AE6010

AIRFRAME MAINTENANCE AND REPAIR PRACTICES

1. What is welding?
Welding is a process used joining metal parts by either fusion or forging.
2. What are the joining methods used in aircraft?
 Bolting
 Riveting,
 Brazing,
 Soldering,
 Bonding,
 Welding.
3. Give reason for welding process is the best joining method?
 Rigidity
 Simplicity
 Low weight
 High strength
4. What is Gas welding? List its types?
Gas welding is accomplished by heating end & edges of metal to molten state with a
high temperature flame.
Types:
 Oxy-acteylene
 Oxy-hydroyen
5. What is electric resistance welding?
Is a process in which a low –voltage , high amperage current is applied to the metal to
be welded through heavy , low resistance copper conductor.
6. What are the types of electric resistance welding?
 Butt welding
 Spot
7. List down the equipments used in Oxy-acteylene welding technique?
  Cylinder (Oxygen, acetylene)
 Pressure regulator
 Welding torch
 Hose
 Special wrench
 Spark lightner
 Goggles , Gloves
 Fire extinguisher
8 . What type of fire extinguisher use in Oxy-acteylene welding?
Carbon dioxide type used , is a chemical powder for special in gases or oil fire.
10. How to identify the oxygen- hose & acetylene –hose?
Oxygen – right hand thread
Acetylene - left hand thread
11. What are the types of NDT?
 Eddy current method
 Ultrasonic
 Dye-penetrate
 Maganetic
12. List the types of plastic used in aircraft?
 Acrylics plastic
 Cellouse,
 Acetates
13. What is thermosetting plastic ?

