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What are the 5 types of stresses? What are the 2 primary stresses?
Tension (Primary)
Compression (Primary
Bending
Torsion
Shear
How must a joint be manufactured to deal with extreme loads?
The joint must be manufactured in a way such that the fasteners will fail before the base metal does.
What are the 3 duties of a proper aircraft structure repair?
Accept all of the loads
support the loads
transfer any loads back into the structure
List the aluminum alloying agent for each of the following:
1xxx
1xxx - Aluminium
List the aluminum alloying agent for each of the following:
2xxx
2xxx - Copper
List the aluminum alloying agent for each of the following:
3xxx
3xxx - Manganese
List the aluminum alloying agent for each of the following:
4xxx
4xxx - Silicon
List the aluminum alloying agent for each of the following:
5xxx
5xxx - Magnesium
List the aluminum alloying agent for each of the following:
6xxx
6xxx - Magnesium and Silicon
List the aluminum alloying agent for each of the following:
7xxx
7xxx - Zinc
List the aluminum alloying agent for each of the following:
8xxx
8xxx - Other Elements
What is the purpose of an alclad coating?
Greatly improve corrosion resistance, so long as there are no scratches or abrasions
What are the 2 types of heat treatments?
Solution Heat Treatment
Precipitation Heat Treatment
What is the purpose/outcome of Annealing?
Annealing softens a metal and decreases internal stresses
opposite of hardening.
What are the 3 most common heat treating designations?
-T3
-T4
-T6
What diameter rivet is used with a No. 40 Drill bit?
3/32 or 3- Rivet
What diameter rivet is used with a No. 30 Drill bit?
4/32 or 4- Rivet
What diameter rivet is used with a No. 21 Drill bit?
5/32 or 5- Rivet
What is the difference between a cornice (or leaf) brake and a box brake?
A box brake is similar to a cornice brake, except that it has split leaves to allow bending of different sections of metal without bending other sections.
What is a slip roll former used for?
to make gentle curves in a large piece of sheet metal, typically for skin replacements on a fuselage.
Why would a shrinker or stretcher be used?
Shrinkers can be used to more easily form inside curves
Stretchers can be used to form outside curves
both of these tools can be used to prevent tearing of the metal, especially thick metal, when tight curves are being formed.
What are the three most common fasteners that can be used to temporarily hold/align sheet metal structures during fabrication?
Cleco Fasteners
C-Clamps
Wingnut clamps
List the color that corresponds with each hole size below:
3/32”
1/8”
5/32”
3/32” - Silver
1/8” - Copper
5/32” - Black
What is the purpose of a hole finder?
a hole finder helps transfer old holes on old skin sheets to new sheets
What is the purpose of a chip chaser?
to remove metal chips between skins that cannot be disassembled after drilling
what does the rivet code “470” indicate?
a rivet with a universal head
what does the rivet code “426“ indicate?
A rivet with a countersunk head
What does each part of “MS20426DD5-6” mean?
MS20426 : Head style
DD : Material
5 : Diameter (1/32 inch increments)
4 : Length (1/16 inch increments)
How are the lengths of universal and countersunk rivets measured?
Universal: measured from the bottom of the manufactured head to the end of the shank
Countersunk: Measured from the top to bottom, including the manufactured head
What are the two must common rivet materials? how are their heads indicated?
AD rivets: Indicated by a small dimple on their head, AKA field rivets
DD Rivets: AKA “Icebox rivets”, indicated by two raised dashes on their head.
What are Rivnuts used for?
attaching parts and pieces with screws to sheet metal, commonly found in GA cowlings and access pannels
What are the 3 types of turnlock fasteners used today? what are they used for
Dzus
Airloc
Camloc
Commonly used for quick access panels for inspection and/or servicing purposes
when driving a rivet, what should the dimensions of the shop head be?
width: 1.5 D
Height: ½ D
When selecting the length of a rivet, what is a good rule of thumb to use?
The rivet should be
1.5 D + the grip length of the material
in length
What is the standard edge distance for rivet layout patterns?
2 ½ times the rivet diameter
What is the pitch of a rivet layout?
the distance between adjacent rivets in a row.
commonly, rivet pitch should be between 3D-12D
What is the gauge of a rivet layout?
The distance between rows of rivets in a multi-row layout.
what are the acceptable measurements of the gauge for staggered and non staggered layouts?
Staggered: Rivet gauge should be about 75% of the pitch
Non Staggered: Rivet gauge should equal pitch
what is the difference between a clearance fit and an interference fit?
Clearance fit: The fastener is smaller than the hole, allowing the fastener to easy slip into the hole
Interference fit: The fastener is larger than the hole, requiring the fastener to be driven into place
What is required after a hole is drilled, but before the rivet is installed?
Deburring, to remove any excess material from around the edges of the sheet metal hole
what are the 4 methods of rivet installation
Hand Riveting
Compression Riveting
Gun Riveting
what is a rivet set? what is the ideal size for a cupped rivet set?
A rivet set is the tip of the rivet gun, which have different sizes based on the different size universal head rivets.
the idea size for the cup of the rivet set is slightly larger than the radius of the rivet head
Explain the process of removing a rivet
using a drill slightly smaller than the size of the rivet head, drill down to the base of the rivet head
use a pin punch to pry the head off
back up the underside of the skin with a bucking bar
use a pin punch to drive the rivet shank out
what is NACA Flush riveting?
A process where universal head rivets are installed from the inside out, then their shop heads milled flush. this process is more flush than even countersunk rivets.
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