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This is exam number 1. You've been here 1 times.


--------------------------------------------------------------------------------

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 # multi strand
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

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

1
ans[1] = "a";
ans[2] = "c";
ans[3] = "a";
ans[4] = "a";
ans[5] = "b";
ans[6] = "b";
ans[7] = "c";
ans[8] = "a";
ans[9] = "a";
ans[10] = "b";

explainAnswer[1]="Read CAIPs";
explainAnswer[2]="Read CAIPs";
explainAnswer[3]="Read up on cable/wire types";
explainAnswer[4]="Read up on adhesive joints";
explainAnswer[5]="A 14 gauge cable is thicker than an 18 gauge cable";
explainAnswer[6]="Read up on adhesive joints";
explainAnswer[7]="Read up on adhesive joints";
explainAnswer[8]="Read up on cable/wire types";
explainAnswer[9]="A turboprop reduction gearbox is a good example of an epicyclic gear system";
explainAnswer[10]="Read up on composite repairs";

2
=========================
This is exam number 2. You've been here 1 times.
--------------------------------------------------------------------------------

1. 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 #

2. 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

3. 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

4. How many times can clad alloy be treated?


a) 3 times #
b) as many times as required
c) Once only

5. Two parts of the adhesive process are

a) wetting and setting #


b) wetting and gripping
c) spreading and setting

6. What is the largest hole in honeycomb repairable with microballoons?

a) 2.54 cm #
b) 2.54 inches
c) 2.54 mm

7. 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

8. How are flexible hoses categorised?

a) by length
b) by maximum pressure #
c) by diameter

9. A joggle in a removed rivet is indication of what type of partial failure?

a) shear #
b) bearing
c) compression

10. Over extended honeycomb can bend in which direction?


a) In all directions
b) Across the ribbon
c) Along the ribbon #

3
ans[1] = "c";
ans[2] = "a";
ans[3] = "b";
ans[4] = "a";
ans[5] = "a";
ans[6] = "a";
ans[7] = "a";
ans[8] = "b";
ans[9] = "a";
ans[10] = "c";

explainAnswer[1]="Read up on work-hardening and age-hardening of aluminium alloys";


explainAnswer[2]="Read up on composite repairs";
explainAnswer[3]="Read up on composite repairs";
explainAnswer[4]="Read up on solution treatment of aluminium alloys";
explainAnswer[5]="Read up on the use of adhesives";
explainAnswer[6]="Answer is 1 inch";
explainAnswer[7]="Read up on solution treatment of aluminium alloys";
explainAnswer[8]="Read up on hoses";
explainAnswer[9]="Read up on rivet failures";
explainAnswer[10]="Read up on composite repairs";

4
For full explanations of all these questions, and for many more new and up-to-date questions, with correct
answers, full explanations, downloadable material and Tutorial Support, please visit
http://www.club66pro.co.uk
=========================
This is exam number 3. You've been here 1 times.
--------------------------------------------------------------------------------

1. The vacuum connections in a fibre glass repair must overlap the


a) breather mat #
b) peel ply
c) top layer of glass fabric directly

2. 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

3. 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

4. Max temperature of tin coated copper cable?


a) 105oC #
b) 200oC
c) 260oC

5. The taper of a standard taper pin is

a) 1 in 36
b) 1 in 20
c) 1 in 48 #

6. Spherical roller bearings resist what loads?

a) Large radial and moderate thrust ##


b) Large thrust and moderate radial
c) Large radial but no thrust

7. What are the signs of fretting corrosion?

a) black powder or cocoa staining #


b) intergrannular cracking
c) flaking

8. Plug pins are numbered

a) from the outside in - clockwise


b) from the inside out - anticlockwise
c) from the inside out - clockwise #

9. What are the rigid pipes on gas turbine engines made from?

a) aluminium alloy
b) copper
c) stainless steel #

10. Equipment wire


a) is flexible and suitable for soldering #
b) can be used for interconnect wiring
c) has thicker insulation than interconnect wire