14. How to ensure the quality weld ?

1. Smooth & uniform thickness
2. Extra thickness at the seam
3. Weld metal should taper off smoothy into the base metal.
4. Oxide form not more than ½ in
5. No signs of blowholes , porosity & globules.
6. No signa of pitting, burning, cracks.
15.what is the purpose of APU?
When modern a/c’ s engine s are not operating , there are two available sources of
power to operate its other systems. They are a/c’s battery and auxiliary power unit. b/c of the
limted capacity of the batteries , the amount of supply is insufficient to provide all but the very
basic needs.
16.Differenitate between soldering and brazing?
Soldering is a process in which two or more metal item are joint together by melting and
flowing a filter metal into the joint
Brazing :- if the filler metal has a melting point of more than 800F ,the process is called brazing
17.List the five fundamental types of welded joints?
*Butt joint
*Lap joint
* Tee joint
* Edge joint
*Corner joint
19. What is autoclaves?
An autoclaves is an instrument used to sterilize equipment and supplies by subjecting them to
high pressure saturated stream at 12C for around 15-20min
20.Define ‘Mean Aerodynamics Chord’?
MAC is defined as the chord line is along the wing span and c is the chord at the
coordinates y
21.Explain the meaning of ‘a/c leveling’?
A level bust is also a altitude deviation ,occurs when an a/c fails tofly at certain level.An a/c
leveling off at the correct level or altitude ,but with an incorrect.
23.What are the flammables in aerospace industry?
Frequency found flammables or combustibles materials in the aviation industry include fuels,
paint-related products, alcohols, acetones, toluence and some metal filings
24.State the eight categories of toxins in the aviation industry?
1.solvents and thinners for bluing
2.solids such as metal dust or asbestos
3.Machine lubricants ,cutting fluids ,and oils
 4.Gases such as co2 or N2
5.Polymers,epoxiesand plastics
6.sensitizers,such as epoxy s/m
7.Carcinogens
8.Reproductive hazards,such as carcinogens
25.Differenitate between Thermoplastics and Thermosetting plastics
Thermoplastics: There are a wide range of thermoplastics some that are rigid and some that are
extremely flexible.
Thermosetting plastics: The molecules of thermosetting plastics are heavily cross linked . They
form a rigid molecular structure.
26.What is rigging of the flight control system?
The rigging involves two principal types of operations, first the a/c structure must be rigged for
correct alignment of all fixed components. Second rigging is the alignment of control surface
and the controls that moves the surface.
27.What is meant by trouble shooting?
Trouble shooting is the process of identifying the cause of a malfunction determining its
serverity and eliminating the cause,replacing or repairing.
28.What are the classifications of Damage?
*Negligible damage
*Patch Repairable Damage
*Damage Repair by insertion
*Damage requiring replacement.
29.What are the types of Non-Destructive Inspection?
*Visual Inspection
*dye penetrant
*fluorescent penetration
*Magnetic particle
*Radiological
*Eddy current
30.Define Welding?
Welding is a process used for joining metals parts by either fusion or forging
31.What are the different types of fusion welding?
 Oxyacetylene welding
 Electric arc welding
 Electric Resistance
 Inert Gas Arc
32.What are the purpose of welding jigs & fixtures?
*To minimize distortion caused by heat of welding.
*To prevent Welding in more convenient position .
*Minimise fitting up pblm.
33.What is Welding jigs?
Welding jigs are specialized devices which enables the component to be easily & rapidly
setup& held.
34. What is welding fixtures?
A welding jig, but in addition ,it permits the changing of the position during actual
welding.
35.What are the maintenance practices taken in Electric Resistance welding?
Weekly:
*Inspect electrical connection
*Clean electrode holders& exterior
*Clean transformers with low pr.hose
*If noisy operation & tighten bolts.
36.What is synthetic plasctics?
The main source is crude oil. Coal & natural gas are also used. They are broken down
into monomers.
37.What are the advantages of plastics?
* plastics are used in place of glass for windows because they are light in wt & no
reduction in clarity.
* Resistant to breaking than glass
38.Why we use plastics?
Plastics are easily formed materials. It can be easily printed and decorated.
39. What are the helicopter flight controls?
 *Movement about the 3 axes of the a/c.
*The engine power.
*The rotor system lift.
41. Define Toxins?
Toxins are generally defined as any substance that can cause an illness or injury.
42. What are the physical hazards ?
*Ray, Microwaves, beta or gamma rays invisible laser beams and HF sound waves.
43.What are the biological hazards?
Biological hazards are living organism that cause illness or disease spread through air
droplets or spores and enter the body through contact.
44.What are the different types of welding position?
The four welding positions are flat-position welding, vertical position welding, horizontal
position welding and over head position welding.
45. What are the techniques used to remove paint?
 Solvents
 Sandblasting
 Trialene soap
46.State the composite components used in airplane?
Fibrous glass – reinforced plastics
47. What are jacking?
Raising the a/c for any maintenance & inspection
48. Differentiate between pressure regulator and pressure relief valve?
Pr regulator valve:-
It regulates the flow of pressure
Pr relief valve:-
It prevent the cabin from being at a higher altitude than the ambient air.
49.What is eddy current inspection?
The electrical current are generated in the parts by means of electromagnetic waves.
50.What is radiological Inspection?
 X-ray inspection was limited in valve in the part because of the in accessibility of many
joints and the necessity of taking exposures from several angles to makes certain that all defects
was found.
51. What are the three general categories of hazardous materials?
Hazardous materials are typically grouped into three categories : chemical agents,and
physical and biological hazards.
52.What are the four classes of chemical agents?
*Flammable And Corrosive Toxic Or Reactive
53.How long does it take for a toxic agent to show its effects on human body?
Toxins are generally defined as any substance that can cause an illness or injury .The
effects of toxins, unlike Flammables and corrosives, may appear all at once ,or may build up
over time with additional exposure. Some toxins may dissipate over time when further
exposure. Some toxins may dissipate over time when further exposure is eliminated while
others remains in a human’s system even after death.
54. List some of the flammable materials found in the aviation industry?
Flammables are materials that may easily ignite in the presence of a catalyst such as heat,
sparks, or flame. They may be in any of the three physical forms; Solids, Liquid, or Gas. C
Combustible liquids are very similar to flammable liquids, but they are not as easy to ignite.
Frequency found Flammable or combustible materials in the aviation industry include
fuels, paints-related products, alcohols, acetone, toluene, and some metal filings.
55.What type of corrosives generally come in powder form?
