Exam 21

1. A Hardy Spicer coupling has what type of bearings?

a) Plain bearings
b) Ball Bearings
c) Needle bearings

2. Which of the following metals is an aluminium silicon alloy used mainly for casting?
a) Aldrey
b) Alclad
c) Alpax

3. To correctly tension cables it can help to

a) have control surface locks in to support weight and adjust turnbuckles equally
b) take up initial slack by additional pulleys
c) use a cable run with turnbuckles at least every eight feet

4. Honeycomb for repair can be removed with

a) a drill
b) locally manufactured concave knife
c) a router

5. Aircraft skin is joggled to

a) conform to the "Area rule"
b) provide smooth airflow at faying surfaces
c) make a frame lighter but stronger

6. Dzuz Fasteners provide

a) for easy hammering into position
b) a close tolerance fit
c) quick release fasteners at inspection panels

7. The pot life of a cold cured resin

a) increases with increase of temperature
b) is not reliant upon temperature fluctuations
c) decreases with an increase in temperature

8. British turnbuckles are checked for safety by

a) attempting to pass a hardened pin probe through the inspection hole
b) attempting to pass locking wire through the hole
c) looking through the hole and checking for threads showing

9. A full list of decals would be found in

a) ANOs
b) Maintenance Manual
c) Aircraft log book

10. A Skydrol hydraulic seal would be made of

a) butyl rubber, ethelene propylene or Teflon Phosphate Ester based
b) natural rubber vegetable based
c) synthetic rubber mineral based

Exam 22

1. The British system of heat treatment codes is

a) a series of numbers
b) a series if letters
c) numbers and letters
2. What colour is used to identify a primary structure on a diagram or drawing?
a) Yellow
b) Green
c) Red

3. If you are unable to identify a structure classification as either primary or secondary what
action should you take?
a) Grade as secondary
b) Upgrade as primary
c) Paint it red and stamp it as tertiary

4. What is meant by the term Pitch Ratio?

a) The distance between two holes
b) The distance between the hole and the edge of the material
c) The area of contact between the two sheets of metal when joining by rivets

5. What is meant by the term Major Repair?

a) Repairs which can be made without dismantling for access and do not require the use
of specialist tools
b) Repairs which can be made whilst the aircraft is enroute
c) Repairs which require the use of special jigs, supports or jury structure and some
dismantling

6. The length of solid rivets is in graduations of

a) 1/8 inch
b) ¼ inch
c) 1/16 inch

7. What would be the diameter and length of a solid rivet if the following markings are given, AS
162-408?
a) ½ inch dia, 1 inch length
b) ¼ inch dia, ½ inch length
c) 1/8 inch dia, ½ inch length

8. What would the marking .5 indicate after the normal part number of a solid rivet?
a) Indicates close tolerance rivet
b) The diameter of the rivet is half an inch
c) The rivet length in graduations of 1/8 inch

9. What is the pressure range for the Avdel Riveter type F?

a) 20 to 60 psi
b) 60 to 80 psi
c) 40 to 60 psi

10. What is the length of the operation stroke of the Avdel Riveter type F?
a) 7/8 inch
b) 1 inch
c) ½ inch

Exam 23

1. With respect to ferrous metals which of the following is true?

a) Iron is not any element of ferrous metals
b) Iron is a main element and all ferrous metal are magnetic
 c) Iron is a main element and ferrous metal are not magnetic

2. The annealing process on steel is required sometimes as it

a) provides a corrosion resistant layer that prevents oxidation
b) relieves internal stress suffered after engineering processes
c) allows the material a greater stress per unit area

3. The impact testing technique is used on a material to test for

a) hardness
b) toughness
c) shear strain

4. Cobalt steel tested on the Brinell test would have a BHN number between
a) 100 to 175
b) 300 to 400
c) 600 to 700

5. If a material is found to be in the tertiary phase of creep the following procedure should be
implemented:
a) The crack should be stop drill, condition monitoring should be applied
b) The component should be replaced immediately
c) The component should under go dye penetrant process and condition monitored

1. 6. In a sheet metal store the following is marked on a sheet of aluminium alloy L162
(sheet 1). On a different sheet the marking L172 (sheet 2) is found, the following is true:
a) Sheet one is more ductile than sheet 2
b) Sheet two is of a thicker gauge than sheet 1
c) Sheet one has a shinier surface than sheet 2

7. Thermosetting adhesive, during their curing cycle give off

a) static radiation
b) heat
c) carbon monoxide

8. The effect of a lower temperature than ambient during the curing period of a resin, will cause
the curing time to

a) increase
b) decrease
c) remain unchanged

9. Fretting corrosion occurs where

a) pitting corrosion is allowed to become more pronounced

b) a deep scratch increases to become fretting corrosion
c) two material are subject to very slight movement between the two

10. The initials U.N.C when related to aircraft bolts stands for

a) United National Countersunk

b) Unified National Centred
c) Unified National Course

Exam 24

1. Capped nuts are used so

a) the part is not over torqued as the bolt touches he captive part first
 b) to ensure that it is dry bolted
c) to prevent leaks from pipe ends

2. On a rear insert plug the tool is used to

a) insert the pins from the front and extracted from the rear
b) insert the pins from the rear and extract from the rear
c) insert the pins from the rear and extract from the front

3. Wirelocking must be

a) less than 45o to the axis

b) less than 30o to the axis
c) more than 45o to the axis

4. If a sheet of aluminium alloy of 0.032 and 0.064 is to be joined together the rivet should be

a) 0.064 plus 1D
b) 0.096 plus 1.5 D
c) 0.032 plus 2D

5. A self aligning bearing is a

a) angular bearing
b) radial bearing
c) precision bearing

6. A crankshaft would be fitted with a

a) spherical roller bearing

b) taper roller bearing
c) cylindrical roller bearing

7. Where heat is likely to be transmitted through a bearing

a) group 2 bearings are used

b) group 3 bearings are used
c) group 4 bearings are used

8. Shielded ball bearings are inspected by

a) running at operating speed and listening for signs of wear

b) dismantling and inspecting
c) rotating slowly by hand

9. Thrust bearings take

a) sideloads
b) journal loads
c) radial loads

10. How would you check the setting of an adjustable reamer

a) ring guage
b) DTI and V blocks
c) external callipers

Exam 25
1. What is stress corrosion?

