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Quizzes > Lifestyle & Hobbies > Travel & Transportation

2A753 Aircraft Structural Journeyman Quiz - Test Your Skills

Think you're ready for the 2A753 quiz? Dive in and master Volume 2 directives!

Difficulty: Moderate
2-5mins
Learning OutcomesCheat Sheet
Paper art illustration showing aircraft components and tools arranged around quiz text on golden yellow background

Use this 2A753 Aircraft Structural Journeyman quiz to practice Volume 2 directives, technical orders, maintenance manuals, and structural repair criteria so you can spot gaps before the exam. You'll see what you know and what to review next, then try a related warm-up quiz for extra practice.

Which AFI publication provides directives for aircraft structural maintenance?
AFI 10-2501
AFI 21-101
AFI 36-2203
AFI 11-2MDS
AFI 21-101 outlines the policies and procedures for aerospace equipment maintenance, including aircraft structural maintenance. It is the primary reference used in Volume 2 for structural journeymen. Other AFIs cover operations, personnel, or flight protocols rather than maintenance directives. For more details see .
What AFTO Form is used to document corrosion inspection results?
AFTO Form 95
AFTO Form 244
AFTO Form 1492
AFTO Form 22
AFTO Form 1492 is used specifically for documenting corrosion and damage inspections on structural components. It provides a standardized method to record findings, locations, and corrective actions. Other forms like the AFTO Form 22 capture equipment improvement recommendations rather than detailed corrosion data. See for guidance.
Which material is commonly used for structural bonding in aircraft?
Silicone sealants
Butyl rubber
Epoxy-based adhesives
Polyurethane caulk
Epoxy-based adhesives are preferred for structural bonding due to their high strength, good fatigue resistance, and compatibility with various substrates. Silicone sealants and polyurethanes are typically used for sealing rather than load-bearing joints. Butyl rubber is primarily for weatherproofing applications. For further bonding specifications, refer to .
What tool is used to measure metal thickness on an aircraft skin?
Depth gauge
Caliper
Laser rangefinder
Micrometer
A micrometer provides precise measurements of sheet metal thickness, often down to thousandths of an inch. Calipers are less precise for thin materials, and depth gauges measure recesses rather than surface thickness. Laser rangefinders are used for distance measurements, not thickness. More on measurement tools at .
Which color band on a rivet indicates it is manufactured from 7075 aluminum alloy?
Red
Blue
Green
Yellow
Blue bands on rivets indicate 7075-T6 aluminum alloy, known for high strength in structural applications. Other colors correspond to different alloys: yellow for 5056, green for 2117, and red for steel rivets. See standard rivet color codes at .
What is the primary hazard when sanding composite surfaces?
Electrical shock
Dust inhalation
Metal shavings
UV exposure
Sanding composites releases fine dust that can be harmful when inhaled, causing respiratory irritation or long-term lung issues. Appropriate respiratory protection and dust collection systems are mandated. Metal shavings are more typical when working with metals. For PPE requirements see .
What is the recommended cleaning solvent before structural bonding?
Acetone
Water
Hydraulic fluid
MEK (Methyl Ethyl Ketone)
MEK is used to remove oils, greases, and contaminants before bonding, ensuring optimal adhesive performance. Acetone evaporates too quickly and may leave residues. Water and hydraulic fluid are not solvents. Cleaning procedures are detailed in .
Which form tracks corrosion protection equipment calibration?
AFTO Form 95
AFTO Form 350
AFTO Form 1492
AFTO Form 239
AFTO Form 95 documents calibration of shop equipment, including instruments used for corrosion inspection and treatment. It ensures traceability and accuracy of measurements. AFTO Form 239 is for technical orders, and Form 1492 is for corrosion records. Calibration guidance: .
Which personal protective equipment is mandatory when handling epoxy adhesives?
Gloves and safety glasses
Steel-toed boots only
Earplugs
Welding mask
Epoxy adhesives can irritate skin and eyes, so gloves and safety glasses are required. Respirators may also be needed for vapors, but gloves and eyewear are the minimum. Steel-toed boots are general shop safety gear but not specific to adhesives. PPE details: .
What does corrosion pitting on aluminum indicate?
Localized metal loss
Structural buckling
Surface cracking
Paint blistering
Pitting is localized corrosion leading to small cavities in metal surfaces and indicates a breakdown of protective coatings. It is more severe than uniform surface corrosion and requires repair. Paint blistering is a coating failure, while cracks and buckling are separate issues. Corrosion types: .
Which inspection method uses penetrating dyes to reveal surface cracks?
Radiographic inspection
Ultrasonic inspection
Dye penetrant inspection
Eddy current inspection
Dye penetrant inspection applies a colored liquid to the surface; the dye seeps into cracks and is made visible by a developer. It is effective for detecting surface-breaking defects. Ultrasonic, eddy current, and radiography detect subsurface flaws. Standard procedures: .
