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9. The British identification of the heat treatment to which an aluminium alloy item has been
subjected is shown by:
a. a letter and number code
b. a number
* c. a letter
10. After solution treatment of aluminium alloy, the effect of immediate refrigeration at a
temperature within the range of -15 EC to -20 EC is:
* a. to suspend natural ageing for a limited period
b. to increase the rate of artificial ageing
c. to permanently soften the metal to retard the onset of fatigue
11. Alclad materials can be heat treated:
a. as many times as required
* b. 3 times only
c. once only
12. Aluminium clad alloy sheet should not be polished with mechanical buffing w heels:
a. as this will cause large static charges to build up
* b. as this may remove the aluminium coating
c. as this may remove the alloy coating
13. 3L72 indicates:
a. specification and gauge
* b. specification and year of manufacture
c. specification, heat treatment and year of manufacture
14. The identification marking, L72W on a sheet of aluminium alloy indicates:
* a. material specification and heat treatment
b. material thickness and specification
c. material specification and fatigue strength
15. What chemical is used to identify aluminium alloys;
*acaustic soda
b copper sulphate
c nitric acid.
16 Pure Aluminium is;
*ahighly resistant to corrosion
b not resistant to corrosion
c reasonably resistant to corrosion.
3. When carrying out a fibreglass repair, if a backing support is used, it should be faced w ith:
a paper
*b cellophane
c glass fibre cloth
4. To prevent the repair sticking to the support plate, when carrying out a fibre glass repair:
*a cellophane sheet is used
b paper sheet is used
c fibre glass is used
5. Nylon is used for bagging because:
* a it has high tensile strength
b it is porous
c it is resistant to temperature
6. Nomex is:
a aluminium foil
b glass fibre honeycomb
* c aramid honeycomb
7. In an epoxy resin mix, the ratio of resin to hardener is 100:45 How much hardener would
be required to cure a resin of 60g?
a 133g
*b 27g
c 186g
8. When repairing damaged honeycomb structure the core is removed using:
a a wood chisel
b an abrasive wheel
*c a router
9. Micro-balloons as used in composite repairs are:
a cheaper than normal agents
*b lighter than normal agents
c used to give better bonding with the resin than normal agents
10. How is the air extracted from between the laminates when using an autoclave?
a by pressure
* b by vacuum
c by rolling
11. When applied to aircraft structures, a hot bond is the name given to:
a a blind rivetted joint
b a machined rivetted joint
*c a resin sealed joint
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12. When carrying out a fibre glass repair, the direction of the fibres in each layer must be
layed:
a in the same direction layer upon layer
b outer layer facing one way and the inner layer the same way
*c each layer is layed in a different direction to the next layer
13. Why are micro-balloons mixed with the resin when carrying out composite repairs?
*a to keep the repair as light as possible
b because they are cheaper than other additives
c because they interlock with the fibres of the composite
14. Before inspecting damage to an aramid composite panel, how is the surface finish
removed?
a with paint stripper
*b with wet and dry in a circular motion
c mechanically by vacuum sandblasting
15. After using an epoxy resin compound, what is used to put oil back into your skin?
a acetone/lanolin mixture
*b refatting cream
c resin removing compound
16. What do you refer to when carrying out repairs to a composite panel?
a aircraft maintenance manual
b CAIP
*c aircraft structural repair manual
17. What is separation of the layers in an aramid panel called?
*a delamination
b debonding
c detachment
18. When applying flame spray treatment of Kevlar, how is the depth and thickness
measured?
