1

Module Six
1. How do you check a chain for elongation? # a) Apply a load, measure chain and use 2% max formula to check extension b) Apply a load, measure chain and use 5% max formula to check extension c) Hang the chain under its own weight, measure chain and use 2% max formula to check extension 2. How do you store a chain? a) Lay uncoiled and flat in greaseproof paper b) Hanged so they do not kink # c) Oiled and coiled in greaseproof paper 3. An HT lead is # a) single core screened b) multi core screened c) single core unscreened 4. Two parts of the adhesive process are # a) wetting and setting b) wetting and gripping c) spreading and setting 5. A 14 gauge cable when compared to an 18 gauge cable has a) lower current rating # b) higher current rating c) the same current rating 6. Types of adhesive joints are a) cemented and specific # b) mechanical and specific c) mechanical and cemented 7. What tests are done on adhesive joints? a) impact and shear b) impact and peel # c) peel and shear 8. An interconnect cable has what insulation? # a) thinner than airframe cable b) thicker than airframe cable c) same thickness as airframe cable

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2 9. Epicyclic gears are used on # a) shafts rotating on the same axis b) shafts rotating on offset axis c) shafts rotating on axis 90 degrees from each other 10. What is the effect of heat on a cold cure resin? a) Increase pot life # b) Decrease pot life c) No effect on pot life 11. Forming a solution treated rivet gives it 75% of its hardness. What gives it the other 25%? a) Put them in a refrigerator b) Precipitation treat the component when forming is complete # c) Leave at room temperature for four hours 12. What two components of a three part polyester resin are dangerous to mix together directly? # a) Accelerator and free catalyst b) Catalyst and resin c) Accelerator and resin 13. What is the effect of adding too much hardener to a resin? a) The resin will not harden # b) Makes the repair more brittle c) No effect 14. How many times can clad alloy be treated? # a) 3 times b) as many times as required c) Once only 15. Two parts of the adhesive process are # a) wetting and setting b) wetting and gripping c) spreading and setting 16. What is the largest hole in honeycomb repairable with microballoons? # a) 2.54 cm b) 2.54 inches c) 2.54 mm 17. If D or DD rivets are not broached in time , or removed from the freezer in time, they @ a) must be re-heat treated before use b) can be re-heat treated once then discarded c) must be discarded Page 2 Mod 6

3 18. How are flexible hoses categorised? a) by length # b) by maximum pressure c) by diameter 19. A joggle in a removed rivet is indication of what type of partial failure? # a) shear b) bearing c) compression 20. Over extended honeycomb can bend in which direction? a) In all directions b) Across the ribbon # c) Along the ribbon 21. The vacuum connections in a fibre glass repair must overlap the # a) breather mat b) peel ply c) top layer of glass fabric directly 22. The pattern of a gear is the a) profile of the gear teeth # b) mark it leaves on a mating gear c) the path they take when the gear is rotating 23. How do you check a turnbuckle is in safety? # a) Use the inspection hole or count the threads showing b) Ensure that the turnbuckle cannot be turned by hand c) Make sure no threads are showing at either end of the turnbuckle 24 Max temperature of tin coated copper cable? # a) 105oC b) 200oC c) 260oC 25. The taper of a standard taper pin is a) 1 in 36 b) 1 in 20 # c) 1 in 48 26. Spherical roller bearings resist what loads? # a) Large radial and moderate thrust b) Large thrust and moderate radial c) Large radial but no thrust

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4 27. What are the signs of fretting corrosion? # a) black powder or cocoa staining b) intergrannular cracking c) flaking 28. Plug pins are numbered a) from the outside in - clockwise b) from the inside out - anticlockwise # c) from the inside out - clockwise 29. What are the rigid pipes on gas turbine engines made from? a) aluminium alloy b) copper # c) stainless steel 30. Equipment wire # a) is flexible and suitable for soldering b) can be used for interconnect wiring c) has thicker insulation than interconnect wire 31. In the wiring code shown, what does the number 6 (4th number from the left) represent? 1EF6B22 NMS V a) Cable size # b) Cable number c) Circuit function 32. An aluminium oxide layer on a conductor will do what when the temperature is increased? # a) Become thicker b) Become thinner c) Remain the same 33. When not under load where should a pair of gears sit? # a) In the middle b) On the heel c) On the toe 34. For a pair of gears to operate properly, they must have # a) lash and pattern b) end play and thrust c) pattern and profile 35. Coil springs are made from @ a) carbon or high alloy steels with low working stress b) carbon or alloy steels with high working stress c) low carbon steels with high working stress Page 4 Mod 6