What is the minimum tensile strength for standard AN bolts in structural applications?
75,000 psi
150,000 psi
100,000 psi
45,000 psi
Standard AN3 through AN20 bolts are graded for 100,000 psi tensile strength. This ensures they can handle design loads in structural assemblies. Lower strengths are for non-critical hardware; higher strengths are specialty. Bolt specifications: .
What process removes oxides before anodizing aluminum?
Pickling in caustic solution
Solvent wipe with MEK
Shot peening
Vibratory polishing
MEK solvent wipes remove oils and surface oxides prior to anodizing, ensuring uniform oxide growth. Caustic pickling etches base metal but may create roughness. Shot peening and vibratory polishing affect surface finish, not chemical cleanliness. Pre-anodizing prep: .
Which equipment is calibrated using AFTO Form 95?
Refrigerant recovery units
Aligned infrared cameras
Thickness gauges
Ammunition loading machines
Thickness gauges, used for corrosion and wear inspections, require precise calibration documented on AFTO Form 95. Infrared cameras and other equipment have different calibration protocols, and recovery units are not maintenance tools covered in Volume 2. Calibration program: .
What is the term for reinforcing damage repair with multiple layers of composite cloth?
Thermal spray
Cold bonding
Layup build
Sandwich core
"Layup build" refers to applying successive layers of composite cloth and resin to restore structural integrity. Sandwich core is a lightweight filler, while cold bonding and thermal spray are metal repair processes. Composite repair steps: .
Which chemical is used for alodine conversion coating on aluminum?
Nitric acid
Sulfuric acid
Chromic acid
Hydrofluoric acid
Chromic acid solutions are used in alodine conversion coatings to produce a chromate layer for corrosion resistance. Hydrofluoric acid etches glass and silica, sulfuric acid anodizes, and nitric acid is used for pickling steel. Conversion coating details: .
What is the allowable pit depth in thousandths of an inch for class 3 aluminum aircraft surfaces before repair is required?
15 mils
10 mils
5 mils
20 mils
Volume 2 specifies a maximum pit depth of 10 mils (0.010 inch) for Class 3 aircraft aluminum surfaces. Exceeding this depth often requires blending or structural repair to restore integrity. Lower classes may have different tolerances, but Class 3 is typical for major skins. Refer to .
Which nondestructive inspection method is most effective for detecting subsurface corrosion in aluminum?
Magnetic particle
Dye penetrant
Ultrasonic testing
Visual inspection
Ultrasonic testing uses sound waves to detect subsurface defects and corrosion, making it ideal for aluminum structures. Dye penetrant only reveals surface flaws, and magnetic particle requires ferrous materials. Visual inspection has limited depth detection. For ultrasonic procedures see .
What torque is specified for a standard 3/8-inch AN hex head bolt in a safety-critical joint?
25 ft-lbs
35 ft-lbs
15 ft-lbs
45 ft-lbs
Standard torque tables in Volume 2 list 25 ft-lbs for 3/8-inch AN bolts in critical joints. This ensures proper clamping without over-stressing the fastener. Lower torque may loosen under load, and higher torque can cause bolt failure. See torque charts at .
How often must calibration records for structural inspection instruments be reviewed according to Volume 2?
Every 18 months
Every 24 months
Every 6 months
Every 12 months
Volume 2 mandates annual review of calibration records for nondestructive inspection and structural measurement tools. This interval maintains equipment accuracy and compliance. Six months is more stringent than required, while 18 or 24 months exceed allowable drift limits. See calibration intervals at .
What does the dash number on composite repair materials typically indicate?
Cloth weave type
Cloth weight in oz/yd²
Resin hardness
Cure temperature
Composite cloth dash numbers correspond to fabric weight in ounces per square yard, affecting layup strength and thickness. Resin hardness and cure temperature are specified separately. Fabric weave type is indicated in vendor specs rather than the dash number. For composite data see .
What shelf life is typically assigned to two-part epoxy primer in unopened cans?
18 months
12 months
6 months
24 months
Unopened two-part epoxy primers generally have a 12-month shelf life when stored at recommended temperatures. Beyond that, chemical performance may degrade. Six months is too short per most manufacturer data, while 18 or 24 months exceed typical limits. Storage guidelines: .
Which AFTO form is used to recommend technical order changes for structural procedures?
Form 95
Form 781
Form 22
Form 1492
AFTO Form 22 captures improvement and change recommendations for technical orders, including structural procedures. It ensures feedback is documented and routed appropriately. Form 95 is calibration, Form 1492 is corrosion, and Form 781 is maintenance logs. More on TO feedback: .
What is the minimum bend radius for a composite patch per Volume 2 guidelines?
20 times material thickness
15 times material thickness
5 times material thickness
10 times material thickness