5
var score = 0;
ans[1] = "a";
ans[2] = "b";
ans[3] = "a";
ans[4] = "a";
ans[5] = "c";
ans[6] = "a";
ans[7] = "a";
ans[8] = "c";
ans[9] = "c";
ans[10] = "a";

explainAnswer[1]="The breather mat allows the air to flow from the repair";
explainAnswer[2]="The test involves painting the surface of a gear tooth then running the gear, then inspecting the
'pattern' worn into the painted surface.";
explainAnswer[3]="Read CAIPs/CAAIPs";
explainAnswer[4]="Read CAIPs/CAAIPs";
explainAnswer[5]="Read CAIPs/CAAIPs";
explainAnswer[6]="'Radial' means outward, 'thrust' means axial.";
explainAnswer[7]="Read up on signs of corrosion.";
explainAnswer[8]="Get a copy of Pallett's Aircraft Electrical Systems";
explainAnswer[9]="Stainless steel has a high resistance to heat";
explainAnswer[10]="Read CAIPs";

6
=========================
This is exam number 4. You've been here 1 times.
--------------------------------------------------------------------------------

1. 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

2. 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

3. When not under load where should a pair of gears sit?


a) In the middle #
b) On the heel
c) On the toe

4. For a pair of gears to operate properly, they must have


a) lash and pattern #
b) end play and thrust
c) pattern and profile

5. 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

6. What is a coaxial cable?

a) Two or more conductors


b) A twisted pair of conductors
c) A single conductor #

7. 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

8. How is a British al alloy rivet identified?

a) Natural anodised finish


b) Violet anodic finish
c) Black anodic finish #

9. 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

10. ‘X’ on a cable indicates


a) emergency power
b) control system
c) AC power #

7
var score = 0;
ans[1] = "b";
ans[2] = "a";
ans[3] = "a";
ans[4] = "a";
ans[5] = "b";
ans[6] = "c";
ans[7] = "a";
ans[8] = "a";
ans[9] = "a";
ans[10] = "c";

explainAnswer[1]="See CAAIPs / CAIPs.";


explainAnswer[2]="Oxides of metals always become thicker with elevated temperatures.";
explainAnswer[3]="Read up on gears.";
explainAnswer[4]="See Jeppesen Helicopter Maintenance.";
explainAnswer[5]="Spring steel is hardened (therefore high carbon) steel or alloy steel.";
explainAnswer[6]="A coaxial cable is a single shielded cable.";
explainAnswer[7]="See CAAIPs / CAIPs.";
explainAnswer[8]="A British al alloy rivet is natural anodised.";
explainAnswer[9]="See Jeppesenn Advanced Composites.";
explainAnswer[10]="'X' indicates AC power.";

8
=========================
This is exam number 5. You've been here 1 times.
--------------------------------------------------------------------------------

1. A BS rivet made from L36 would be what colour and marking?


a) Black anodic #
b) Green anodic
c) Natural anodic

2. The teeth on the smaller wheel of a bevel gear are called the
a) heel
b) toe #
c) foot

3. What must you be careful with a hot stamped cable?


a) Wet arc tracking #
b) Corrosion
c) Peeling of the insulation

4. Where should you not use a nyloc nut?


a) Temperatures above 200oC #
b) Temperatures above 120oC
c) Temperatures above 80oC

5. 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

6. The correct meshing of gears is found on what part of the tooth?

a) Top
b) Middle #
c) Bottom

7. What type of gear would be used on a prop reduction gearbox?

a) Epicyclic #
b) Bevel
c) Split epicyclic

8. What is the effect of aluminium oxide on aluminium electrical cable?

a) Provides strength
b) Reduces resistance
c) Insulates #

9. 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

10. 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

9
ans[1] = "a";
ans[2] = "b";
ans[3] = "a";
ans[4] = "a";
ans[5] = "b";
ans[6] = "b";
ans[7] = "a";
ans[8] = "c";
ans[9] = "a";
ans[10] = "a";

explainAnswer[1]="An L36 rivet is anodised black.";


explainAnswer[2]="See Jeppesen Helicopter Maintenance";
explainAnswer[3]="Hot stamping has been known to cause wet arc tracking.";
explainAnswer[4]="See CAAIPs / CAIPs.";
explainAnswer[5]="See CAAIPs / CAIPs.";
explainAnswer[6]="See Jeppesen Helicopter Maintenance";
explainAnswer[7]="Read up on prop reduction gears.";
explainAnswer[8]="All metal oxides are insulators.";
explainAnswer[9]="Read up on precipitation heat treatment / age hardening.";
explainAnswer[10]="Read up on banjo hoses.";