5 36. What is a coaxial cable? @ a) Two or more conductors b) A twisted pair of conductors c) A single conductor 37. What is the nominal length of a UNF bolt? # a) Under head to screw threads (i.e. plain shank) b) Under head to end of the threads c) The length of the threads 38. How is a British al alloy rivet identified? a) Natural anodised finish b) Violet anodic finish @ c) Black anodic finish 39. What do you do if you forget to add hardener to a composite repair? # a) Clean all traces of the resin away and start again b) Add hardener at the edges and it will cure c) It will cure eventually anyway 40. X on a cable indicates a) emergency power b) control system # c) AC power 41. A BS rivet made from L36 would be what colour and marking? # a) Black anodic b) Green anodic c) Natural anodic 42. The teeth on the smaller wheel of a bevel gear are called the a) heel # b) toe c) foot 43. What must you be careful with a hot stamped cable? # a) Wet arc tracking b) Corrosion c) Peeling of the insulation 44. Where should you not use a nyloc nut? a) Temperatures above 200oC @ b) Temperatures above 120oC c) Temperatures above 80oC

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6 45. What is the nominal screw length? a) The overall length of a bolt (from under the head) and the overall length of a screw (including the head) # b) The overall length of a countersunk screw and the non-threaded portion of a bolt c) The length of thread for a bolt, overall length for a countersunk screw 46. The correct meshing of gears is found on what part of the tooth? a) Top # b) Middle c) Bottom 47. What type of gear would be used on a prop reduction gearbox? # a) Epicyclic b) Bevel c) Split epicyclic 48. What is the effect of aluminium oxide on aluminium electrical cable? a) Provides strength b) Reduces resistance # c) insulates 49. What is the effect of precipitation heat treatment on aluminium? # a) It speeds up age hardening process b) It softens the material to allow it to be worked c) It delays the age hardening process 50. How do you assemble a banjo hose? # a) Put washer either side of the banjo b) Put a washer on the outside of the banjo only c) Put a washer on the inside of the banjo only 51. The pitch of a screw thread is a) crest to root # b) crest to crest c) 2 x crest to root 52. A single start thread the lead is a) 2 x pitch # b) 1 x pitch c) x pitch 53. How would you test a hydraulic hose? a) Pressure test 1.0 x working pressure # b) Pressure test 1.5 x working pressure c) Pressure test 2.0 x working pressure Page 6 Mod 6

7 54. A unified thread is identified by # a) 2 or 3 rings on the head b) a raise ring on the head c) an 'X' on the head 55. A wire thread insert tap is a) slightly larger than the hole # b) supplied in a fitting kit c) slightly smaller than the hole 56. Aluminium exposed to air will a) oxidise and become weaker b) oxidise and become stronger # c) oxidise and become electrically insulated 57. What do the letters and numbers on a British rivet mean? a) material and finish b) material specification only # c) head shape, material and finish 58. A natural finish aluminium alloy rivet with a D on it is # a) duralumin L37 b) aluminium L36 c) hiduminium L86 59. A 5% magnesium rivet is identified by a) violet anodise with 'S' on it # b) green anodise with X on it c) black anodise with 'A' on it 60. Why would you use microballoons as a filler? a) It cross-links with the panel b) It is the cheapest filler material # c) it is the lightest filler material 61. Black streaks back from a rivet hole signify a) galvanic corrosion # b) fretting c) intergrannular corrosion 62. An AN steel bolt is identified by what marking on the head? a) 14E # b) An 'X' c) A dash 63. What care should you take with 2024-T3? a) Do not bend at sharp angles # b) Do not scratch or make nicks in it c) Do not remove the surface of the sheet metal Page 7 Mod 6

8 64. When using a backing former on a composite repair you need to use # a) cellophane b) breather cloth c) a vacuum bag 65. Heater mats should overlap the repair by a) 4 b) 6 # c) 2 66. When using a spring washer, the plane washer would be fitted a) between head a spring b) under the nut # c) between spring and part 67. Composition of silver solder is a) tin and lead b) tin, lead and silver # c) tin, lead, silver and antimony 68. How many times can you use a locking plate? # a) As long as it remains serviceable b) Once only c) Until all the tabs have been broken off 69. Wire locking approach angles should not be less than # a) 45o b) 90o c) 10o 70. Where would you find the inspection interval for chains? a) Maintenance manual # b) Maintenance schedule c) Flight manual 71. What amperage is an 18 swg cable? # a) 10 amp b) 5 amp c) 1 amp 72. A thermoplastic fibre reinforced composite is prepared by a) etching b) a solvent wipe # c) corona method 73. A British close tolerance bolt is identified by # a) a raised ring on the head b) a dropped collar under the head c) an 'X' on the head Page 8 Mod 6

9 74. A blind fastener described as external sleeve and internally threaded would be a) a cherry lock # b) a jo bolt c) a rivnut 75. A co-axial cable is better than a normal cable because # a) there is an electrostatic field around it which helps to reduce the electromagnetic field b) weight for weight it can carry more signal c) it has less resistance