Volume 2 specifies a minimum bend radius of 10 times the material thickness for composite patches to prevent fiber breakage and delamination. Lower ratios risk crack initiation, while higher ratios are overly conservative. Detailed composite handling: .
Which NDI method requires the component to be electrically conductive and magnetic?
Ultrasonic
Magnetic particle
Dye penetrant
Liquid penetrant
Magnetic particle inspection works only on ferromagnetic materials because it induces a magnetic field to reveal surface and near-surface defects. Dye and liquid penetrant are for nonmagnetic parts, and ultrasonic does not require magnetism. See .
What is the purpose of shot peening aluminum components?
Increase surface reflectivity
Apply chemical conversion
Induce compressive residual stresses
Remove paint
Shot peening creates a layer of compressive residual stress on the surface to improve fatigue life and crack resistance. It does not remove coatings or apply chemicals. Reflectivity is irrelevant to the process. For shot peening procedures see .
Which thermocouple type is recommended for monitoring composite cure ovens?
Type T
Type E
Type K
Type J
Type K thermocouples have a wide temperature range and stability, making them suitable for composite cure cycles up to 500°F. Type J and T are less stable at higher temperatures, and Type E is less common. For oven monitoring see .
What is the recommended post-anodize sealing method?
Electroless nickel plate
Powder coat
Chromate dip seal
Dry film lubricant
A chromate dip seal closes anodic pores and enhances corrosion resistance by depositing a chromate layer. Electroless nickel plating and powder coating are separate finishing processes. Dry film lubricant reduces friction but does not seal anodize. Sealing procedures: .
According to Volume 2, how long is the dwell time after applying alodine conversion coating before rinsing?
30 seconds
5 minutes
120 seconds
60 seconds
A 60-second dwell ensures adequate chemical reaction for uniform conversion coating formation without overetching. Shorter times may not fully form the protective layer, while longer times can embrittle the substrate. Volume 2 details times: .
What concentration of chromic acid is specified for alodine conversion baths?
5 to 7 percent
1 to 3 percent
10 to 12 percent
15 to 18 percent
Volume 2 specifies 5 - 7 percent chromic acid by weight for conversion baths to ensure proper coating thickness and corrosion protection. Lower concentrations may under-convert, and higher can overetch. For mixing guidelines see .
During dye penetrant inspection, what is the maximum dwell time for the penetrant?
10 minutes
5 minutes
30 minutes
20 minutes
A 10-minute dwell allows adequate seepage into fine defects without excessive background staining. Five minutes may miss tight flaws, and longer times can cause bleed-out. See penetrant procedures at .
Which acid is used for pickling aluminum prior to anodizing?
Sulfuric acid
Phosphoric acid
Hydrochloric acid
Nitric acid
Sulfuric acid pickling removes surface oxides and contaminants before anodizing and is specified in Volume 2. Nitric acid is more for steel, hydrochloric for deep etch, and phosphoric for other alloys. Pickling details: .
What is the cure cycle temperature and duration for typical epoxy structural adhesive?
275°F for 2 hours
250°F for 1 hour
300°F for 15 minutes
350°F for 30 minutes
Volume 2 lists a standard cure of 275°F for 2 hours for many epoxy adhesives to achieve full cross-linking. Lower temperatures or times may lead to undercure, and shorter cycles are insufficient. For the full cure matrix see .
In eddy current inspection, what variable controls penetration depth?
Surface roughness
Probe orientation
Frequency of the alternating current
Coil diameter
Higher frequencies reduce penetration depth, while lower frequencies increase it, allowing selection for subsurface or near-surface flaw detection. Probe orientation and coil size affect resolution but not primary depth. For eddy current parameters see .
What method is used to detect honeycomb core disbond in composite panels?
Magnetic particle
Radiography
Hardness testing
Tap testing
Tap testing or coin tapping produces acoustic responses that change over disbonded areas, revealing honeycomb core separation. Radiography can detect but is more complex; magnetic particle and hardness tests are not applicable. For tap testing refer to .
Which procedure details the neutralization step after caustic etch?
Acid dip in nitric solution
Solvent wipe
Alkaline rinse
Rinse with deionized water
An acid dip, typically dilute nitric acid, neutralizes residual caustic etch chemicals and restores surface pH. Deionized water rinse alone may not neutralize alkalinity, and alkaline rinse worsens it. See neutralization steps at .
For chemical milling of aluminum, what masking material is specified?
Silicone rubber
Vinyl lacquer
Epoxy-phenolic resist
Polyurethane foam
Epoxy-phenolic resist films are used for chemical milling masks because they withstand acid baths and produce clean patterns. Vinyl lacquers and silicones degrade in acid, and polyurethane foam is not appropriate. Masking details: .
Which factor most influences adhesive bond strength on metal surfaces?
Adhesive viscosity
Color of adhesive
Surface cleanliness
Ambient humidity