*a by ultrasonic
b by X-ray
c by eddy current
19. Which composite material must be shielded from sunlight?
a glass fibre
b carbon fibre
*c Kevlar
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37. It is important to mix the resin system correctly this should be done by
a volume by weight and as quickly as possible
*b volume by weight and the mixing process should take between 3 to 5 minutes
c volume by quantity and mixing should be as slow as possible
38. If a resin is removed from a refrigerator
*a It should be allowed to warm up before mixing, as cold resin will be heavier than the
same amount at room temperature
b it should be allowed to warm up before mixing, as cold resin will be lighter than the
same amount at room temperature
c it can be mixed straight from the refrigerator as temperature does not matter
39. What type of container should the resin system be mixed in
a a wax coated container
*b a wax free container
c the special container supplied by the resin manufacture
40. What does the term pot life refer to
a the amount of time the resin can be stared in the pot
*b the amount of time you have to work with the resin
c the amount of time it takes for the resin to cure
41. With advance composites Resin Rich refers to
*a a weak structure which is brittle and has extra weight
b the extra resin that is required when using pre-preg material
c any fabric material which has been coated in resin
42. With advance composites Resin Starved refers to
*a where not enough resin was used, causing the part to be weak because the matrix cannot
transfer the stresses to the fibres
b where not enough resin was used, causing the part to be weak because the matrix
transfers sheer loads onto the fibres material
c this is the desired state of the fibre material during lay-up as all excess resin must be
removed
43. The correct amount of resin ratio is important to get the desired strength In advance
composite 50/50 ratio is good, however,
*a a 60/40 fibre to resin ratio is better as the fibres gives you the strength not the resin
b a 40/60 resin to fibre is better as the resin gives you the strength not the fibre
c a 60/40 fibre to resin ratio is better as the resin gives you the strength not the fibre
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60. When drilling aramid composites the hole may appear to be fuzzy:
a extending fibres should be removed with a rotary file
*b quick curing epoxy resin should be applied to the fuzzy area and filed smooth after
curing
c if a fastener is being fitted through the hole the fuzziness can be left untreated as the
fastener will seal it
61. Nomex and other aramid honeycombs should :
a cut to size and used immediately after they have been removed from storage as they are
hygroscopic and may absorb moisture
*b be dried out at a temperature 40c (104F) for sixteen hours prior to use
c there is no prerequisite requirement prior to us
62. How much should a heat mat overlap surrounding structure when carrying out a
composite repair requiring heat to allow matrix to cure?
*
a 2 inches
b 3 inches
c 4 inches
63. Where should the vacuum gauge be placed in a vacuum bag
a next to the vacuum hose
b next to the repair material
*c at the opposite side to the vacuum hose
64. What grade of Kevlar is use on aircraft
a 129
*b 49
c 29
65. The accelerator in a matrix resin should
*a be added to the resin
b be added to the catalyst
c be added to the accelerator
66. When drilling aramid composites fuzzy holes can be avoided by
a using a high speed and high feed rate
*b using a brad point drill
c using a pilot drill
67. When drilling aramid composites fuzzy holes can be avoided by
a using a high speed and high feed rate
*b using a high speed and low feed rate
c using a pilot drill
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85 A repair is being carried out on penetration damage and both surfaces are damaged:
a both surfaces are vacuum bagged at the same time
*b while carrying out the first repair, the opposite side must be sealed with bagging
material before commencing the vacuum bagging operation
c a coat of double bond is applied to one side of the penetration before commencing the
vacuum bagging operation, this will prevent air being drawn through the repair
86 The sealant tape used to seal the bagging material should be:
a applied in a circle
*b applied in straight lines overlapping at the corners
c applied in straight lines curved at the corners
87 If a heat blanket is used during the bagging process, the thermocouple wires should placed
a to one side of the heat blanket
b on top of the heat blanket
*c under the heat blanket
88 Bagging film is
*a hydrophilic
b hydroponic
c hygroscopic
89 Bagging film is stored enclosed in a plastic wrap this is to:
*a stop the water content escaping (which would make the bagging material brittle)
b stop the bagging film from absorbing moisture in humid conditions
c stop it sticking together, which would make if difficult to unroll.
90 On completion of a repair the lower layer (peel ply) is removed, the top surface of the
repair is slightly rough in appearance, this should be:
a sanded with 400 grit to leave a smooth finish
b sanded with 250 grit to leave a smooth finish
*c it is permitted to leave in the rough condition as this allows the paint to adhere
91 What is the purpose of the bleeder layer as used during the bagging process:
*a to absorb excess resin
b to allow excess moisture to escape
c to allow vacuum pressure to bear down on the repair
92 Insulation plies are sometime used during the bagging process
*a over the heat blanket to minimise heat loss during the curing process
b under the heat blanket to minimise heat loss during the curing process
c to encapsulate the whole repair to minimise heat loss
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EC is:
b P.T.F.E.
* c ceramic.
106. A disadvantage of a ceramic is:
a a high melting point.
b hardness.
* c brittleness.
107. Expanded honeycomb structure:
*a bends with the web
b
c
108. Which composite material has the greater stiffness?
a Kevlar
*b carbon fibre
c G.F.R.P.
109. On a Kevlar structure, electrical charge is dissipated using:
a aluminium wire woven into the fabric
*b a layer of aluminium or copper sprayed onto the surface
c
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110. Resin and hardener are mixed to a ratio of 3:1 respectively, therefore 9 grams of hardener
would require:
a 3 grams of resin
b 6 grams of resin
*c 27 grams of resin
111 A composite solid joint is:
a cement and mechanical
b specific and mechanical
c
112 Thermo-plastic resins are usually supplied:
a alkaline etched
b solvent wiped
c
113 The vacuum bag on a composite repair should:
a overlap the breather fabric
b overlap the release film
c
114 When carrying out a composite repair the order of mixing is:
a Accelerator, catalyst, resin
b catalyst, resin, accelerator
*c resin, catalyst, accelerator
CORROSION
1. Corrosion is;
*a electro-chemical action
b electro-mechanical action
c hydro-electro action.