76. A 0.5 in. diameter pipe is to be joined using standard nuts and fittings. What coupling would you use? a) AN8-8852-2 # b) AN8-8852-8 c) AN8-8852-1 77. What metal is suitable for riveting magnesium alloy? a) Monel metal b) 1100 aluminium alloy @ c) 2024 aluminium alloy 78. What metal is suitable for riveting alloy steel a) monel metal # b) mild steel c) aluminium alloy 79. What is the danger if a silver coated connector comes into contact with glycol de icing fluid # a) Fire hazard b) Corrosion c) Wet arc tracking 80. When silver coated connectors are used in unpressurised parts of the aircraft @ a) corrosion can occur b) wet track arcing can occur c) separation of the coating can occur 81. When a steel part is welded, corrosion occurs because # a) the strip has become cathodic b) it is affected by spatter c) the paint has been removed

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10 82. Intergrannular corrosion # a) may have no visual surface indication b) can be recognized by a grey powder deposit c) can be recognized by its flaking and lifting of the material layers 83. If aluminium alloy is not quenched after heat treatment is it will be # a) brittle b) subject to corrosion c) malleable 84. Anodizing protects alloy metal from corrosion and does what else? # a) Makes a good surface for paint to adhere to b) Makes the surface alkaline c) Seals the surface from moisture 85. Active flux does what? # a) Cleans b) Protects c) Both cleans and protects 86. Jointing compound is used for what reason? a) To make the components easier to disassemble b) To bond the components together # c) To prevent dissimilar metal corrosion 87. During vacuum bag lay-up the vacuum gauge is placed where? a) Next to the vacuum port # b) Opposite side to the vacuum port c) Over the repair 88. An aluminium alloy rivet identification is @ a) D embossed b) X embossed c) O embossed 89. Rivet allowance is # a) 1.5d b) 1.5d plus the thickness of the material c) 1d plus the thickness of the material 90. D and DD rivets are refrigerated to # a) retard age hardening b) increase age hardening c) precipitation harden 91. What do you do to 2017 and 2024 rivets after heat treatment? # a) Use immediately or refrigerate b) Leave for a minimum of 2 hours before using c) refrigerate for a minimum of 2 hours before using Page 10 Mod 6

11 92. Stepped curing has # a) more than 2 dwell periods b) variable cure time c) no constant dwell period 93. To prevent damage to seals on fitment you would a) use grease b) compress and stretch them # c) use a cardboard protector over the threaded portions 94. Maximum repair dimensions for use of microballoons? # a) 10mm b) 20mm c) 30mm 95. In an autoclave what pressure would the vacuum alarm be set at a) operating pressure b) higher than operating pressure @ c) lower than operating pressure 96. Fibre strength is strongest in the direction of the # a) warp b) weft c) bias 97. In an autoclave what would you cover the repair in? # a) High temp nylon b) Polythene c) Polypropelene 98. If caustic soda turns a material black what is it? a) Aluminium b) Alclad # c) Aluminium alloy 99. Intergrannular corrosion is caused by # a) improper heat treatment b) dissimilar metal contact c) improperly assembled components 100. Galvanic action caused by dissimilar metal contact may best be prevented by # a) applying a non-porous dielectric material between the surfaces b) priming both the surfaces with a light coat of zinc chromate primer c) Special precautions are not required if they are properly bonded

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12 101. Corrosion caused by electrolytic action is the result of a) excessive anodization # b) contact between two unlike metals c) the wrong quenching agent 102. A spring type washer when used on an aluminium component must be used a) by itself b) with a tab washer # c) with a plain washer 103. Nickel alloy steel split pins can be used a) repeatedly provided they remain a good fit # b) only once, because the legs are spread and bent c) with a spring washer and a stiff nut 104. The standard taper for a taper pin is a) 1:20 # b) 1:48 c) 1:600 105. Corrosion may be regarded as the destruction of metal by # a) electrochemical action b) electromechanical action c) hydroelectric action 106. Tempering steel gives a) greater hardness b) greater brittleness # c) relief of internal stress after hardening 107. After welding, stainless steel is susceptible to a corrosion known as # a) weld decay b) weld rot c) weld deterioration 108. The lifting or flaking of the metal at the surface due to delamination of grain boundaries caused by the pressure of corrosion is a) electrolysis b) transgranulation # c) exfoliation 109. The addition of chromium to steel will produce a) toughness b) ductility # c) hardness Page 12 Mod 6