a) Corrosion in an area under continuous loading

b) Corrosion in an area under cyclic loading
c) Corrosion due to fretting

2. What is used as the base covering on a honeycomb repair?

a) Glass cloth or thin aluminium sheet

b) Plywood
c) Thick aluminium sheet

3. What is used for marking out steels?

a) Engineers blue
b) Wax crayon
c) Copper sulphate

4. What is used to remove corrosion from magnesium?

a) Chromic acid solution

b) Phosphate acid solution
c) Sulphuric acid solution

5. Where would a pop rivet with a break stem mandrel be used?

a) In a closed structure
b) Where the head can be retrieved
c) Any situation calling for a pop rivet

6. A press fit requires

a) the hole to be expanded by heat

b) some sort of driving force
c) the shaft to be shrunk by cooling

7. A chobert rivet gun may be used

a) once only
b) indefinitely
c) until the end has worn 0.002 inch below nominal diameter

8. Avdel rivets are closed by

a) squeezing
b) broaching
c) a tapered mandrel

9. Surface corrosion on stainless steel is identified by

a) white film
b) black pitting
c) red rust

10. Hooks, wires and other suspension devices used in an anodic bath should be made of
 a) steel or copper
b) aluminium or titanium
c) brass or copper

Exam 26

1. Phosphating of steels is carried out by immersing the steel in to a solution of

a) phosphoric acid and metal phosphates

b) metal phosphates and sulphuric acid
c) nitric acid and sulphur

2. Electro chemical reaction is caused by the contact of

a) dissimilar metals
b) moisture on the surface of the metal
c) bonding

3. When drilling a carbon fibre reinforced plastic use

a) a tungsten carbide drill
b) a steel drill and carbarundum powder
c) a tungsten drill with a pointed tip

4. Hydraulic pipes are made from

a) 1100 or 2020 H14

b) annealed steel

c) 5056 or 7075

5. When laying up a glass fibre repair, the extra layer of fibre is

a) sacrificial layer for sanding

b) for extra strength

c) for shrinkage

6. Nickel coated cables temperature range is

a) 100 to 150°C

b) 150 to 200°C

c) 200 to 250°C

7. Tempering entails
a) heating over the UCP and fast cooling

b) heating over the UCP and slow cooling

c) heating under the UCP and slow cooling

8. A non metallic locknut is
a) never torqued

b) never used over 250°F

c) never re-used

9. Aluminium wiring when flexed will

a) work harden and embrittle
b) have no effect

c) have a higher resistance

10. Which can be re-used?

a) Locking plate, circlip, spring washer
b) Tab washer, circlip, locking plate

c) Shake proof washer, spring washer, locking plate

Exam 27

1. A bolt part number AN25C15 when compared to a bolt part number AN25-15 has

a) a less expensive design and product costs

b) a higher resistance to corrosion
c) a higher pitch thread

2. Countersunk rivets have two angles of countersink, these are

a) 125 - 135 degrees

b) 100 - 160 degrees
c) 100 - 115 degrees

3. On a CHERRY MAX rivet, after the riveting process the mandrel section or stem is

a) discarded
b) remains in the rivet sleeve to provide mechanical strength
c) is ground down flush to rivet head

4. A single row ball bearing is best suited to accepting

a) axial and radial Loads

b) radial loads only
c) axial loads only

5. During a inspection interval one segment of a long chain is found to be defective, the solution
to this is to
a) replace the particular segment and run components to check for serviceability
b) replace 3 segment either side of the deficiency
c) replace the whole chain

6. When fitting a replacement hacksaw blade, the new blade's teeth should face

a) towards the user

b) away from the user
 c) either direction, not dependent on safety or efficiency of saw

7. Cold working of a material is used to reduce

a) wear of manufacturing tools

b) fatigue
c) material hardness

8. An S-N curve is useful in the design evaluation process for testing

a) shear force
b) fatigue life
c) tension

9. A 'HUCK' rivet is similar in design to a

a) blind rivet
b) dome head rivet
c) cherry rivet

10. A tab washer has been removed after fitment for a short time from a non essential system,
the tab washer may be

a) re-used
b) not re-used
c) re-used if a spare is not available

Exam 28

1. On a structural repair, what type of rivet would you use when the back side cannot be
accessed?

a) Hi-loc rivet
b) Blind rivet
c) Pop rivet

2. What are the signs of fretting corrosion on steel?

a) Rust on surface
b) Dark staining around area
c) Surface cracking as corrosion breaks through to
surface of component

3. Taper pins are subject to what loads?

a) Tensile
b) Compressive
c) Shear

4. Bending of stretched honeycomb is

a) with the web

b) across the web
c) either way

5. A foot operated hydraulic swaging tools is checked for fluid level

 a) vertically
b) horizontally
c) only when operating pressure is reached

6. On a hydraulic swaging tool, the swage is formed when

a) swage pressure is reached on the gauge

b) the bypass valve closes and ram is neutrally loaded
c) the bypass valve opens and ram is neutrally loaded

7. Bubbles are removed from a wet composite lay-up by

a) application of pressure
b) application of vacuum
c) use of a roller

8. Interference in ribbon cables can be prevented by

a) grounding alternate wires so that signal wires are never adjacent

b) the use of a common earth return between signal wires in the cable
c) using alternate return wires so that the cable differences cancel each other out

9. H.T. leads are made up of

a) multi-strand, multi-core, screened

b) multi-strand, single-core, screened
c) single-strand, single-core, screened

10. Use of excessive hardener in polyester resin leads to

a) a less stiff joint

b) stiffer joint
c) reduced pot life

Exam 29

1. The head marking on a close tolerance BSF bolt is

a) a lowered ring under the hexagon

b) a series of dots on the head face
c) a raised disk on the head face

2. In the drawing, what letter represents the nominal length of a BSF bolt?

a) B
b) C
c) A
3. In the drawing, both bolts are correctly wire locked when

a) both A and B are right hand threads

b) both A and B are left hand threads
c) A is a right hand thread and B is a left hand thread