1
=========================
This is exam number 6. You've been here 1 times.
--------------------------------------------------------------------------------

1. The pitch of a screw thread is


a) crest to root
b) crest to crest #
c) 2 x crest to root

2. A single start thread the lead is


a) 2 x pitch
b) 1 x pitch #
c) ½ x pitch

3. 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

4. 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

5. A wire thread insert tap is

a) slightly larger than the hole


b) supplied in a fitting kit #
c) slightly smaller than the hole

6. Aluminium exposed to air will

a) oxidise and become weaker


b) oxidise and become stronger
c) oxidise and become electrically insulated #

7. 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 #

8. A natural finish aluminium alloy rivet with a D on it is

a) duralumin L37 #
b) aluminium L36
c) hiduminium L86

9. 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

10. 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 #

1
ans[1] = "b";
ans[2] = "b";
ans[3] = "b";
ans[4] = "a";
ans[5] = "b";
ans[6] = "c";
ans[7] = "c";
ans[8] = "a";
ans[9] = "b";
ans[10] = "c";

explainAnswer[1]="Pitch is crest to crest.";


explainAnswer[2]="Lead = pitch x starts.";
explainAnswer[3]="See CAAIPs / CAIPs.";
explainAnswer[4]="See CAAIPs / CAIPs.";
explainAnswer[5]="See CAAIPs / CAIPs.";
explainAnswer[6]="Oxides of all metals are insulators.";
explainAnswer[7]="Example SP80 is snap head, al alloy, violet finish.";
explainAnswer[8]="L37 is aluminium alloy with a D.";
explainAnswer[9]="5% magnesium is green anodised with an X.";
explainAnswer[10]="Microballoons is the lightest filler material.";
For full explanations of all these questions, and for many more new and up-to-date questions, with correct
answers, full explanations, downloadable material and Tutorial Support, please visit
http://www.club66pro.co.uk

1
=========================
This is exam number 7. You've been here 1 times.
--------------------------------------------------------------------------------

1. Black streaks back from a rivet hole signify


a) galvanic corrosion
b) fretting #
c) intergrannular corrosion

2. An AN steel bolt is identified by what marking on the head?


a) 14E
b) An 'X' #
c) A dash

3. 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

4. When using a backing former on a composite repair you need to use


a) cellophane #
b) breather cloth
c) a vacuum bag

5. Heater mats should overlap the repair by

a) 4”
b) 6”
c) 2” #

6. 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 #

7. Composition of silver solder is

a) tin and lead


b) tin, lead and silver
c) tin, lead, silver and antimony ##

8. 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

9. Wire locking approach angles should not be less than

a) 45o #
b) 90o
c) 10o

10. Where would you find the inspection interval for chains?
a) Maintenance manual
b) Maintenance schedule #
c) Flight manual

1
var score = 0;
ans[1] = "b";
ans[2] = "b";
ans[3] = "b";
ans[4] = "a";
ans[5] = "c";
ans[6] = "c";
ans[7] = "c";
ans[8] = "a";
ans[9] = "a";
ans[10] = "b";

explainAnswer[1]="Fretting corrosion is identified by black / grey streaks.";


explainAnswer[2]="An AN steel bolt is identified with an 'X'.";
explainAnswer[3]="2024-T3 has a low fatique resistance.";
explainAnswer[4]="See Jeppesen Advanced Composites.";
explainAnswer[5]="See Jeppesen Advanced Composites.";
explainAnswer[6]="The plain washer is to protect the surface of the part from the edge of the spring washer.";
explainAnswer[7]="See CAAIPs / CAIPs.";
explainAnswer[8]="See CAAIPs / CAIPs.";
explainAnswer[9]="See CAAIPs / CAIPs.";
explainAnswer[10]="Time intervals are only in the Maintenance Schedule.";