Strong acids are most normally found in a liquid form, whereas bases tend to come in
powered form.
56.What type of toxin may cause cancer?
Carcinogens may cause change in the genetics makeup of a human cell, resulting in
cancer. Although the use of carcinogens is rare in the aviation industry, aviation maintenance
technicians associated with cargo a/c should pay particular attention to the cargo manifest
before cleaning spillage.
57.What are the basic five requirements of a hazard communication pgm?
*Inventory
*Labeling
 *Material safety data sheets
*Training
*Written program
58.What is mean by Fuse welding?
It is the process used by welders in the aviation and other industries in which enough heat
is applied to melt the edge or surfaces of the molten parts flow together, leaving a single, Solid
piece of metal when cool.
60.Define electric Arc welding?
This method requires a special generator to provide a low-voltage , high amperage
current for the arc. The power supply may be an electric motor driven generator, an engine-
driven generator, or a special transformer.
61.Define MIG?
The type of inert gas welding utilizes a metal electrode, which melts and is carried into
the weld pool it provide the extra thickness desired. This type of weld has been called metal
inert gas welding.
62.What is TIG ?
It is the gas tungsten arc welding by the AWS, is accomplished by means of a torch with
a non-consumable tungsten electrode. The electrode is used to sustain the arc and the molten
pool of metal.
63. What are the different types of Inert gas welding?
1.TIG welding
2.MIG welding
3.Plasma-Arc welding
64. Define Plasma –Arc welding?
In the plasma arc welding the flow of plasma is restricted but is at an increased speed
through an orifice, resulting in higher temp and improved concen of heat.
65.What are the different types of soldering?
The different types of soldering are dip soldering, Resistance soldering, Induction
soldering, Furnace soldering.
66.What is Dip soldering?
It is where the joint is lowered into a pot of molten solder.
67.What is Resistance soldering?
It is where the heat is produced by passing electric current through the joint materials
68. Define Induction soldering?
It is where the passing if a magnetic field over the joint materials produces an electric
current.
69.Define Furnace soldering?
It is where the units to be soldered are passed through an electric or gas furnace.
70.Explain the difference between safe life and fail safe design?
Safe Life:-Originally, the recognized theory of structural design was called safe-life. The
philosophy of safe life was to test the various components to failures and to use as a
component’s airworthy maximum life 25% of the average life, when tested to destructive
failure.
Fail safe:-The next stage in the structural design philosophy was fail-safe construction. In
fail safe construction each component was designed to be able to accept the forces of adjacent
components should their neighbor components fail.
71.What is a safety factor?
When designing an original structure it is unwised to design a part so that the entire
strength of material is utilized under standard operating condition.
72.How is stress measured?
The result of such forces is called stress. Stress is load applied over a given area, in which
these forces are applied determines the type of stress (compression, tension, torsion, bending, or
shear) some stress are most typically unidirectional, such as tension and shear. In such cases the
cross sectional area over which the load is applied may be easily determined, and these area can
be used to calculate the amt of stress.
73. Describe Strain?
Strain is measured by establishing a ratio of the increased in length the result from a
stress divide by the original length of the material. If the unit of measure for a strain calculation
inches the unit of measure for strain is inches per inches.
74. What is Fatigue ?
As an a/c ages, it is subject to variety of stress. These stresses come from the load applied
on the ground, during take off, taxing, Landing,a/c pressurization and during flight. The
accumulation of these stresses over time results in a weakening of the material. This weakening
is called Fatigue.
75. What is the purpose of a relief hole?
When a piece of metal has two bends that interest, it is nessceory to provide relief holes
in the metal at the intersection of the bends. If relief holes are not provided , the metal crowds
together in the corners and set up stresses that lead to cracks.
76.What is bend allowance?
The distance of the bend allowance depends upon the thickness of the metals, the radius
of the bend and the degree of the bend.
77.What are the hand tools used for Sheet metal work?
*Hammer
*Hand nibbling tool
*Hole saw
*Chassis punch
*Hand rivet set
*Rivet gun
*Bucking bar
*Sheet fasteners
*Hole finder
*Rivet cutter
78. What is the difference b/w aircraft assembly and rigging?
Assembly: of an a/c refers to the joining of parts or subassemblies by various by
various means until the entire a/c is in condition for operation .
Rigging is the alignment of a/c parts oo sections to obtain proper flight characteristics.
79.What are precaution must be taken in the hoisting of an a/c?
A fuselage is provided with fitting or attachment for the purpose of hoisting or jacking.
When it is necessary to hoist or jack the a/c the technician must make sure that the correcet
procedure is used and the proper fitting are available. The manufacturer’s manual gives detailed
instruction for handling the a/c.
80.Define symmetric check?
 A/c symmetry is determined by first leveling the a/c and then measuring the distance
from reference points on the a/c central axis to reference points on the adjustable components.
81.What are the principle operation involved in a/c rigging?
The a/c structure must be rigged for correct alignment of all fixed components.The
fuselage is aligned at the time of manufacture in the assembly jigs.
The second type of rigging is the alignment of control surfaces and the control that move
the surface. These operations require the adjustment of cable length ,cable tension, push-pull
rods, bell cranks, cable drums, and various other parts.
82. Define Stagger in biplane?
Stagger is the longitudinal difference in the position of the leading edges of the wings of
the biplane. If the leading edge of the upper wing is ahead of the leading edge of the lower
wing, the stagger is positive.
83.Define Decalage in biplane?
Decalage is the difference b/w the angles of incidence of the upper and lower wings.
84. What is angle of incidence?
The angle formed by the intersection of the wing chord line and the horizontal axis
of the aircraft.
85. What are the inspections carried on the control system ?
1. Examine all cables for wear or corrosion
2. Examine all pulleys for wear , cracks and alignment
3. Where the cables passes through fairleads or guides
4. Wear of pulley bearing, bearing bolt, bushings, clevis pins and other
moving parts
5. Cable tension
6. The system should be checked to see that no cable fitting comes within
2in of a pulley.
7. Control surface travel area should be checked
8. After all adjustments are made, all safetying turnbuckles, clevis pins, nuts,
etc…
86. What is tricycle landing gear?
 Tricycle landing gear is characterized by having a nose wheel assembly and two