4. Turnbuckles are correctly fitted when

a) the inspection hole is blind or the required number of threads are showing
b) both rods are seen to touch in the inspection hole
c) both rods enter the barrel by the same amount
5. Taper roller bearings are used for which of the following purposes?

a) To transmit thrust loads with radial loads

b) To transmit radial loads whilst resisting axial movement
c) To permit axial movement whilst resisting radial load

6. Sheet metal should be stored

a) on its edge in racks to prevent scratching

b) stacked flat to prevent bending of sheets
c) above 25 degrees centigrade

7. An aluminium alloy bolt may be identified by

a) its colour (dyed green)

b) the letter A stamped on the head
c) its colour (dyed black)

8. A (British) 3/8" dia UNF bolt will have the diameter code letter

a) N
b) J
c) G

9. The continuous coloured line on a hose assembly

a) will assist in detection of any twist in an installed hose

b) identifies hose material
c) identifies fluid compatibility of hose

10. Clad aluminium alloy (alclad) has a pure aluminium coating of

a) 5% of alloy thickness
b) 1% of alloy thickness
c) 0.002" regardless of alloy thickness

Exam 30

1. The main metal in monel is

a) nickel
b) stainless steel
c) aluminium
2. Austenitic stainless steels are

a) magnetic
b) non-magnetic
c) hardened by heat treatment

3. A tube complying to BS T51 is

a) tungum
b) high pressure seamless copper tube
c) HTS tube

4. Adapter nipples are not required on

a) pipe to pipe coupling

b) pipe to internally coned adapter
c) pipe to externally coned adapter

5. The storage life of a flexible hose can be up to but not exceeding

a) 2 years
b) 4 years
c) 5 years

6. The markings on a flexible hose must include the

a) manufacturers name
b) date of manufacture
c) internal bore size

7. The stationary race of a journal bearing is normally

a) an interference fit
b) a push fit
c) a spigoted fit

8. Inspection of bearings is normally carried out

a) in situ
b) when dismantled
c) when removed from an assembly

9. Damage to the shield of a bearing should result in

a) rejection of the bearing

b) replacement of the shield
c) no action

10. The formation of steel depends upon

a) the formation of pearlite into austenite

b) the presence of pearlite in the structure
c) the formation of austenite into pearlite
Exam 31

1. The teeth of a gear would normally be

a) nitrided
b) case hardened
c) tempered

2. Which of the following could best be manufactured from Perspex panel?

a) A passenger window
b) A radome
c) A cockpit windscreen

3. Titanium alloys

a) have a high strength to weight ratio

b) are corrosion resistant but heavy
c) are cheap to manufacture

4. Why is nickel chromium used in many exhaust systems?

a) Corrosion resistant and low expansion coefficient

b) Lightweight and flexible
c) Corrosion resistant and high heat conductivity

5. Which part of the 2017-T36 aluminium alloy designation indicates the primary alloying agent
used in its manufacture?

a) 2
b) 20
c) 17

6. Spilled mercury on aluminium

a) increases susceptibility to hydrogen embrittlement

b) causes rapid and severe corrosion in prolonged contact
c) may cause impaired corrosion resistance if left in prolonged contact

7. Non-reversible chains can

a) only be moved in one direction

b) not be fitted through pressure bulkheads
c) only be fitted in one direction

8. When fitting a replacement flexible hose

a) ensure adequate clearance between the hose and the aircraft structure
b) use the old one to apply the 'set'
c) always pressure test before fitting

9. How is residual magnetism removed?

a) Degaussing
b) EMC
c) EMI

10. The hardness of steel depends upon

 a) the iron austenite grain structure
b) formation of pearlite into austenite
c) formation of cementite

Exam 32

1. When the temperature increases on a hot bond repair is paused is is known as

a) ramping up
b) ramping down
c) arrest point

2. What material is suitable for riveting steel?

a) Monel
b) Copper
c) Aluminium alloy

3. Cadmium plated rivets should not be used where the temperature may exceed

a) 120oC
b) 250oC
c) 200oC

4. High Tension leads are

a) multi-core, screened
b) solid-core, screened
c) multi-strand, single core, screened

5. The difference between annealing and normalizing is

a) both are heated above the UCT, cool slowly to anneal, cool in air to normalize
b) both are heated below the UCT, cool in air to anneal, cool slowly to normalize
c) both are heated above the UCT, cool in air to anneal, cool slowly to normalize

6. What rivets should be used with nickel alloy steel?

a) Monel
b) Mild Steel
c) Aluminium Alloy

7. Kevlar and Nomex are types of

a) aluminium alloy
b) advanced composite
c) glass fibre composite

8. How is the diameter of a cable measured?

a) Overall diameter
b) Diameter of one wire multiplied by the number of wires
c) Diameter of one wire only

9. MIL-H-5606 hydraulic fluid O-rings are identified with a

a) blue dot
 b) yellow and white dot
c) yellow dot

10. The large diameter on a bevel gear is called the

a) heel
b) toe
c) foot

Exam 33

1. Chemical attack is a direct result of

a) intergranular corrosion
b) cathodic & anodic changes in the material
c) filiform corrosion

2. A watermark on a bearing indicates

a) bearing running dry

b) lack of lubrication
c) intergranular corrosion

3. What is a fusible material?

a) The ability of two dissimilar metals to melt together

b) The ability of a metal to melt
c) The ability of a metal to be welded

4. 9 x 16 cable is

a) 9 strands of 16 wires
b) 9 cables having 16 turns per inch
c) cable size 9/16 inch diameter

