A-6a Assignment A-1

Unit A-6a
Theory Assignment
Name ...
Student No...
THEORY ASSIGNMENT PAPER

A-6a BASIC AIRCRAFT MATERIALS
& CORROSION
Topic 1,2,3,4,5 & 6
Number of Questions:
92
Question Format:
Written Response
Instructions:
1. For this assignment you will follow all directions from your instructor.
2. Attempt all questions.
3. All answers require a reference of the figure (if Applicable) and page
number.
4. Mark your responses in black or blue biro only.
5. Ensure your name and student number is completed on the Assignment
paper.
6. There is no time limit attached to this Assignment.
Example:
Question 1 A10a 1.1
What is the method called that requires you to remove metal in the
repair of damaged compressor stator blades?
Ans
Blending
Ref
Jeppesen Power Pg 4-34
Issue A September 2006
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Unit A-6a
Theory Assignment
Index
Page
Topic 1
Aircraft Materials Ferrous
Topic 2
Aircraft Materials Non-Ferrous
11
Topic 3
Aircraft Materials Composite / Non-Metallic
15
Topic 4
Corrosion
21
Topic 6
Pipes, Hoses and Unions
23
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Topic 1 Aircraft Materials Ferrous

1.
What does the acronym (SAE) stand for?
2.
What substance is used to make steel?
3.
What do the numbers in the SAE numbering identify?
4.
What are some of the more common alloying agents used in steel?
5.
Why is carbon added to steel?
6.
How much carbon do low carbon steels contain and where are low carbon
steels primarily used?
7.
Which type of steel contains between 0.30% and 0.50% carbon, accepts heat
treatment well, and is especially adaptable for machining or forging?
8.
Where is high carbon steel primarily used?
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9.
What effect does chromium have on steel and where are chromium steels
used?
10.
What properties do would nickel steels have, and where are they used on
aircraft?
11.
What characteristics do Nickel-Chromium steels possess, and where would
they be used?
12.
In what applications is the strength and corrosion resistance of stainless steels
best suited to?
13.
What characteristics do molybdenum steels have and where are they used?
14.
Identify the three types of stainless steel and their properties?
15.
Why is sulphur removed from steel?
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16.
If sulphur can not be removed from steel, how can its affects be nullified?
17.
What properties does silicon bring to an alloy steel?
18.
What affect does phosphorous have on steel?
19.
What other metal is vanadium combined with to produce a strong, tough,
ductile steel alloy?
20.
What characteristic does tungsten have on steel, and where are tungsten
steels used?
21.
Why are steels annealed and what properties does it have after treatment?
22.
What is one of the most important reasons for normalizing steel in aircraft
structures?
23.
Why are steels tempered?
24.
Explain the hardening process of alloy steels?
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25
Theory Assignment
What is the reason for case hardening steel?
26.
Explain the following?
Carburising
Nitriding
27.
Name 2 types of hardness testing and the difference between them?
28.
Explain tensile strength testing?
29.
Explain fatigue strength testing?
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30.
Theory Assignment
Explain impact resistance testing?
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Topic 2 Aircraft Materials Non-Ferrous

1.
How is aluminium alloy classified?
2.
What does the first digit identify in the four-digit index system for aluminium
alloys?
3.
What does the second digit identify in the four-digit index system for aluminium
alloys?
4.
What do the last two digits in the 1XXXX group of alloys indicate?
5.
What do the last two digits in the 2XXXX to 8XXXX group of alloys indicate?
6.
Name the major alloying elements in the following group of alloys, and the
properties of these groups?
1xxx
2xxx
3xxx
4xxx
5xxx
6xxx
7xxx
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7.
Identify the alloys present in 7075 Aluminium alloy and their percentages.
8.
What is Alclad?
9.
What is the thickness of Alclad coating?
10.
What is the purpose of heat treatment?
11.
Name and explain the two types of heat treatment used on aluminium alloys?
12.
What do the following numbers mean in relation to heat treatment?
-T
-T3
-T4
-T6
-O
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13.
What term is used to describe the situation when an alloy is allowed to cool at
room temperature following heat treatment?
14.
Define annealing.
15.
Which alloy has a solution heat treatment temperature of 870F.
16.
Give another two terms for strain hardening.
17.
How is magnesium obtained?
18.
When compared to aluminium, how much does magnesium weigh?
19.
What benefits are gained by solution heat treating magnesium alloys?
20.
What is the designation for the alloying element zirconium.
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Theory Assignment
21.
Name and describe the three classifications for Titanium.
22.
Name and describe the two nickel alloys that can be found in aircraft?
23.
Where in an aircraft is copper to be found?
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Topic 3 Aircraft Materials Composite / Non-Metallic