1
=========================
This is exam number 8. You've been here 1 times.
--------------------------------------------------------------------------------

1. What amperage is an 18 swg cable?


a) 10 amp #
b) 5 amp
c) 1 amp

2. A thermoplastic fibre reinforced composite is prepared by


a) etching
b) a solvent wipe
c) corona method #

3. 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

4. A blind fastener described as external sleeve and internally threaded would be


a) a cherry lock
b) a jo bolt #
c) a rivnut

5. 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

6. 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

7. What metal is suitable for riveting magnesium alloy?

a) Monel metal
b) 1100 aluminium alloy
c) 5056 aluminium alloy #

8. What metal is suitable for riveting alloy steel

a) monel metal #
b) mild steel
c) aluminium alloy

9. 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

10. 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

1
var score = 0;
ans[1] = "a";
ans[2] = "c";
ans[3] = "a";
ans[4] = "b";
ans[5] = "a";
ans[6] = "b";
ans[7] = "b";
ans[8] = "b";
ans[9] = "a";
ans[10] = "b";

explainAnswer[1]="18 swg is a 10 amp cable.";


explainAnswer[2]="Corona method is used to prepare a thermoplastic material.";
explainAnswer[3]="A British close tolerance bolt is identified with a raised ring on the head.";
explainAnswer[4]="A jo-bolt is externally sleeved and internally threaded.";
explainAnswer[5]="The shielding in a coaxial cable converts the electromagnetic field into electrical energy.";
explainAnswer[6]="Pipes are graded in 1/6 inch steps. The last dash number is the number of 16ths. i.e. 8/16 = 0.5
inches.";
explainAnswer[7]="Get a galvanic series table and see that 1100 al.alloy is closest to magnesium alloy.";
explainAnswer[8]="Mild steel is closest to alloy steel on the galvanic series.";
explainAnswer[9]="Silver coated connectors and glycol deicing fluid is a fire hazard.";
explainAnswer[10]="Silver coated connectors in unpressurised parts of the aircraft can cause wet arc tracking.";

For full explanations of all these questions, and for many more new and up-to-date questions, with correct
answers, full explanations, downloadable material and Tutorial Support, please visit
http://www.club66pro.co.uk

1
=========================
This is exam number 9. You've been here 1 times.
--------------------------------------------------------------------------------

1. 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

2. 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

3. If aluminium alloy is not quenched after heat treatment is it will be


a) brittle #
b) subject to corrosion
c) malleable

4. 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

5. Active flux does what?

a) Cleans #
b) Protects
c) Both cleans and protects

6. 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 #

7. 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

8. An aluminium alloy rivet identification is

a) D embossed #
b) X embossed
c) O embossed

9. Rivet allowance is

a) 1.5d #
b) 1.5d plus the thickness of the material
c) 1d plus the thickness of the material

10. D and DD rivets are refrigerated to


a) retard age hardening #
b) increase age hardening
c) precipitation harden

1
ans[1] = "a";
ans[2] = "a";
ans[3] = "a";
ans[4] = "a";
ans[5] = "a";
ans[6] = "c";
ans[7] = "b";
ans[8] = "c";
ans[9] = "a";
ans[10] = "a";

explainAnswer[1]="Read up on corrosion types.";


explainAnswer[2]="Read up on corrosion types.";
explainAnswer[3]="If al.alloy is not quenched, it remains in its hard state.";
explainAnswer[4]="Read up on anodizing.";
explainAnswer[5]="See CAAIPs / CAIPs.";
explainAnswer[6]="Jointing compound is used to prevent dissimilar metal contact.";
explainAnswer[7]="See Jeppesen Advanced Composites.";
explainAnswer[8]="An aluminium alloy rivet is identified with an 'O'.";
explainAnswer[9]="Rivet allowance is 1.5 x diameter.";
explainAnswer[10]="Refrigeration retards age hardening.";

1
=========================
This is exam number 10. You've been here 1 times.
--------------------------------------------------------------------------------