5. Turnbuckle lock nut is a

a) stiff nut
b) slotted nut
c) castle nut

6. An AN steel bolt is identified by

a) X on head
b) - on head
c) plain bolt

7. Normalizing of steel is done to

a) remove residual stress of the manufacturing process

b) make steel softer
c) restore the fatigue life of steel

8. Needle bearings resist

a) radial and axial load

b) radial load only
c) axial load only
9. Turnbuckles are used to

a) adjust minor tension on the cable

b) join the two ends of the cable
c) adjust major tension on the cable

10. Rivnuts were originally used for

a) securing rubber de-icing boots

b) securing structural parts
c) securing cabin floorings

Exam 34

1. The drill bit to be used for stainless steel should have included angle of

a) 90 degrees
b) 140 degrees
c) 118 degrees

2. Brittleness is

a) the property to get deform before cracking

b) the property to resist wear
c) the property to resist deformation

3. The angle of a screw thread is

a) the inclusive angle of the thread sides

b) half the inclusive angle of the thread sides
c) the distance the thread moves in one turn

4. A turnbuckle is in safety when

a) the colour on the threads is showing

b) the witness hole is covered or the amount of
threads showing at the cable end is in accordance with the Maintenance Manual
c) it is lockwired

5. A turnbuckle can be safetied by

a) teflon lock nuts

b) doesn't require to be safety locked
c) by lock nuts and safety wirelocking

6. What is an advantage of a double flare on aluminium tubing?

a) It is less resistant to the shearing effect of torque

b) It is more resistant to the shearing effect of torque
c) Ease of construction

7. What type loads cause the most rivet failures?

a) Head
b) Shear
c) Bearing
8. Which part of the 2017-T36 aluminium alloy designation indicates the primary alloying agent
used in its manufacture?

a) 17
b) 2
c) 20

9. Clad aluminium alloys are used in aircraft because they

a) can be heat treated much easier than the other forms of aluminium
b) are stronger than unclad aluminium alloys
c) are less subject to corrosion than uncoated aluminium alloys

10. Non heat treatable aluminium alloys

a) cannot be softened
b) cannot be hardened
c) can be hardened by strain hardening

Exam 35

1. Galvanic corrosion is caused by

a) the joining of 2 dissimilar metals

b) cyclic stressing and a decrease in cross sectional area
c) incorrect heat treatments or incorrect alloying

2. In the galvanic series, the most noble metal will, if joined to another metal

a) corrode before the less noble metal

b) allow the less noble metal to corrode first
c) always be at the top of the table

3. Stress corrosion is associated with

a) cyclic loading and a corrosion pit

b) a corrosion pit in a member under a compressive load
c) a corrosion pit in a member under stress

4. Intercrystalline corrosion

a) always appears as small surface cracks

b) is detectable by X-rays
c) is the same as exfoliation corrosion

5. The usual manufacturers anti-corrosion process to be applied to Fe aircraft parts is

a) anodising
b) cadmium plating
c) metal spraying

6. Chromate treatment is applied to

a) magnesium alloys
 b) Al alloys
c) Fe alloys

7. A spring washer

a) must not be used more than once

b) may be used a second time provided it is fitted the reverse way round
c) maybe used more than once provided it continues to provide an efficient lock

8. If the cross sectional area of a cable is increased, what will happen to the voltage drop?

a) Increase
b) Decrease
c) Stay the same

9. Spring locking clips for turnbuckles can be used on

a) all flying control cables

b) no flying control cables
c) only on trim control cables

10. The cross sectional area of a copper crimp barrel is

a) same as an aluminum one

b) larger than an aluminum one
c) smaller than an aluminum one

Exam 36

1. What is the small hole on a swaged turnbuckle for?

a) To check if correct amount of cable has been inserted before swaging

b) To check for moisture deposits
c) To alloy the turnbuckle to be wire locked

2. Electrical cable on aircraft is mainly made from copper because

a) it offers low resistance to current flow

b) it more malleable
c) it does not oxidise

3. Fork end fittings on control rod ends should have

a) bolt heads fitted upwards

b) 0.002 inch axial movement
c) anti vibration compound

4. Rivets main strength quality is to resist

a) tensile loads
b) torsion
c) shear loads

5. Non heat treatable aluminium alloys

a) can not be softened

b) cannot be hardened
 c) can be hardened by strain hardening

6. Advantages of electric arc steel making are

a) no gas fumes or impurities are produced

b) cheaper steel is produced
c) no impurities exist in finished steel

7. Solution treatment after manufacturers have performed it out once can be carried out a
further

a) 1 time
b) 2 times
c) 3 times

8. Following solution treatment aluminium alloy can be placed into service

a) straight away
b) after 24 hours
c) after 5 days

9. The time between removal from heat treatment furnace and quenching must be not more
than

a) 3 seconds
b) 7 seconds
c) 10 seconds

10. Specified time of contact between the indentor and test piece in a vickers or brinell hardness
test is

a) 10 seconds
b) 15 seconds
c) 20 seconds

Exam 37

1. In an Izod impact test the striking energy of the striker is approx

a) 150J
b) 163J
c) 300J

2. When buffing surface of Aluminium Alloy, what material are you removing

a) aluminium
b) alloy
c) oxidised layer

3. When crimping, what chapter in the ATA system should you refer to?

a) 20
b) 24
c) 12

4. When checking the safety of turnbuckles you should use what?

a) Wire the same diameter as the inspection hole

 b) Wire smaller than inspection hole
c) Visual check

5. Anti-corrosive treatment used on Magnesium is

a) chromating
b) phosphating
c) electro-plating

6. Fretting corrosion occurs with

a) vibration in bolted parts

b) water trapped between moving parts
c) improper heat treatment

7. Intergranular corrosion is also known as what?

a) Exfoliation
b) Galvanic
c) Stress corrosion

8. When normalising, the material is?

a) Quenched immediately
b) Left to cool in room temperature
c) Cooled slowly

9. Why is clad alloy preferred to pure Aluminium?

a) Tougher
b) Less brittle
c) More ductile

10. Why are aluminium alloys used on aircraft?

a) Lighter
b) Stronger
c) Corrosion resistant

Exam 38

1. An internal circlip can be used to

a) retain a ball bearing on a shaft

b) retain a ball bearing in a housing
c) to do both of the above

2. The colour coding of metals indicates

a) specification only
b) specification and gauge
c) quality standard

3. Silver solder is made from

a) zinc, copper, silver

b) zinc, copper, tin
c) zinc, copper, lead
4. How do you check a chain for elongation?