13 110. A feather key locates a gear on a shaft and permits a) a positive and strong drive for transmissions # b) positive drive and axial movement c) positive drive with the gear firmly locked 111. A pre-load indicating washer is correctly loaded when a) the inner ring rotates @ b) the outer ring is gripped c) the inner ring is gripped 112. What chemical is used to identify aluminium alloys # a) caustic soda b) copper sulphate c) nitric acid 113. Multi-start threads # a) increase the lead without increasing the pitch b) increase the lead and the pitch c) increase the lead and decrease the pitch 114. Pure aluminium is # a) highly resistant to corrosion b) not resistant to corrosion c) reasonably resistant to corrosion 115. Cylinder containing purified oxygen for breathing are painted a) black with a grey collar # b) black with a white collar c) grey with a white collar 116. Buttress threads are used a) to transmit power in both directions # b) to transmit power on one direction c) on nuts and bolts 117. The electrolytic process that forms an oxide film on the surface of aluminium alloys is known as a) electroplating b) galvanizing c) anodizing

118. Studs which have a size larger thread at one end are called # a) stepped studs b) plain studs c) shouldered studs

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14 119. The conductor in tersil cable is a) tinned copper # b) nickel plated copper c) stainless steel 120. A cable is marked NYVIN 22. The 22 represents the a) current rating b) current/weight ratio # c) cross sectional area 121. Copper is an inferior conductor to aluminium when comparing # a) weight for weight b) CSA with CSA c) load for load 122. Chromium added to plain carbon steel a) turns it into a non-ferrous alloy b) makes the metal softer # c) increases it's resistance to corrosion 123. The purpose of case hardening is to # a) produce a hard case over a tough core b) introduce carbon into the steel c) reduce the carbon in the steel 124. What is the indication of fretting corrosion on aluminium alloy? # a) Black powder b) Brown powder c) White powder 125. Exfoliation corrosion is sometimes referred to as # a) layer corrosion b) sub-surface corrosion c) filiform corrosion 126. What action is taken to protect integral tanks from corrosion due to micro-biological growth? # a) A biocidal additive is used in the fuel b) The inside of the tank is coated with yellow chromate c) Rubber liners are installed in the tank 127. When dissimilar metals are brought together, or the same metal in different states, one metal forms the anode and the other the cathode. Which will suffer from corrosion? a) The cathode b) Both will corrode equally # c) The anode Page 14 Mod 6

15 128. What type of corrosion attacks grain boundaries of aluminium alloys which are improperly or inadequately heat treated? a) Stress corrosion # b) Intergrannular corrosion c) Surface corrosion 129. British aircraft cables are classified by their a) diameter and breaking load in Hundredweights # b) breaking load in hundredweights c) breaking loads in lbf, where 1 lbf = 4.448N

130. An American rivet with a cross on the head is a) 2117 aluminium alloy # b) 5056 aluminium alloy c) 2124 aluminium alloy 131. A countersunk rivet of the SP series has a head style of a) 90o # b) 100o c) 20o 132. The lead on a single start thread is a) 1/2 the pitch # b) 1 x the pitch c) 2 x the pitch 133. The coding of a British rivet indicates a) head type and colour b) length and diameter @ c) material and head type 134. At normal temperatures HC steel is harder because a) it has more austenite b) it has less austenite # c) of the % of carbon in the granules 135. When mixing resin it is dangerous to add # a) accelerator and catalyst before resin b) catalyst and resin before accelerator c) resin and accelerator before catalyst 136. Silver plated copper wire has a maximum working temp of @ a) 200 oC b) 250 oC c) 300 oC Page 15 Mod 6

16 137. In an autoclave to apply pressure a) weights are used # b) a vacuum bag is used c) clamps are used 138. Precipitation treating makes the metal a) harder, stronger and more ductile # b) harder, stronger and less ductile c) less strong and hard 139. 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 140. Intergrannular corrosion in structural aluminium alloy parts a) are not likely to occur in parts fabricated from heat-treated sheet aluminium b) may be detected by the white, powdery deposit formed on the surface of the metal # c) cannot always be detected by surface indications 141. Corrosion will spread more rapidly when metals are exposed to # a) high temperatures b) dry climates c) cold climates 142. A material has the code 2024-TH6 on it. Which part of the code indicates the percentage of the alloying element? # a) 20 b) H c) 6 143. A worm drive creates a) a drive in 2 planes and 2 directions b) a drive in 1 plane but 2 directions # c) a drive in 2 planes but 1 direction 144. Colour identification of an aluminium rivet is # a) black b) violet c) green 145. A factor which determines the minimum space between rivets is the a) length of the rivets being used # b) diameter of the rivets being used c) thickness of the material being riveted Page 16 Mod 6