1.
Describe the following composite fibres?
Glass
Aramid
Carbon / Graphite
Boron
2.
Describe the following resin systems?
Polyester
Epoxy
3.
Explain the following adhesives?
Resin
Film
Foam
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4.
Why is it important to place layers of fibre in the correct orientation?
5.
State the warp direction on a roll of fabric?
6.
In which direction do the fill/weft threads run in a roll of fabric?
7.
Define bias in relation to fabric orientation?
8.
Describe the following styles that fibres are available in?
Unidirectional
Bi-directional
Mat
9.
Explain the following common weave patterns?
Plain
Twill
Satin
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10.
Define pot life.
11.
Describe pre-pregs?
Theory Assignment
12.
What type of inspection method is the most frequently used method for
inspecting composites?
13.
What must an operator have a good knowledge of, before commencing a tap
testing inspection?
14.
What is tap testing good at detecting?
15.
What are the two main methods of ultrasonic inspection?
16.
What is ultrasonic inspection useful for?
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17.
In relation to honeycomb core composites, what is radiography (X-ray) useful
at detecting?
18.
How does thermography detect flaws in composite components?
19.
Why is it inadvisable to use dye penetrant inspection on composite
components?
20.
Explain the process of differentiating between transparent plastic materials?
21.
List some basic storage and handling requirements for transparent
thermoplastic sheets.
22.
What must be done before heating any transparent plastic?
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23.
Theory Assignment
Explain the following repairs?
Step cut
Scarf
Potted repair
Injection
24.
Explain how the following materials are cut?
Fibreglass
Carbon / graphite
Aramid
Pre-preg
25.
What problems can arise when drilling and machining composite fibres?
26.
Explain heat curing?
27.
Explain the following pressure applications?
Compression molding
Vacuum bag
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Theory Assignment
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Topic 4 Corrosion
1.
Dry
Explain the following types of corrosion?
Direct Chemical
Electrochemical
Galvanic
Dissimilar Metal
Surface
Intergranular
Stress
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Filiform
Fretting
Exfoliation
Microbiological
2.
Explain the effects on corrosion with differing sized anodes and cathodes, and
if the metals are close or far apart on the electrochemical scale ?
3.
Explain the corrosion tendencies towards each other of stainless steel,
magnesium and aluminium alloys in relation to the electrochemical scale?
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Topic 6 Pipes, Hoses and Unions

1.
What Do the markings on the lower piece of tube indicate?
5052-O
0.028 wall
OD 0.250
2.
How are flared fittings identified?
3.
Explain the colour coding of flared fittings?
4.
Explain the use of flareless fittings?
5.
Explain the use of beading?
6.
What 4 materials are used for the construction of the inner liner of a flexible
line?.
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7.
Explain the construction and associated pressures associated with the
following flexible lines?
Low pressure :
Medium pressure :
High Pressure :
8.
Explain flexible line identification?
9.
Explain the different types of end fittings used on flexible lines?
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Unit A-6a

THEORY ASSIGNMENT PAPER

Jeppesen Power Pg 4-34

Issue A September 2006

This page intentionally left blank

Issue A September 2006

Aircraft Materials Ferrous

Aircraft Materials Non-Ferrous

Aircraft Materials Composite / Non-Metallic

Pipes, Hoses and Unions

Issue A September 2006

This page intentionally left blank

Issue A September 2006

Topic 1 Aircraft Materials Ferrous

What does the acronym (SAE) stand for?

What substance is used to make steel?

What do the numbers in the SAE numbering identify?

Why is carbon added to steel?

Where is high carbon steel primarily used?

Issue A September 2006

Issue A September 2006

Identify the three types of stainless steel and their properties?

Why is sulphur removed from steel?

Issue A September 2006

Issue A September 2006

What properties does silicon bring to an alloy steel?

What affect does phosphorous have on steel?

Why are steels tempered?

Explain the hardening process of alloy steels?

Issue A September 2006

Issue A September 2006

What is the reason for case hardening steel?

Name 2 types of hardness testing and the difference between them?

Explain tensile strength testing?

Explain fatigue strength testing?

Issue A September 2006

Explain impact resistance testing?

Issue A September 2006

This page intentionally left blank

Issue A September 2006

Topic 2 Aircraft Materials Non-Ferrous

How is aluminium alloy classified?

Issue A September 2006

What is the thickness of Alclad coating?

What is the purpose of heat treatment?

What do the following numbers mean in relation to heat treatment?

Issue A September 2006

Which alloy has a solution heat treatment temperature of 870F.

Give another two terms for strain hardening.

How is magnesium obtained?

When compared to aluminium, how much does magnesium weigh?

What benefits are gained by solution heat treating magnesium alloys?

What is the designation for the alloying element zirconium.

Issue A September 2006

Name and describe the three classifications for Titanium.

Where in an aircraft is copper to be found?

Issue A September 2006

Topic 3 Aircraft Materials Composite / Non-Metallic

Describe the following composite fibres?

Describe the following resin systems?

Explain the following adhesives?

Issue A September 2006

Why is it important to place layers of fibre in the correct orientation?

State the warp direction on a roll of fabric?