main gear assemblies one on each side of the a/c. This arrangement places the aircraft fuselage
in a level attitude when the aircraft is on the ground.
87. Explain the conventional-geared a/c?
It have two main wheel assemblies, one on each side of the a/c, and a tail wheel. This
arrangement has the advantage of reduced drag in the air and recorded landing gear weight.
There is some loss of forward visibility for the pilot when maneuvering on the ground due to the
a/c nose-high attitude.
88.What is the purpose of landing gear?
It supports the air plane during the ground operation, dampens vibrations when the
airplane is being taxied or towed and cushions the landing impact. The landing of an airplane
often involves stresses far in excess of what may be considered normal.
89. What is anti torque rotor?
The direction in which a helicopter is pointed is controlled by anti torque rotor(tail rotor).
The control s/m for the tail rotor to change the pitch of the rotor blade, thus changing the
sideward thrust exerted by the rotor. The rotor speed remains constant.
90.Expalin about rigid landing gear?
A rigid landing gear is commonly found on helicopter and sail planes. This Gear is
rigidly mounted to the a/c with no specific component to the cushion the ground contact other
than through the flexing of the landing gear on air frame structure.
91. What are the types of the shock absorbing landing gear?
The two types of shock absorbing landing gear commonly used are the spring-oleo and
the air-oleo type.
92.what do you mean by rotor system?
It is used to convert the engine power into lift, propulsive force, and directional control.
The helicopter have two main rotor. This system is driven by the a/c powerplant through a
transmission
93.Explain Trunnion?
The trunnion is the portion of the landing gear assembly attached to the airframe. The
trunnion is supported at its ends by bearing assemblies which allows the gear to pivot during
retraction and extension.
94. Define Struts?
The struts is the vertical member of the landing gear assembly that contains the shock
absorbing mechanism the top of the strut is attached to, or is an integral part of the trunnion it is
also called as the outer cylinder.
95. What is snubbing action?
During the strut extension stock the fluid is forced return through the metering
orifice. This is design to prevent the strut from extending too rapidly on the take off or during
bad landing and is often referred to as a snubbing action.
96. Explain about fully articulated rotor system?
It has three or more rotor blades and each blade can move by three different motions,
independent of the other blades in the system.
97. What is feathering in Helicopter?
Each blade is also free to rotate about its central axis . this is called feathering.
98. Explain Collective control?
Collective control lever is located on the left side of the pilot seat. And move up and
down to control the amount lift being generated by the main rotor system.
99. What is auto rotation?
When the freewheeling unit disconnect the engine from the rotor system the helicopter
enters a type of flight known as auto rotation, where the air moving upward through the rotor
system causes the rotors to turn.
100. What is shimmy dampers?
The shimmy damper is a hydraulic snubbing unit that reduces the tendency of the nose
wheel to oscillate from side to side.
101. Explain the types of shimmy dampers?
Shimmy dampers are usually constructed in one of the two general design. They are piston type
dampers and vane type dampers.
102. Explain about the piston shimmy damper?
A piston type shimmy damper is simply a hydraulic cylinder containing a piston rod and
a piston and filled with hydraulic fluid.
103. Explain about the vane type dampers?
Vane type dampers are designed with a set of moving vanes and a set of stationary vane.
104. Explain about Truck?
The truck is located on the bottom of the strut piston and has the axles attached to it. It is
used when wheels are to be placed in tandem or in dual tandem arrangement.
105. What is tracking of Main rotor?
Tracking of a helicopter rotor means determining if one blade follows the path or track of
the other blade or the blades as they rotate during operation. The two principle methods for
rotor tracking
1. Stroboscopic light tracking
2.Flag tracking
107. How hazard materials are grouped?
These materials are grouped into 3categories by
1. Chemical agents.
2. Physical hazards
3. Biological hazards
108. Describe the dye-penetrant inspection process?
Inspection of a metal is easily accomplished by means of dye penetrant inspection. In
this process the dye penetrates any small cracks or fissures and seeps out when a developer Is
applied to the joint. Thus the crack is revealed as bright red line.
109. Describe the basis of fluorescent penetrant inspection?
It can be use for detecting cracks or other flaws in a welding structure. A liquid
containing a fluorescent material is applied to the part to be inspected.
110. What are some of the disadvantages plastics as compared to glass?
1.plastics is readily accepting a static charge and thus attracting dust and dirt particle.
2.glass is softer, plastic is more easy to damaged by surface abrasion than glass.
111. inspection and maintenance of fire protection system?
Mechanical parts are examined for damage, wear, security of mountings and compliance
with technical and regulatory requirements.
112. Inspection and maintenance of ice protection system?
The inspection of pneumatic mechanical deicer system require and examination of the
deicer boots for the condition, adherence to the protected surface and the condition of the
surface of the boots.
113. List the Personal safety equipment’s?
* Fire retardant clothing
* Fire extinguisher
114. What are the types of toxins?
*Reproductive hazards
*Carcinogens
*Gases such as co2 and n2
*Polymer
115. How are the plastic sheets protected while in storage ?
1.Plastic sheets should be store in racks or on flats.
2. In rack plastic sheets stored on edge at 10 degree angle from the vertical.
3. The bottom edges should rest on blocks about 3 inch wide no more than 42inch apart.
4.If store flat, plastics should be supported underneath, thinner and smaller size pieces
placed on the top of thicker and larger size pieces.
5. formed pieces should be store individual racks.
116. If the masking paper adhesive has dried out and will not peel off the surface easily, what
can be done?
Any plastic is storied should hav aspray type or paper masking installed . Care should
Be taken to remove rough egdes from plastics that have been cut before placing them in a
storage rack or stack.do not allow any dirt plastic metal or other particle to get b/n piececs of
plastics as this can damage the platic surface even with a masking installed.
117. What are the basic tools used in cutting the plastics
Radial arm saws, table saw, band saw, jig saw, scroll saw.
118. Explain about PPE?
Personal protection equipment in the form of safety glasses , respirators, dust masks, and
chemical resistant gloves should be used when handling any chemical substance.
119. What are the characteristics of welding fixtures?
Supporting ,clamping, grounding, imparting movement
120. How welding fixtures are classified?
1.act on the work being welded
2. act on the welding equipment
 PART B QUESTIONS
UNIT I