1. 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

2. Stepped curing has


a) more than 2 dwell periods #
b) variable cure time
c) no constant dwell period

3. 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 #

4. Maximum repair dimensions for use of microballoons?


a) 10mm #
b) 20mm
c) 30mm

5. 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

6. Fibre strength is strongest in the direction of the

a) warp #
b) weft
c) bias

7. In an autoclave what would you cover the repair in?

a) High temp nylon #


b) Polythene
c) Polypropelene

8. If caustic soda turns a material black what is it?

a) Aluminium
b) Alclad
c) Aluminium alloy #

9. Intergrannular corrosion is caused by

a) improper heat treatment #


b) dissimilar metal contact
c) improperly assembled components

10. 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

1
ans[1] = "a";
ans[2] = "a";
ans[3] = "c";
ans[4] = "a";
ans[5] = "b";
ans[6] = "a";
ans[7] = "a";
ans[8] = "c";
ans[9] = "a";
ans[10] = "a";

explainAnswer[1]="Read up on age hardening.";


explainAnswer[2]="See Jeppesen Advanced Composites (dwell time = soak time).";
explainAnswer[3]="Use cardboard protection to prevent damage to seals when fitting them.";
explainAnswer[4]="Maximum repair with microballoons is approximately 1/2 inch - closest here is 10 mm. See
CAAIPs / CAIPs.";
explainAnswer[5]="See Jeppesen Advanced Composites.";
explainAnswer[6]="See Jeppesen Advanced Composites.";
explainAnswer[7]="See Jeppesen Advanced Composites.";
explainAnswer[8]="Caustic soda turns al.alloy black, and pure aluminium white.";
explainAnswer[9]="Read up on corrosion types";
explainAnswer[10]="Jointing compound is a non-porous dielectric.";

For full explanations of all these questions, and for many more new and up-to-date questions, with correct
answers, full explanations, downloadable material and Tutorial Support, please visit
http://www.club66pro.co.uk

2
=========================
This is exam number 11. You've been here 1 times.
--------------------------------------------------------------------------------

1. Corrosion caused by electrolytic action is the result of


a) excessive anodization
b) contact between two unlike metals #
c) the wrong quenching agent

2. 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 #

3. 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

4. The standard taper for a taper pin is


a) 1:20
b) 1:48 #
c) 1:600

5. Corrosion may be regarded as the destruction of metal by

a) electrochemical action #
b) electromechanical action
c) hydroelectric action

6. Tempering steel gives

a) greater hardness
b) greater brittleness
c) relief of internal stress after hardening #

7. After welding, stainless steel is susceptible to a corrosion known as

a) weld decay #
b) weld rot
c) weld deterioration

8. 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 #

9. The addition of chromium to steel will produce

a) toughness
b) ductility
c) hardness #

10. 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

2
ans[1] = "b";
ans[2] = "c";
ans[3] = "b";
ans[4] = "b";
ans[5] = "a";
ans[6] = "c";
ans[7] = "a";
ans[8] = "c";
ans[9] = "c";
ans[10] = "b";

explainAnswer[1]="Read up on corrosion types.";


explainAnswer[2]="A spring washer must always be used with a plain washer.";
explainAnswer[3]="Split pins can only be used once.";
explainAnswer[4]="The standard taper on a taper pin is 1:48.";
explainAnswer[5]="Corrosion is electrochemicqal action.";
explainAnswer[6]="Tempering is done to relieve internal stresses.";
explainAnswer[7]="Corrosion after welding is called 'weld decay'.";
explainAnswer[8]="Read up on corrosion types.";
explainAnswer[9]="Chromium is alloyed with steel to make it harder.";
explainAnswer[10]="A feather key allows axial movement.";

2
=========================
This is exam number 12. You've been here 1 times.
--------------------------------------------------------------------------------

1. 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

2. What chemical is used to identify aluminium alloys


a) caustic soda #
b) copper sulphate
c) nitric acid

3. 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

4. Pure aluminium is
a) highly resistant to corrosion #
b) not resistant to corrosion
c) reasonably resistant to corrosion

