm be accomplished?

A. Depth gauge and micrometer

B. Thickness gauge and push-fit arbor

C. Telescopic gauge and micrometer

67. Which tool can be used to measure the alignment of a rotor shaft or the plane of rotation of a disk?

A. Dial indicator

B. Shaft gauge

C. Protractor

68. Holes and a few projecting globules are found in a weld. What action should be taken?

A. Reweld the defective portions

B. Remove all the old weld, and Reweld the joint

C. Grind the rough surface smooth, inspect, and Reweld all gaps/holes

69. 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

A. Exceed the recommended torque range by no more than 10 percent

B. Tighten below the torque range

C. Change washers and try again

70. 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

A. 2,3,4

B. 1,2,3

C. 2,3,5

71. Why should an aircraft maintenance technician be familiar with weld nomenclature?

A. So that accurate visual (pictorial) comparisons can be made

B. In order to gain familiarity with the welding technique, filler material and temperature range used

C. In order to compare welds with written (non-pictorial) description standards

72. Aircraft bolts with a cross or asterisk marked on the bolthead are

A. Made of aluminum alloy

B. Close tolerance bolts

C. Standard steel bolts

73. Select a characteristics of a good gas weld

A. The depth of penetration shall be sufficient to ensure fusion of the filler rod

B. The height of the weld bead should be 1/8 inch above the base metal

C. The weld should taper off smoothly into the base metal

74. One way a part may be demagnetized after magnetic particle inspection is by

A. Subjecting the part to high voltage, low amperage ac

B. Slowly moving the part out of an ac magnetic field of sufficient strength

C. Slowly moving the part into an ac magnetic field of sufficient strength

75. Which tool is used to find the center of a shaft or other cylindrical work

A. Combination set

B. Dial indicator

C. Micrometer caliper

76. Normalizing is a process of heat treating

A. Aluminum alloys only

B. Iron-base metal only

C. Both aluminum alloys and iron-base metals

77. Under magnetic particle inspection, a part will be identified as having a fatigue crack under which condition?

A. The discontinuity pattern is straight

B. The discontinuity is found in a nonstressed area of the part

C. The discontinuity is found in a highly stressed area of the part

78. Which of these nondestructive testing methods is suitable for the inspection of most metals, plastics and ceramics for surface and subsurface defects?

A. Eddy current inspection

B. Magnetic particle inspection

C. Ultrasonic inspection

79. What metal has special short-time heat properties and is used in the construction of aircraft firewalls?

A. Stainless steel

B. Chrome molybdenum alloy steel

C. Titanium alloy

80. The reheating of het treated metal, such as with a welding torch

A. Has little or no effect on a metal’s heat treated characteristics

B. Has a cumulative enhancement effect on the original heat treatment

In the reheated area

81. The pattern for an inclusion is a magnetic particle build up forming

A. A fernlike pattern

B. A single line

C. Parallel lines

82. In the four-digit aluminum index system number 2024, the first digit indicates

A. The major alloying element

B. The number of major alloying elements used in the metal

C. The percent of alloying metal added

83. A bolt with a single raised dash on the head is classified as an

A. AN corrosion-resistant steel bolt

B. NAS standard aircraft bolt

C. NAS close tolerance bolt

84. A part which is being prepared for dye penetrant inspection should be clean with

A. A volatile petroleum-based solvent

B. The penetrant developer

C. Water-base solvents only

85. What tool is generally used to set a divider to an exact dimension?

A. Machinist scale

B. Surface gauge

C. Dial indicator

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