a) Lay flat on a table, apply tensile load and measure

b) Hang chain up, check sight line and measure
c) Adjust the end fittings

5. Drive planes on an epicyclic gear are

a) at right angles to the plane

b) around a common axis of the plane
c) at different angles to the plane

6. What type of material would hydraulic pipes on an undercarriage leg or bay be made from?

a) Stainless steel, annealed, 14H

b) 1100, 2024, in half hard state
c) 7075, H14

7. Music steel wire is

a) used for high strength springs and as progressive-rate springs

b) used for lower strength springs
c) made of high carbon or nickel alloy

8. The magnesium alloys used in aircraft can be recognized by

a) yellowish surface due to protective treatment

b) shiny surface due to chromium plated on the surface
c) silver surface due to protective coating

9. Compared with the spur gears, spiral gears have

a) more wear resistance

b) less stress concentration on gears
c) have mechanical advantages

10. The clutch which can overrun the driving member, is known as

a) overload clutches
b) freewheel clutches
c) no-slip clutches

Exam 39

1. Interconnect cables

a) employ thinner insulation than airframe types

b) are used for equipment wire in the unified system

c) are the cable through the MEC to the engine

2. Slight waviness on a fibre composite structure

a) may be tolerable if lightly loaded

b) could be reinforce with additional plies over the weakened area

 c) may cause fatigue crack eventually

3. A washer having both twisted teeth and spring actions is

a) AN935 split-ring lock washer

b) AN936 shake-proof lock washer

c) AN970 large-area flat washer

4. The tang of thread insert

a) must be removed

b) is removed with a hammer and a punch

c) may left it in the insert after installation

5. The AN526 truss-head screw

a) is a widely used recesses head machine screw

b) provides a good clamping force

c) is a pan-head screw

6. The first step for the coaxial cable to attach to the end fitting is

a) the outer covering is cut back to expose the braided outer conductors

b) back-off the insulator and connect with conductor

c) use a tooling hold between the assembly and cable

7. Strength of fibreglass is

a) along the fibre

b) across the fibre

c) either direction

8. Cable minimum breakage strain for British and American is measured by

a) pounds for both

b) hundredweight for British, c.s.a. and pounds for American

c) hundredweight for British, c.s.a. hundredweight for American

9. A metal pipe has a small indentation what are the limits?

a) No dent on a bend

b) 10% of external diameter

c) 5% internal diameter
10. During construction, sharp internal corners and inaccessible places should be avoided to reduce

a) fretting corrosion

b) filiform corrosion

c) crevice corrosion

Exam 40

1. To check the interior of tubular members for corrosion attack

a) dye penetrant testing should be used

b) ultra sonic testing is necessary
c) any form of test is acceptable

2. Exhaust systems are usually made from stainless steel which is susceptible to

a) surface corrosion
b) intergranular corrosion
c) filiform corrosion

3. Corrosion will spread more rapidly when metals are exposed to

a) high temperatures
b) dry climates
c) cold climates

4. Anodising is a form of

a) artificial protection
b) sacrificial protection
c) metallic coating

5. Age hardening of aluminium is

a) never carried out

b) not necessary
c) a gradual hardening over a period of time

6. Alclad is

a) aluminium with duralumin cladding

b) duralumin with magnesium cladding
c) duralumin with aluminium coating

7. The oxide film on the surface of aluminium is

a) porous
b) non porous
c) hard and porous

8. Steel is tempered
a) after hardening
b) before hardening
c) to increase hardening

9. Cast iron is
a) heavy and brittle
b) very malleable
c) tough
10. Case hardening can be carried out on
a) duralumin
b) titanium
c) any ferrous metal

Exam 41

1. Normalising steels

a) increases the hardness

b) relieves the stresses
c) increases toughness

2. The Alocrom 1200 process was designed to treat

a) surfaces too large for dip treatment

b) small surfaces
c) chromium plating

3. The maximum length of time a component is held in stores is known as the

a) package life
b) shelf life
c) storage life

4. When silica gel has absorbed moisture the colour changes to

a) pink
b) white
c) blue

5. A thrust bearing is designed so that

a) it transmits axial loads, therefore limiting radial movement

b) it transmits axial loads, therefore limiting axial movement
c) it transmits radial loads, therefore limiting axial movement

6. A thread insert may be removed by

a) a blade removal tool

b) a hammer and punch
c) a pre-wind insertion tool

7. If a pulley shows signs of wear on one side

a) the cable is misaligned

b) the pulley is too large for the cable
c) the cable is too tightly tensed

8. Cable end sleeves are made of

a) aluminium alloy
b) copper
c) stainless steel
9. A 7x7 cable has seven strands each of

a) one wire
b) seven wires
c) fourteen wires

10. A spring should be inspected for correct

a) width, strength and squareness

b) length, strength and squareness
c) width, length and strength

Exam 42

1. The process of forming a pure layer of aluminium over an aluminium alloy is

a) electroplating
b) alclad
c) metalizing

2. A fire resistant cable must maintain adequate insulation in a fire for

a) 30 minutes
b) 5 minutes
c) 10 minutes

3. Cable stops are manufactured from

a) copper
b) stainless steel
c) magnesium alloy

4. Capped nuts are used

a) to stop leaks
b) prevent overtightening due to the threaded portion being restricted by the cap
c) to provide a dry torque joint

5. On a pre-preg composite

a) no life extension is allowed, it must be used immediately

b) life can be extended by 12 months if stored below 10oC
c) life can be extended by 12 months if stored above 40oC