17 146. Joggles in removed rivet shanks would indicate partial a) bearing failure b) torsion failure # c) shear failure 147. The teeth of a gear would normally be a) nitrided # b) case hardened c) tempered 148. A rivet that has 5% magnesium is identified as # a) anodic green and has an X b) anodic violet and has an X c) natural and has an m 149. If a chain is removed for routine maintenance a) it must be proof checked to max load b) it must be proof checked to full load # c) it does not have to be proof checked 150. Magnesium alloy components are protected by a) an electro process # b) a chemical process c) a painted process 151. Corrosion products should be removed from magnesium alloys by the use of # a) a solution of 10% by weight of chromic acid in distilled water with 0.1% by volume of sulphuric acid* b) aluminium wool c) a solution of 10% by volume of chromic acid in distilled water with 1% phosphoric acid 152. If it is necessary to remove corrosion from a steel component insitu, the base of a suitable solution for this purpose is a) chromic acid b) nitric acid # c) phosphoric acid 153. A type of protection which is applicable to magnesium alloys is the a) phosphate process b) coslettising process # c) chromating process 154. Heavy corrosion deposits on clad aluminium alloys should be removed a) mechanically using a pneumatic vibrator b) chemically by use of trichloroethylene # c) chemically by use of phosphoric acid Page 17 Mod 6

18 155. What action should be taken on finding intergrannular corrosion? a) De-corrode and reprotect b) Renew corroded area by patching # c) Replace complete component part 156. Black streaks running away from a bolt or rivet would indicate # a) fretting corrosion b) exfoliation corrosion c) intergrannular corrosion 157. Identification of British aluminium alloys is with a) a letter and number code @ b) a colour and number stamped on the head c) a part number on the head 158. On gear teeth, the wear pattern should be a) the top edge most worn b) the middle of the tooth most worn # c) even 159. on bevel gear teeth, the wear pattern should be a) greatest at the toe, tapering off to the heel b) greatest at the heel, least at the toe $ c) at the centre of the tooth 160. Anodic treatment of aluminium alloy gives # a) a pure coating of aluminium oxide on the surface b) a shorter life due to hardening c) a purple finish 161. Cables are preferred to other control systems because # a) they are strong and light b) they maintain slight mechanical advantage over push/pull systems c) single braid allows for 2 way directions 162. If you can only gain limited access to both sides of a structure, what would you use to repair the structure? # a) A hylok b) A pop rivet c) A blind rivet 163. Aluminium alloy with primarily magnesium is numbered # a) 5025 b) 2025 c) 1025

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19 164. Heat treatment is shown on an aluminium alloy by a # a) letter code b) number code c) letter and number code 165. Bevel gears are # a) all over case hardened b) toe is hardened c) heel is hardened 166. Nitriding is # a) case hardening b) anodising c) tempering 167. Alloy rivets are heat treated by a) annealing b) anodising # c) solution treating 168. When a solid rivet is formed it only holds 75% of its shear strength, the other 25% comes from a) heating the completed assembly b) cooling completed assembly # c) leaving assembly for 4 days to age harden 169. For an electrical cable to be fireproof it must be able to stand 1100 deg C for # a) 10 mins b) 15 mins c) 20 mins

170. Oxide on exposed silver plated wires is a) non corrosive # b) an insulator c) a conductor 171. Turnbuckles depending on type are locked by # a) locknuts and wire b) stiffnuts c) castleated nuts and splitpins 172. For a wire insert thread repair, the hole is tapped using a) the next size up # b) a special tap supplied with the kit c) the same size Page 19 Mod 6

20 173. To install a flareless coupling # a) turn until torque is felt plus 2 flats b) turn until torque is felt plus 3 flats c) hand tight plus 2 flats 174. Flexible pipes are identified by a) diameter b) length # c) material 175. A pipe carrying lubricant would be identified by the colour a) white b) white and yellow # c) yellow 176. A chain is checked for stiff links by # a) running the chain over a finger by 180 degrees b) hanging by hand by measure and sight c) stretching out and measuring 177. Medium carbon steels have a carbon content of $ a) 0.3 - 0.5 % b) 0.5 - 0.8 % c) 0.8- 1.05 % 178. Brinell hardness testing measures a) depth # b) diameter c) area 179. In the tensile strength test a) the material is pulled to limit of elasticity # b) the material is pulled to until it breaks c) the material is pulled until it reaches its UTS 180. Impact resistance measures the # a) material toughness b) material hardness c) material ductility 181. A ferrous metal contains # a) iron b) aluminium c) magnesium 182. What is Alumina? a) Aluminium ore # b) A ceramic oxide of aluminium c) An alloy of aluminium Page 20 Mod 6