Contaminants severely reduce bond strength, making surface cleanliness the critical factor. Humidity and viscosity play secondary roles, while color is irrelevant. Proper cleaning and abrading are emphasized in Volume 2. See bonding prep: .
What is the maximum allowable area for delamination in a single 24-inch span per ASTM standards?
2 square inches
1 square inch
6 square inches
4 square inches
ASTM guidelines allow up to 2 square inches of delamination in a 24-inch span for certain aircraft composites before mandatory repair. This limit balances structural integrity and repair practicality. Larger areas require reinforcement or replacement. ASTM reference: .
Which method corrects core bond separation in honeycomb panels?
Apply surface heat and pressure
Install fasteners through core
Inject low-viscosity epoxy
Spot weld facesheets
Injecting low-viscosity epoxy under vacuum restores core bond by reinstating adhesive between skins and honeycomb. Fasteners damage the core, heat and pressure alone won't reflow adhesive, and welding is not possible on composites. Repair steps: .
What's the first step in performing an eddy current conductivity measurement?
Apply couplant
Clean and dry the surface
Calibrate on a reference standard
Clamp the part
Calibrating on a known conductivity standard ensures instrument accuracy. Although cleaning is important, calibration comes first to set the reference. Couplant is not used, and clamping is not relevant. For calibration procedures see .
Explain the fatigue life extension process per Volume 2 for wing skins exhibiting micro-cracking at stiffener sites.
Install doublers over cracks and reduce future inspection intervals
Replace entire wing skin section immediately
Apply additional paint layers to slow crack growth
Use a higher torque on existing fasteners
Volume 2 recommends installing reinforcing doublers over the cracked area and increasing inspection frequency to monitor crack propagation, extending fatigue life without full replacement. Paint layers do not affect structural cracks, and higher torque or immediate replacement are not prescribed as the first corrective action. See fatigue repairs: .
Analyze a failure scenario where integrally stiffened aluminum panels exhibit rivet pull-through; what corrective measure aligns with Volume 2?
Install blind rivets with larger bearing plates
Remove stiffeners entirely
Switch to smaller rivets to reduce stress
Apply thicker corrosion primer
Blind rivets with bearing plates distribute load over a larger area, minimizing pull-through in thin skins - a Volume 2 approved method. Smaller rivets concentrate stress, and removing stiffeners is unacceptable. Primer thickness does not affect rivet mechanics. For rivet repair see .
Propose a repair for multi-site corrosion found under fastener rows on a lower wing surface per Volume 2 guidance.
Heat treat the entire panel then repaint
Fill pits with epoxy putty and repaint
Loosen fasteners to relieve stress
Cut out corroded zones, blend edges, apply corrosion inhibiting primer, and install flush fasteners
Volume 2 requires removal of corroded material, edge blending to local limits, priming with corrosion-inhibiting coatings, and reinstalling proper fasteners. Epoxy putty does not restore structural strength. Heat treatment is not an approved corrosion repair for aluminum panels, and loosening fasteners is not corrective. See corrosion repair: .
Evaluate the effectiveness of skim-coat stripping vs. chemical stripping for painted composite radomes based on Volume 2 criteria.
Chemical stripping preserves core integrity better but requires neutralization steps
Chemical stripping is faster and leaves no residue
Skim-coat is preferred for large structural panels
Skim-coat yields no waste disposal concerns
Chemical strippers can remove coatings without mechanical abrasion that can damage composite cores, but require thorough neutralization to prevent substrate attack. Skim-coat sanding risks core delamination and generates hazardous dust. Volume 2 compares methods under .
Compare chromate and non-chromate primers in terms of long-term corrosion protection in salt-water environments per Volume 2.
Chromate primers offer superior inhibition but pose environmental disposal challenges
Chromate primers are only used on steel components
Non-chromate primers are preferred for all structural surfaces
Non-chromate primers outperform in abrasion resistance
Chromate primers provide excellent corrosion inhibition in marine conditions but contain hexavalent chromium requiring special handling. Non-chromate primers comply with environmental regs but offer slightly less protection. Volume 2 details trade-offs at .
Develop a maintenance schedule for critical fastener inspections to meet Volume 2 fatigue monitoring guidelines.
Inspect at 500-hour intervals with eddy current checks every alternate inspection
Only inspect after reported damage events
Replace fasteners annually without inspection
Perform visual checks every 1000 flight cycles
Volume 2 recommends 500-hour interval inspections with detailed eddy current NDI on alternating checks to monitor fatigue cracks. Visual checks alone or 1000-cycle intervals risk missing early fatigue. Replacing without inspection or only after damage is non-compliant. Scheduling guidance: .
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Study Outcomes