6. Pulleys are manufactured from

a) brass and phenolic resin

b) tungum and high tensile steel
c) stainless steel and nylon

7. A pin in a fork end fitting is subjected to what loading?

a) Torsion
b) Shear
c) Tensile
8. The artificial production of a film of hydroxide on the surface of aluminium or any of its alloys
is commonly called

a) alodizing
b) parco lubrizing
c) anodizing

9. Alodizing protects alloy metal from corrosion and does what else?

a) Seals the surface from moisture

b) Makes a good surface for paint to adhere to
c) Makes the surface alkaline

10. When silver coated connectors are used in unpressurised parts of the aircraft

a) red plague can occur

b) wet track arcing can occur
c) separation of the coating can occur

Exam 43

1. An aircraft pipe has a number stamped on it. It is the

a) fluid it is carrying
b) serial number
c) aircraft system

2. A pipe with a 0.25" inside diameter would be made from

a) 2024 alloy
b) 5056 alloy
c) steel

3. Hylocks

a) are pre lubricated

b) do not require lubrication
c) lubricate the screw part only

4. Hot bond composite pane has a crack. When it reaches the ribbon it will

a) stop
b) carry on along the ribbon
c) have no effect on its direction

5. When cleaning aircraft faying surfaces, a cause for concern is

a) sharp corners etc trapping corrosive chemicals

b) corrosion acting on the end faces of panels
c) leaks into the fuselage

6. Which is the following correct statement?

 a) All corrosion is a chemical action
b) Selenious acid is used for the re-protection of aluminium alloys
c) The chemical test for bronze is nitric acid which produces a white precipitate

7. In a poorly produced repair to skin structure, where would stress corrosion start?

a) Along the edges of repair

b) Radiate from the corner or sharp edges
c) Form internally to produce surface corrosion

8. The form of corrosion most likely to cause stress concentration is

a) Surface Corrosion
b) Fretting Corrosion
c) Pitting Corrosion

9. Lead acid battery fluid has been found to be leaking on the surface of the aircraft structure.
What substance would you use to neutralise the acid?

a) Sulphur and Lime

b) Hot distilled water
c) Sodium bicarbonate of soda

10. What colour is the corrosion found on the surface of aluminium alloys?

a) Green/Blue
b) White/Grey
c) Black

Exam 44

1. Titanium can be identified by placing it on a grinding wheel and looking for

a) White Sparks
b) Red Sparks
c) Yellow Sparks

2. Adding more catalyst to a composite mix

a) Increases brittleness
b) Decreases cure time
c) Increases cure time

3. Some metals are inherently stable. What does this suggest?

a) They try to revert to their natural state

b) They are highly prone to corrosion
c) They strongly resist corrosion

4. Re-treatment of aluminium alloys can be performed by

a) Brushing on phosphate treatment followed by paint

b) Selenious acid treatment
c) Alocrom treatment

5. Corrosion on copper is identified by

a) red/brown rust
 b) green discolouration
c) black powder

6. A plate 10 inches by 5 inches is to be riveted with 3 rows of rivets, with the normal 4D rivet
spacing and 2 D edge distances. The rivets are AN460AD4-6. How many rivets are required?

a) 56
b) 60
c) 52

7. A composite flap panel has corrosion. What NDT method will you use to detect?

a) High voltage x-ray

b) Low voltage x-ray
c) Coin tap test

8. A composite flap panel has structural damage. What NDT method will you use to detect?

a) High voltage x-ray

b) Low voltage x-ray
c) Coin tap test

9. When metal is first heated slightly above its critical temperature and then cooled rapidly it is
common that the metal will increase in

a) brittleness
b) hardness
c) both of the above

10. The oxide film formed on the surface of aluminium is

a) porous
b) non-porous
c) hard and porous

Exam 45

1. Steel is tempered

a) after hardening
b) before hardening
c) to increase hardening

2. If a steel component is operated below the fatigue limit the fatigue life is

a) finite
b) infinite
c) depend on its proof stress

3. The critical process of heat treatment is

a) method of heating only

b) temperature and method of heating only
c) temperature, method of heating and cooling
4. What is generally true for titanium alloy?

a) It is stronger than the steel

b) It is stronger than the aluminium
c) It has lower density than magnesium

5. Malleable material are

a) easy to forge
b) highly ductile
c) easy to cast

6. Sound is best absorbed by a material which is

a) dense
b) hard
c) soft and porous

7. If a material has to undergo deep cold forming operation. The essential property would be

a) ductility
b) malleability
c) elasticity

8. When examining a piece of metal through a magnifying glass hair line cracks would indicate

a) crevice corrosion
b) intergrannular corrosion
c) surface corrosion

9. Corrosion control begins at the

a) design stage
b) manufacturing stage
c) production stage

10. In the anodic film inspection and sealing test if a good seal has been accomplished

a) the dye mark will rub off

b) the dye mark will not rub off
c) the dye mark has no importance

Exam 46

1. After a product has been manufactured and all heat treatment has been carried out the
stress remaining if any is termed as

a) working stress
b) residual stress
c) applied stress

2. Aluminium alloy parts are often protected by the

a) Alocrom 1200 process

b) Alocrom plating
c) chromium plating process
3. Corrosion is always completely removed

a) to fit new parts

b) to permit the extent of damage to be assessed
c) to prevent further damage

4. The metal which must not be heated in salt bath is

a) duralumin
b) magnesium alloy
c) rivets made of alclad

5. Lubrication of roller bearings and needle bearings are

a) under pressure
b) by hand
c) at low pressure via a tube

6. The colour code on sheet metal indicates

a) only the specification of the material

b) the spec and gauge of the material
c) that the material is from an approved source

7. The length of a straight hose assembly is measured

a) along the coloured line

b) between the outer faces of the union nuts
c) between the extremities of the two nipples

8. UNF means

a) unified fine
b) united nations fine
c) union national fine

9. Knuckling is a problem on earlier aircraft cables due to

a) hot stamping of cables

b) too much flux
c) wires being pulled through too hard

10. A low carbon steel would normally be case hardened using:

a) pack or gas carburising

b) flame or induction hardening
c) the nitriding process

Exam 47

1. When two or more metallic materials are fused together, the combination is known as

a) an alloy
b) a composite material
c) a thermosetting compound

2. Annealing steels
 a) toughens the metal
b) makes the metal brittle
c) makes the metal malleable

3. Tempering of hardened steel is carried out to

a) retain core hardness, but soften the surface

b) retain surface hardness, but soften the core
c) significantly reduce the brittleness without suffering a major drop in its strength