21 183. Non heat treatable materials a) by annealing # b) can be hardened strain hardening or cold working c) cannot be hardened 184. In corrosion, the electrode that loses electrons is a) the cathode # b) the anode c) either the cathode or the anode depending upon the electrolyte 185. Which of these core materials will be used in the making of a composite material flat panel a) rectangular core # b) hexagonal core c) flexible core 186. Corrosion at the grain boundaries is called a) filiform # b) intergrannular c) fretting 187. What does MSDS stand for? a) Maximum Structural Design System # b) Material Safety Data Sheet c) Metal Surface Dimension Sector 188. Which of these is a common coz for corrosion? a) Water in fuel # b) Spilled battery acid c) Untreated metal 189. Most commonly used thread form in aviation is a) round thread b) buttress # c) V thread 190. Pitch of a screw thread is defined as # a) distance from the centre of one crest to the next b) difference between major diameter and minor diameter c) distance between the crest and the root of the thread 191. A bolt with a raised dash is a) An standard # b) Corrosion Resistant Steel c) close tolerance 192. A rivet with no marking has the material code # a) A b) AD c) D Page 21 Mod 6

22 193. A dowel will take what loads? # a) shear b) tensile c) torsion 194. The advantage of circlips is a) cheap b) can be used for both inner and external applications # c) Both a and c 195. Rivet MS 20426 has what head type? a) Round b) Universal # c) CSK 196. Cable tension is maintained by # a) a cable tension regulator b) a grommet c) a fair lead 197. Which material are hydraulic fluid hoses made from a) Butyl b) Teflon # c) Rubber 198. What load are spring hooks subjected to? a) tension b) compressive # c) bending 199. Where are needle roller bearings used # a) where there are space restrictions b) high speed operations c) Where is fluid damped bearing used 200. Loads on tapered roller bearings a) axial only b) thrust only # c) axial and thrust 201. A Hardy Spicer coupling has what type of bearings? a) Plain bearings b) Ball Bearings # c) Needle bearings

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23 202. Which of the following metals is an aluminium silicon alloy used mainly for casting? a) Aldrey b) Alclad # c) Alpax 203. 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 204. Honeycomb for repair can be removed with a) a drill b) locally manufactured concave knife # c) a router 205. 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 206. Dzuz Fasteners provide a) for easy hammering into position b) a close tolerance fit # c) quick release fasteners at inspection panels 207. 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 208. 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 209. A full list of decals would be found in a) ANOs # b) Maintenance Manual c) Aircraft log book 210. 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 Page 23 Mod 6

24 211. The British system of heat treatment codes is a) a series of numbers # b) a series if letters c) numbers and letters 212. What colour is used to identify a primary structure on a diagram or drawing? a) Yellow b) Green # c) Red 213. 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 214. 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 215. 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 216. The length of solid rivets is in graduations of a) 1/8 inch b) inch # c) 1/16 inch 217. What would be the diameter and length of a solid rivet if the following markings are given, AS 162-408? a) inch dia, 1 inch length b) inch dia, inch length # c) 1/8 inch dia, inch length 218. 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

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219. 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 220. What is the length of the operation stroke of the Avdel Riveter type F? a) 7/8 inch b) 1 inch # c) inch 221. 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 222. 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 223. The impact testing technique is used on a material to test for a) hardness # b) toughness c) shear strain 224. Cobalt steel tested on the Brinell test would have a BHN number between a) 100 to 175 b) 300 to 400 # c) 600 to 700 225. 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 226.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 Page 25 Mod 6

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227. Thermosetting adhesive, during their curing cycle give off a) static radiation # b) heat c) carbon monoxide 228. 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 229. 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 230. The initials U.N.C when related to aircraft bolts stands for a) United National Countersunk b) Unified National Centred # c) Unified National Coarse 231. Capped nuts are used so a) the part is not over torqued as the bolt touches the captive part first # b) to ensure that it is dry bolted c) to prevent leaks from pipe ends 232. 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 233. Wirelocking must be a) less than 45o to the axis b) less than 30o to the axis # c) more than 45o to the axis 234. 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 235. A self aligning bearing is a a) angular bearing # b) radial bearing c) precision bearing Page 26 Mod 6

27 236. A crankshaft would be fitted with a a) spherical roller bearing b) taper roller bearing # c) cylindrical roller bearing 237. 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 238. 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 239. Thrust bearings take # a) sideloads b) journal loads c) radial loads 240. How would you check the setting of an adjustable reamer $ a) ring guage b) DTI and V blocks c) external callipers 241. 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 242. What is used as the base covering on a honeycomb repair? # a) Glass cloth or thin aluminium sheet b) Plywood c) Thick aluminium sheet 243. What is used for marking out steels? a) Engineers blue b) Wax crayon # c) Copper sulphate 244. What is used to remove corrosion from magnesium? # a) Chromic acid solution b) Phosphate acid solution c) Sulphuric acid solution 245. 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 Page 27 Mod 6