1. State the characteristics of a good weld & How ‘welded-patch repair’ is carried out.
2. Explain in detail the procedures and instructions for setting up ‘Acetylene
Welding Equipment’.
3. Explain in detail the various NDT methods used in aircraft maintenance.
4. (i). State the five fundamentals type of welded joints.
(ii). Explain the characteristics of a good weld.
(iii). What is plasma Arc welding?
(iv). Differentiate between MIG and TIG welding.
5. Explain welding jigs of fixtures used in aircraft industry?
6. Explain maintenance of welding equipment’s.
7. Explain different types of inert gas welding?
8. Explain NDI checks used in sheet method?
9. Explain rivet repair design?

UNIT II
1. Discuss about the maintenance and repair of plastic components.
2. Explain in detail about the inspection and repair of composite components.
3. Explain the common method of cementing transparent plastics.
4. Explain an typical example of the procedure used in the repair of a mat-molden
assembly.
5. Explain NDI methods for composites inspection?
6. Explain cementing of plastics.

UNIT III
1. Describe the important guide lines for installation and rigging of control surfaces.
2. Explain the methods used for checking the track of the main rotor of a helicopter.
3. Explain the procedure of jacking an aircraft.
4. Describe the various methods used in tracking the main rotor of a helicopter.
5. Explain control surface rigging?
6. Explain procedure for AC leveling?
7. Explain symmetric check on aircraft?

UNIT IV
1. Describe the inspections on fixed-gear and retractable landing gear carried
out for maintenance of landing gear.
2. Write short notes on Fire Protection system and Ice Protection system.
3. Write the procedure for servicing and maintenance of oxygen system in any airplane.
4. Write short notes on:
(i). water and waste system inspection.
(ii) fire protection system inspection.
5. Explain inspection and maintenance of fire protection system?
6. Explain inspection and maintenance of instruments?
7. Explain inspection and maintenance of fixed and retractable landing gear.

UNIT V
1. Describe in brief about the three categories of hazardous materials in aircraft
maintenance.
2. Explain quoting an example of trouble shooting procedure followed in aircraft
servicing.
3. Write in detail the safety precautions to be followed while storing and handling
hazardous materials.
4. Explain the causes and remedial actions of the following defects:
(i). Aircraft has a tendency to fly one wing low
(ii). Aircraft has a tendency to be nose or tail heavy.
5. Explain with diagram on position and warning system used in aircraft?
6. Explain trouble shooting with and without chart?
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