4. High speed steel relies heavily on the following metallic element for its ability to cut other
metals, even when it is heated to a dull red colour

a) Tungsten
b) Vanadium
c) Nickel

5. The proof stress of a material is the stress at which

a) the material yields

b) necking of the material begins
c) small amount of permanent set takes place

6. Malleable materials are normally

a) easy to cast
b) also highly ductile
c) easily forged

7. When low carbon steel bolt is stretched beyond its elastic limit without breaking, it will

a) become more ductile

b) deform temporarily
c) deform permanently

8. 1% Nickel, 1% Carbon, steel is widely used for

a) high tensile steel bolts

b) ball and roller bearings
c) exhaust valves

9. The Common bonding material for Tungsten Carbide is

a) Cobalt
b) Invar
c) Silicon

10. In an autoclave the air is removed by

a) pressure
b) vacuum
c) roller

Exam 48
1. Grain size will effect the mechanical properties of metal. Which of the following is true?

a) Large grain size is attributed to slow cooling rates and will give less tensile strength
b) Small grain size is normally attributed to rapid cooling rates and will give less tensile
strength
c) Materials with large grain size are more prone to creep

2. Cable current ratings are based on a conductor temperature rise of 40 degrees Celsius and if
the maximum design ambient temperature is
continuously exceeded they should be

a) multiplied by the 'K' factor.

b) divide by the 'K' factor
c) halved

3. Which of the following types of electrical wire is likely to be used for connection of thermo-
couples around the jet-pipe of a turbine engine?

a) Nyvin
b) Tersil
c) Fepsil

4. In a Teleflex flexible control system, the Teleflex cable consists of

a) multi strand steel wires and is used primarily as a

single one way device operated from a control lever
b) a high tensile steel wire with a right or left hand helix wire wound on to it. The system
can operate in two directions
c) a flexible seven or nineteen strand steel cable used for the operation of manual flying
controls

5. A cable tension regulator will be installed in a flying

control system to

a) compensate for rapid movement of the controls by taking up the slack

b) allow for variations in temperature which will vary the cable tension
c) automatically compensate for low cable tension caused by worn cables

6. A clevis bolt in a control cable fork end would be loaded in

a) tension
b) shear
c) both tension and shear

7. Aircraft flying control cables are normally classified by the

a) minimum breaking load or the diameter in inches

b) number of strands it contains and the number of wires in each strand
c) circumference of the cable and overall length

8. The cracking of structural members under repeated stress

lower than the ultimate tensile load is known as

a) stress reversal
b) fatigue failure
c) creep

9. Fatigue failure may be defined as

a) failure due to impact

b) failure caused by stress in excess of the material U.T.S
c) reduction in strength due to alternating loads

10. The Charpy test measures

 a) impact energy
b) strain
c) Young's modulus

Exam 49

1. The main reason why crimped joints are preferable to soldered joints is

a) the quality of crimped joints will be constant

b) no flux is needed
c) there is no heat required

2. A piece of duralumin has been annealed and bent into shape prior to fitting to an aircraft.
Which of the following is correct? It must be

a) solution treated prior to fitting to an aircraft

b) fitted to the aircraft within 24 hours
c) solution treated, precipitation treated and fitted to the aircraft within 2 hours

3. The maximum tensile strength of fibre reinforced plastic is achieved using

a) unidirectional fibres
b) chopped strand mat
c) fibres uniformly distributed at 45 degrees to each other

4. A sheet of metal is designated 2024-T4. The code tells us that the material is a copper based
aluminium alloy

a) solution treated and artificially aged

b) solution treated and naturally aged
c) annealed and Naturally aged

5. A metal is coded 1285 using the IADS coding method. This

means the metal is

a) a copper based aluminium alloy i.e. duralumin

b) 99.85% pure aluminium
c) 85% pure aluminium
6. In the cable identification '2 P 215 A 28 N' the position of the letter P indicates

a) which segment the cable is in

b) that it is a Pneumatics system cable
c) the circuit function

7. A material containing approximately 66% nickel and 33%

copper is known as

a) Monel metal
b) Nimonic
c) Invar

8. Crimping terminals are colour coded. The colour indicates

a) the type of crimping tool to be used only

b) the wire size to be used with that crimp only
c) both the crimping tool and the size of the wire to be used
9. Monel metal consists of approximately

a) 66% Copper and 33% Nickel

b) 63% Nickel and 33% Copper
c) 66% Chromium and 33% Copper

10. Silver solder is composed of the materials

a) Copper, Zinc and Silver

b) Copper, Tin and Silver
c) Zinc, Lead and Silver

Exam 50

1. Age hardening of aluminium is

a) never carried out

b) not necessary
c) gradual hardening over a period of time

2. What is the separation of an aramid panel layers described as

a) delamination
b) debonding
c) detachment

3. What type of load is taken by an " I " beam

a) shear
b) tension
c) bending

4. Corrosion on a copper alloy can be recognised by

a) white deposit
b) grey deposit
c) blue / green deposit

5. Silica gel is used for moisture control during storage, when serviceable it is coloured

a) pink
b) white
c) blue

6. Corrosion is always completely removed

a) to fit new parts

b) to permit the extent of the damage to be assessed
c) to prevent further damage