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246. 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 247. A chobert rivet gun may be used a) once only b) indefinately # c) until the end has worn 0.002 inch below nominal diameter 248. Avdel rivets are closed by a) squeezing # b) broaching c) a tapered mandrel 249. Surface corrosion on stainless steel is identified by a) white film # b) black pitting c) red rust 250. 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 251. 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 252. Electro chemical reaction is caused by the contact of # a) dissimilar metals b) moisture on the surface of the metal c) bonding 253. When drilling a carbon fibre reinforced plastic use # a) a tungsten drill b) a steel drill and carbide powder c) a drill with a pointed tip 254. Hydraulic pipes are made from a) 1100 or 2020 H14 # b) annealed steel c) 5056 or 7075 Page 28 Mod 6

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255. When laying up a glass fibre repair, the extra layer of fibre is # a) a sacrificial layer for sanding b) for extra strength c) for shrinkage 256. Nickel coated cables temperature range is a) 100 to 150oC b) 150 to 200oC # c) 200 to 250oC 257. 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 258. A non metallic locknut is a) never torqued # b) never used over 250oF c) never re-used 259. Aluminium wiring when flexed will # a) work harden and embrittle b) have no effect c) have a higher resistance 260. 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 261. 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 262. Countersunk rivets have two angles of countersink, these are a) 125 - 135 degrees b) 100 -160 degrees # c) 100 - 115 degrees 263. 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

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264. A single row ball bearing is best suited to accepting a) axial and radial Loads # b) radial loads only c) axial loads only 265. 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 266. 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 267. Cold working of a material is used to reduce # a) wear of manufacturing tools b) fatigue c) material hardness 268. An S-N curve is useful in the design evaluation process for testing a) shear force # b) fatigue life c) tension 269. A 'HUCK' rivet is similar in design to a a) blind rivet b) dome head rivet # c) cherry rivet 270. 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 271. 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

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272. 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 273. Taper pins are subject to what loads? a) Tensile b) Compressive # c) Shear 274. Bending of stretched honeycomb is a) with the web # b) across the web c) either way 275. A foot operated hydraulic swaging tools is checked for fluid level a) vertically $ b) horizontally c) only when operating pressure is reached 276. 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 277. Bubbles are removed from a wet composite lay-up by a) application of pressure b) application of vacuum # c) use of a roller 278. 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 279. 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 280. Use of excessive hardener in polyester resin leads to a) a less stiff joint b) stiffer joint # c) reduced pot life Page 31 Mod 6

32 281. 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 282.In the drawing, what letter represents the nominal length of a BSF bolt? a) B b) C # c) A 283.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 284. 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 285. 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 286. 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 287. 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) 288. A (British) 3/8" dia UNF bolt will have the diameter code letter a) N # b) J c) G 289. 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 Page 32 Mod 6

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290. 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 291. The main metal in monel is # a) nickel b) stainless steel c) aluminium 292. Austenitic stainless steels are a) magnetic # b) non-magnetic c) hardened by heat treatment 293. A tube complying to BS T51 is a) tungum # b) high pressure seamless copper tube c) HTS tube 294. Adapter nipples are not required on a) pipe to pipe coupling b) pipe to internally coned adapter # c) pipe to externally coned adapter 295. The storage life of a flexible hose can be up to but not exceeding a) 2 years b) 4 years # c) 5 years 296. The markings on a flexible hose must include the a) manufacturers name # b) date of manufacture c) internal bore size 297. The stationary race of a journal bearing is normally # a) an interference fit b) a push fit c) a spigoted fit 298. Inspection of bearings is normally carried out # a) in situ b) when dismantled c) when removed from an assembly

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299. Damage to the shield of a bearing should result in # a) rejection of the bearing b) replacement of the shield c) no action 300. 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 301. The teeth of a gear would normally be a) nitrided # b) case hardened c) tempered 302. Which of the following could best be manufactured from Perspex panel? # a) A passenger window b) A radome c) A cockpit windscreen 303. Titanium alloys # a) have a high strength to weight ratio b) are corrosion resistant but heavy c) are cheap to manufacture 304. 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 305. Which part of the 2017-T36 aluminium alloy designation indicates the primary alloying agent used in its manufacture? # a) 2 b) 20 c) 17 306. 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 307. 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 Page 34 Mod 6

35 308. 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 309. How is residual magnetism removed? # a) Degaussing b) EMC c) EMI 310. The hardness of steel depends upon a) the iron austenite grain structure b) formation of pearlite into austenite # c) formation of cementite 311. When the temperature increases on a hot bond repair is paused is is known as a) ramping up b) ramping down # c) arrest point 312. What material is suitable for riveting steel? # a) Monel b) Copper c) Aluminium alloy 313. Cadmium plated rivets should not be used where the temperature may exceed a) 120oC # b) 250oC c) 200oC 314. High Tension leads are a) multi-core, screened b) solid-core, screened # c) multi-strand, single core, screened 315. 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