2. Corrosion on copper alloy can be recognised by a;
a white deposit
b black deposit
*c blue/green colour.
3. Exfoliation corrosion is sometimes referred to as;
*a layer corrosion
b sub-surface corrosion
c filiform corrosion.
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12. In the procedure to be followed after spillage of battery acid, neutralising is carried out:
* a. with a dilute solution of sodium bicarbonate
b. by washing with distilled water
c. by applying a coating of Vaseline
13 A smoke black substance found on a metal component may be:
a inter-crystalline corrosion
b galvanic action
*c fretting corrosion
14. What is the indication of fretting corrosion on aluminium alloy;
*a black powder
b brown powder
c white powder.
15. How does filiform corrosion appear on aluminium alloy;
*a worm casts
b flakiness
c cocoa.
16. Which is the following correct statement;
a all corrosion is a chemical action
b selenious acid is used for the re-protection of aluminium alloy
*c the chemical test for bronze is nitric acid which produces a white precipitate.
17. Which type of atmospheres will encourage the highest rates of corrosion?
a temperate, Suburban.
* b tropical, Industrial, Marine.
c arctic, Rural, Inland.
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FASTENERS
1. How is a 5% magnesium alloy rivet identified
a green in colour and the letter M on the head or shank
*b green in colour and the letter X on the head or shank
c natural in colour with the letter M on head or shank
2. What is the tangential approach when wire locking
*a 90
b 45
c 120
3. A tandard taper on a taper pin is
*a 1 in 48
b 1 in 20
c 1 in 600
4. What is the pitch of a screw thread
*a the distance between the centre of one crests to the centre of the next
b the distance between the roots of adjacent threads
c the distance travelled by a nut during one revolution
5. How many times can a rivet be heat treated
a2
b4
* c3
6. Hi-loc fasteners are in safety when:
a the hexagonal head has sheared off
*b there are at least one thread protruding from the top of the locking collar
c the collar is free to rotate
7. The major diameter of a screw thread is;
a the diameter taken across the roots
b the diameter taken across the crests of an internal thread
*c the diameter taken across the crests of an external thread.
8. When comparing a 3/8 in. BSW and a 3/8 in. BSF thread;
a the BSW will have a larger minor diameter than the BSF
b the BSF will have a smaller minor diameter than the BSW
*c the BSW will have a smaller minor diameter than the BSF.
9. Multi start threads;
*a increase the lead without increasing the pitch
b increase the lead and pitch
c increase the pitch without increasing the lead.
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19. When fitting a hi-lock fastener, the lubrication used would be:
a. as specified in the maintenance manual
* b. none as it is pre-lubricating
c. as specified on the repair drawing
20. 31J on the head of a bolt indicates:
a. 3/8 dia. bolt 3.1" overall length
b. 5/16 dia. bolt 3.7/8" overall length
* c. 3/8 dia. bolt 3.1 plain portion
21. A UNJF thread is a unified thread:
* a. of high fatigue resisting properties
b. for joint application (Military and Civil)
c. for jet engine use only
22. How is a close tolerance bolt identified:
* a. by a raised disc ring
b. by "SS" on the head
c. by a machined ring under the head
23. The word "MOD" after the designation of a unified thread would specify a thread which:
* a. is for use in high temperature zones
b. is a fatigue resisting thread
c. is for use in shear applications only
24. A self locking nut provides its locking by:
a. different rates of expansion of the bolt and nut
b. needing more torque loading than a plain nut
* c. deformation of the "out of pitch" of the nut
25. Cap nuts:
* a. seal the threads on which they are fitted against leakage
b prevent over-tightening of the nut by restricting the amount of thread which may
protrude through the nut
c. indicate correct torque loading of the nut by movement of the cap
26. Stiffnuts incorporating non-metallic friction elements should not be used:
a. where torque loading is to be applied to the nut
* b. on structure exposed to excessive heat
c. unless stainless steel split pins are called for
27. Stiff nuts w hich secure control system adjusters:
* a. should have at least one thread projecting through the nut
b. should always be fitted so that the male threaded part is flush with the top of the nut
c. should be fitted with the locking device adjacent to the component
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28. Peening:
a. should be used with stiffnuts to give positive locking
* b. should only be used when specified on a drawing
c. should be used whenever a thread projects through a nut
29. A spring washer can be used:
* a. repeatedly provided there is sufficient springiness
b. only once
c. repeatedly provided the torque loading is correct
30.
The correct size spanner for use on a 5/16" unified threaded hexagon headed bolt is:
a 5/16" A/F
b 1/4" A/F
c 1/2" A/F
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46 What does 18N and contiguous circles on the head of a bolt indicate;
a 1.8 nominal length BSF.