  1. Identify Key Volume 2 Directives -

    Recognize and recall the essential Volume 2 directives and publications relevant to the 2A753 Aircraft Structural Journeyman role.

  2. Analyze Structural Repair Procedures -

    Critically assess common aircraft structural repair guidelines to ensure compliance with Air Force 2A753 test standards.

  3. Apply Technical Knowledge -

    Utilize Volume 2 directives to solve quiz scenarios accurately and demonstrate practical understanding of structural journeyman tasks.

  4. Evaluate Compliance Standards -

    Examine Air Force structural maintenance requirements to verify adherence to safety and performance criteria.

  5. Boost Confidence in 2A753 Skills -

    Strengthen readiness for on-the-job success by self-assessing knowledge gaps and reinforcing critical Aircraft Structural Journeyman concepts.

Cheat Sheet

  1. Technical Order Numbering System -

    The Air Force Technical Order numbering structure in Volume 2 follows a Chapter-Section-Publication model, helping 2A753 candidates quickly locate structural manuals. Remember the mnemonic "C-S-P" to recall how codes like 2-2-61 map to aircraft structural journeyman directives for the 2A753 quiz.

  2. Stress and Strain Fundamentals -

    Structural integrity calculations rely on Hooke's Law, expressed as σ = F/A for stress and ε = ΔL/L for strain. Use the example of a 10,000 lbf load on a 5 in² aluminum plate to practice: σ = 2,000 psi. Remember the proportional limit to avoid elastic-to-plastic transition during your 2A753 test.

  3. Corrosion Types and Prevention -

    Volume 2 directives reference five common corrosion types - uniform, pitting, intergranular, galvanic, and fretting - outlined in TM 1-1. Use the mnemonic "UPIGF" to lock in these categories and apply correct cleaning and plating procedures. Keeping ahead of corrosion checks will boost your confidence on the 2A753 Aircraft Structural Journeyman quiz.

  4. Fastener Identification and Torque Standards -

    A proper 2A753 Aircraft Structural Journeyman must distinguish between MS, AN, and NAS fastener series using color bands and dash numbers. Torque values follow the formula T = K·F·D (where K is the friction coefficient, F is preload, and D is nominal diameter), so memorize general K≈0.2, or refer to TO 1-1-610. This ensures consistent installations and passing your 2A753 quiz on Volume 2 directives.

  5. Non-Destructive Inspection Methods -

    Key NDI techniques like Visual, Dye Penetrant, Magnetic Particle, and Ultrasonic inspections are covered in TO 1-1-5, often recalled with the acronym "VDMU". Practice dye pen checks on sample coupons to see capillary action in action, and review magnetization patterns for ferrous alloys. Mastering VDMU steps will give you an edge on the Air Force 2A753 test.

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