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36 316. What rivets should be used with nickel alloy steel? # a) Monel b) Mild Steel c) Aluminium Alloy 317. Kevlar and Nomex are types of a) aluminium alloy # b) advanced composite c) glass fibre composite 318. 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 319. MIL-H-5606 hydraulic fluid O-rings are identified with a # a) blue dot b) yellow and white dot c) yellow dot 320. The large diameter on a bevel gear is called the # a) heel b) toe c) foot 321. Chemical attack is a direct result of a) inter-granular corrosion # b) cathodic & anodic changes in the material c) filiform corrosion 322. A watermark on a bearing indicates a) bearing running dry b) lack of lubrication # c) intergranular corrosion 323. 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 324. 9 x 16 cable is # a) 9 cables of 16 strands b) 9 cables having 16 turns per inch c) cable size 9/16 inch diameter 325. Turn buckle lock nut is a # a) stiff nut b) slotted nut c) castle nut Page 36 Mod 6

37 326. An AN steel bolt is identified by # a) X on head b) - on head c) plain bolt 327. 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 328. Needle bearings resist a) radial and axial load # b) radial load only c) axial load only 329. 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 330. Rivnuts were originally used for # a) securing rubber deicing boots b) securing structural parts c) securing cabin floorings 331.The drill bit to be used for stainless steel should have included angle of a) 90 degrees # b)140 degrees c) 118 degrees 332. Brittleness is a) the property to get deform before cracking b)the property to resist wear # c) the property to resist deformation 333. 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 334. 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 Page 37 Mod 6

38 335. 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 336. 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 337. What type loads cause the most rivet failures? # a) Head b)Shear c) Bearing 338.Which part of the 2017-T36 aluminium alloy designation indicates the primary alloying agent used in its manufacture? a) 17 # b)2 c) 20 339. 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 340. Non heat treatable aluminium alloys a) cannot be softened b)cannot be hardened # c) can be hardened by strain hardening 341.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 342. 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 Page 38 Mod 6

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343. 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 344. Intercrystalline corrosion # a) always appears as small surface cracks b)is detectable by X-rays c) is the same as exfoliation corrosion 345. The usual manufacturers anti-corrosion process to be applied to Fe aircraft parts is a) anodising # b)cadmium plating c) metal spraying 246. Chromate treatment is applied to # a) magnesium alloys b)Al alloys c) Fe alloys 347. 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 348. 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 349. 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

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350. The cross sectional area of a copper crimp barrel is a) same as an aluminium one b)larger than an aluminium one # c) smaller than an aluminium one 351.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 352. 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 353. Fork end fittings on control rod ends should have # a) bolt heads fitted upwards b)0.002 inch axial movement c) anti vibration compound 354. Rivets main strength quality is to resist a) tensile loads b)torsion # c) shear loads 355. Non heat treatable aluminium alloys a) can not be softened b)cannot be hardened # c) can be hardened by strain hardening 356. 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 357. Solution treatment after manufacturers have performed it out once can be carried out a further a) 1 time # b)2 times c) 3 times Page 40 Mod 6

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358. Following solution treatment aluminium alloy can be placed into service a) straight away b)after 24 hours # c) after 5 days 359. The time between removal from heat treatment furnace and quenching must be not more than # a) 3 seconds b)7 seconds c) 10 seconds 360. 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 361.In an Izod impact test the striking energy of the striker is approx a) 150J # b)163J c) 300J 362. When buffing surface of Aluminium Alloy, what material are you removing a) aluminium b)alloy # c) oxidised layer 363. When crimping, what chapter in the ATA system should you refer to? # a) 20 b)24 c) 12 364. 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

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42 365. Anti-corrosive treatment used on Magnesium is # a) chromating b)phosphating c) electro-plating 366. Fretting corrosion occurs with # a) vibration in bolted parts b)water trapped between moving parts c) improper heat treatment 367. Intergranular corrosion is also known as what? # a) Exfoliation b)Galvanic c) Stress corrosion 368. When normalising, the material is? a) Quenched immediately # b)Left to cool in room temperature c) Cooled slowly 369. Why is clad alloy preferred to pure Aluminium? # a) Tougher b)Less brittle c) More ductile 370. Why are aluminium alloys used on aircraft? a) Lighter # b)Stronger c) Corrosion resistant 371.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 372. The colour coding of metals indicates # a) specification only b)specification and gauge c) quality standard 373. Silver solder is made from # a) zinc, copper, silver b)zinc, copper, tin c) zinc, copper, lead Page 42 Mod 6

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374. 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 375. 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 376. 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 377. 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 378. 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 379. Compared with the spur gears, spiral gears have a) more wear resistance # b)less stress concentration on gears c) have mechanical advantages 380. The crutch which can overrun the driving member, are known as a) overload clutches # b)freewheel clutches c) no-slip clutches 381.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 Page 43 Mod 6

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382. 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 383. 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 384. 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 385. 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 386. 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