*b 1.8 plain shank, UNF
c 1.8 threaded portion and plain shank, UNF.
47 The crest of a thread is;
a the tip of an external thread and the bottom of an internal thread
b the bottom of an external thread and the tip of an internal thread
*c the tip of the thread whether it is internal or external.
48 The lead of a thread is;
a the same as the pitch
*b the linear distance moved by a nut when turned through one revolution on a bolt
c the same as the start.
49 A coarse thread will have;
a more threads per inch than a fine thread
*b less threads per inch than a fine thread
c the same number of threads per inch as a fine thread.
50 Taper taps are used first to cut a screw thread because;
*a it is easier to start cutting the thread
b it has a smaller thread angle
c it is stronger than a plug tap.
51 It is necessary to cut the internal thread of a threaded pair first because;
a the tap is adjustable
*b the die can be adjusted to cut the external thread to the correct depth
c the die cannot be adjusted.
52 The abbreviation A/F means; aluminium
a American Fine
b Associated Fine
*c Across Flats.
53 When is a locking plate used as a locking device in preference to a tab washer;
*a When the nut is removed frequently
b When the nut is removed infrequently
c When the nut is removed from an inaccessible place.
55 An AN -12bolt is:
a 1 inch long
b 1 inches long
c 1 inches long
RIVETS
1. The heat treatment carried out to light alloy rivets, before fitment, is known as:
a. annealing
b. precipitation
* c. solution treatment
2. How is a 5% magnesium alloy rivet identified:
a. by a green anodic coating and a letter "M"
* b. by a green anodic coating and a letter "X"
c. by a violet anodic coating and a letter "S"
3. A dural rivet is identified by:
a. natural colour and a letter "S"
* b. natural colour and a letter "D"
c. anodic coating and a letter "X"
4 An aluminium alloy, snap head rivet, violet anodic finish with the identification O has
a material specification;
a L37
b L16
*c L86.
5 The anodized coating on a rivet:
a allows better paint adhesion
b reduces case hardening stress
c
6 A joggle in a rivet indicates
a shear failure
b torsion failure
c compression failure
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TRANSMISSIONS
1. A small cog has 20 teeth the adjoining cog has 120 teeth, for one revolution of the small cog
what degree w ill the large one turn:
a. 45
* b. 60
c. 90
2 On a bevel gear
a the small gear is the heel
b the small gear is the toe
c the small gear is the foot
3 Gear teeth are:
*acase hardened
b hardened all the way through
c
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6. What is a HT cable
a multi core single strand
b multi strand single core
*c both of above
7. What is w et arc tracking
*a when cables are contaminated due to moisture which causes arcing
b water ingress in an electric motor
c tracking in a fuel tank
8. How can w et arc tracking be avoided
a by not doing up p clips too tight
*b avoiding hot stamp printing as this could cause insulation damage
c by protecting cables with water proof insulation
9. Electronic instrument w ires are:
*a not usually insulated
b always insulated
c
10 An X on an electrical wire indicates
*a a.c. use only
b a.c. and dc use
c d.c. use only
11. Has a 14 AWG cable a higher rating than an 18 AWG cable
*a yes
b no
c they are the same
12. The maximum load carrying capacity of an 18 AWG copper conductor:
a 7.5 amps
b 5.0 amps
*c 10 amps
13 During a fire, fire resistant cables should maintain electrical insulation for a period of:
a 10 mins
*b 5 mins
c 15 mins
14 Conductor knuckling through is caused by:
*a excessive tension when cables are being pulled through
b excessive flux residue
c hot stamp printing
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15. The maximum temperature rating for tin coated copper cable is:
a 200c
b 260c
*c 135c
16. What is the effect of aluminium oxide on electrical cables?
a none
*b increases the resistance
c reduces the resistance
17 What is the advantage of co-axial cable over normal cable
*a it is shielded from interferance
b no corrosion on the inner core
c less internal impedance
18 When is a hydraulic crimping action complete?
a when pressure is released
b when the tool will not close any further
*c when the by-pass valve opens
19 Co-axial cable has:
*a a single conductor
b a pair of conductors twisted together
c two or more conductors
20 An HT lead is:
*a single core, screened
b multi-core, screened
c 3 strand screened
21. Equipment wire is:
*a flexible and suitable for soldering
b suitable for interconnect cables
c
22 When should a hydraulic crimping tool be checked for fluid level?
*a Before use checking it horizontally
b
c
23 On an electrical cable, what does the fourth digit in from the left indicate?
*a cable segment letter
b cable number
c cable segment letter
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30 On the wire number shown, what does the first number indicate?
*a Unit number
b
c
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1EF6B22NMSV
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