7. Normalising steels

a) increases the hardness

b) relieves the stresses
c) increases toughness

8. Cast iron is

a) heavy and brittle

 b) very malleable
c) tough

9. Steel is tempered

a) after hardening
b) before hardening
c) to increase hardening

10. Aluminium is

a) highly resistant to corrosion

b) not resistant to corrosion
c) reasonably resistant to corrosion

Exam 51

1. The ease with which a material can be forged, rolled and extruded without fracture is an
indication of a material's

a) brittleness
b) ductility
c) malleability

2. Austenitic steel is produced when the material is heated to

a) below the Upper Critical Point

b) above the Upper Critical Point
c) above the Lower Critical Point

3. Steel is produced by refining pig iron where air/oxygen is blown through the molten material
to remove

a) sulphur
b) oxides
c) carbon

4. The 'Fatigue limit' for steel is generally in the region of, compared to the static U.T.S

a) 20%-40%
b) 40%-60%
c) 60%-80%

5. Young's Modulus is a measure of

a) stress
b) strain
c) stiffness

6. The ability of mild steel to accept more load after the yield point is reached is due to

a) necking
b) strain hardening
c) plasticization

7. Hooke's law states that, within the elastic region, elastic strain is
 a) indirectly proportional to stress
b) directly proportional to stress
c) directly opposite to stress

8. The S.I. unit for strain is

a) Nmm
b) P.S.I.
c) no units

9. The value of stress for a given material can be derived by

a) Load x Cross sectional area

b) Load / Cross sectional area
c) Cross sectional area / Load

10. A material's yield strength is the ability to

a) resist deformation
b) resist side loads
c) withstand a crushing force

Exam 52

1. What is fatigue?

a) Constant stressing of a part

b) Cyclic stressing of a part
c) Failure of a component due to corrosion

2. The defects not allowed at all on wooden structures are

a) checks , shakes and splits

b) pitch pockets
c) mineral streaks

3. The basic structure of an aircraft made of wood can be

a) non-monocoque
b) monocoque
c) non-monocoque, monocoque, semi-monocoque

4. Polyester resin and glass fibre cloth, becomes

a) GRP
b) PTFE
c) PVC

5. Fabrics may be fitted to airframe structures by

a) always riveting
b) tying on with string
c) wood nails
6. A gear system, or gear train, is made up of gears that are

a) driven and driver

b) idler
c) all of the above

7. Split pins

a) may be used more than once

b) may be used only once
c) can be used more than once but depends on the material of the split pin

8. Why is stop drilling carried out at the end of a crack?

a) to change the direction of the crack

b) to increase the stress concentration at the crack end
c) to stop the crack from propagating

9. A new rivet made of aluminium alloy is

a) anodised with 's'

b) anodised with 'x'
c) anodised with 'd'

10. A thermoplastic can be

a) heated and formed only once

b) is not affected by even low temperatures
c) can be reheated and reformed more than once

Exam 53

1. Tap testing a sandwich panel construction

a) will not give very reliable results

b) is not an approved method of testing
c) is crude, but works remarkably well

2. An impact adhesive is part of the

a) thermoset group
b) Anaerobic resin group
c) thermoplastic group

3. A butyl rubber seal is made from

a) latex natural rubber

b) silicon rubber
c) synthetic rubber

4. Which product is a serious health hazard when handling?

a) Glass fibre
b) Asbestos
c) Ceramic

5. Aircraft transparent plastics are cleaned using

 a) paraffin and soft cotton pad
b) clean dry soft leather
c) warm soapy water, rinsed and dried

6. When galvanic corrosion takes place, which part corrodes?

a) Anode
b) Cathode
c) Oxide film coating

7. Which of the following is a temporary protective measure?

a) Sacrificial protection
b) Paint finish
c) Chromating

8. Which anti-corrosion treatment is normally applied to

aluminium alloys?

a) Cadmium
b) Pure aluminium
c) Anodising

9. A 14 SWG electrical cable when compared to a 18 SWG cable can carry

a) more current
b) less current
c) the same current

10. Co-axial cables are used

a) as they are able to handle high current

b) as they produce an electrostatic field around them which prevents HIRF interference
c) as the fields due to current flow in the inner ando uter cancel each other out

Exam 54

1. 7 x 7 cable has seven stranded wires each with

a) 49 wires
b) 7 wires
c) 14 wires

2. A thermosetting adhesive

a) can be re-formed when hot

b) undergoes a chemical transformation and creates an
insoluble substance
c) will be resistant to heat

3. Direct removal connector pins are fitted from the rear

a) and removed from the rear

b) and removed from the front
c) are fitted from the front but removed from the rear

4. Spilled mercury on aluminium causes

 a) yellowish stains on surface of the metal
b) greyish powder, fuzzy deposit or whiskery growth
c) black pits going into brown rust

5. Capped nuts are used

a) to provide dry bolting of the joints

b) to stop leaks due to metal caps fitted on the heads
c) to lock the nut to the bolt

6. A spring should be inspected for correct

a) width, length, strength

b) length, strength, squareness
c) diameter, strength, squareness

7. Tension regulators on aeroplanes with fully metal bodies are used to

a) set up the necessary tension

b) maintain the necessary tension
c) relax the tension in cold conditions

8. When hot stamping the cable number be sure it is not done too deep, otherwise

a) wet track arcing may occur

b) may become not readable in the future
c) may become susceptible to HIRF

9. Why do hydraulic pipes have bends in them?

a) To fit airframe structure

b) To allow for heat expansion and vibration
c) Absorb vibration

10. When should control cables be changed?

a) When 20% wire diameter is worn

b) When single wires are blended together
c) The protective coating is displaced or missing

Exam 55

1. What does the 0 in 2024-T3 mean?

a) The alloy has been modified

b) The percentage of impurities in the alloy
c) The alloy has not been modified

2. What type of heat treatment can be used on DD rivets?

a) Annealing
b) Solution Treatment
c) Precipitation

3. What type of test involves using a weighted pendulum to

strike a material until fracture?
 a) Impact Resistance Test
b) Fatigue Testing
c) Hardness Test

4. During a Rockwell Hardness test, what dimension is measured?

a) The diameter of the indent

b) The depth of the indent
c) The diameter and depth of the indent

5. What type of a test involves stretching material until it breaks?

a) Fatigue Testing
b) Tensile Testing
c) Hardness Testing

6. What is a Rockwell tester used for?

a) Hardness Testing
b) Fatigue Testing
c) Tensile Testing

7.
a)
b)
c)

8.
a)
b)
c)

9.
a)
b)
c)

10.
a)
b)
c)