5. 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

6. Buttress threads are used

a) to transmit power in both directions


b) to transmit power on one direction #
c) on nuts and bolts

7. The electrolytic process that forms an oxide film on the surface of aluminium alloys is known as

a) electroplating
b) galvanizing
c) anodizing #

8. Studs which have a size larger thread at one end are called

a) stepped studs #
b) plain studs
c) shouldered studs

9. The conductor in tersil cable is

a) tinned copper
b) nickel plated copper #
c) stainless steel

10. A cable is marked NYVIN 22. The 22 represents the


a) current rating
b) current/weight ratio
c) cross sectional area #

2
ans[1] = "c";
ans[2] = "a";
ans[3] = "a";
ans[4] = "a";
ans[5] = "b";
ans[6] = "b";
ans[7] = "c";
ans[8] = "a";
ans[9] = "b";
ans[10] = "c";

explainAnswer[1]="A preload washer is correctly loaded when the inner ring is gripped.";
explainAnswer[2]="Caustic soda turns al.alloy black and pure aluminium white.";
explainAnswer[3]="Lead = pitch = starts";
explainAnswer[4]="Pure aluminium is highly resistant to corrosion.";
explainAnswer[5]="Breathing oxygen is black with a white collar.";
explainAnswer[6]="Buttress threads are used to transmit power in one direction (like some vice lead screws).";
explainAnswer[7]="Read up on anodizing.";
explainAnswer[8]="Stepped studs have a size larger at one end.";
explainAnswer[9]="The conductor in tersil cable is nickel plated copper.";
explainAnswer[10]="The 22 represents the cross sectional area.";

For full explanations of all these questions, and for many more new and up-to-date questions, with correct
answers, full explanations, downloadable material and Tutorial Support, please visit
http://www.club66pro.co.uk

2
=========================
This is exam number 13. You've been here 1 times.
--------------------------------------------------------------------------------

1. Copper is an inferior conductor to aluminium when comparing


a) weight for weight #
b) CSA with CSA
c) load for load

2. 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 #

3. 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

4. What is the indication of fretting corrosion on aluminium alloy?


a) Black powder #
b) Brown powder
c) White powder

5. Exfoliation corrosion is sometimes referred to as

a) layer corrosion #
b) sub-surface corrosion
c) filiform corrosion

6. 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

7. 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 #

8. 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

9. 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

10. An American rivet with a cross on the head is


a) 2117 aluminium alloy
b) 5056 aluminium alloy #
c) 2124 aluminium alloy

2
ans[1] = "a";
ans[2] = "c";
ans[3] = "a";
ans[4] = "a";
ans[5] = "a";
ans[6] = "";
ans[7] = "c";
ans[8] = "b";
ans[9] = "b";
ans[10] = "b";

explainAnswer[1]="Aluminium is better than copper when you compare CSA to CSA (CSA = cross sectional area).";
explainAnswer[2]="Chromium, when added to steel increases its hardness and corrosion resistance (hence CRS).";
explainAnswer[3]="Case hardening hardens the surface only.";
explainAnswer[4]="Fretting corrosion is identified by a black / grey powder streak.";
explainAnswer[5]="Read up on corrion types.";
explainAnswer[6]="Read up on corrion types.";
explainAnswer[7]="The anode always corrodes";
explainAnswer[8]="Read up on corrion types.";
explainAnswer[9]="See CAAIPs / CAIPs.";
explainAnswer[10]="A cross on the head of a rivet indicates it is 5056 al.alloy.";

2
=========================
This is exam number 14. You've been here 1 times.
--------------------------------------------------------------------------------

1. A countersunk rivet of the ‘SP’ series has a head style of


a) 90o
b) 100o #
c) 20o

2. The lead on a single start thread is


a) 1/2 the pitch
b) 1 x the pitch #
c) 2 x the pitch

3. The coding of a British rivet indicates


a) head type and colour ##
b) length and diameter
c) material and head type

4. 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 #

5. 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

6. Silver plated copper wire has a maximum working temp of

a) 200 oC
b) 250 oC ##
c) 300 oC

7. In an autoclave to apply pressure

a) weights are used


b) a vacuum bag is used #
c) clamps are used

8. Precipitation treating makes the metal

a) harder, stronger and more ductile


b) harder, stronger and less ductile #
c) less strong and hard

9. 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

10. 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 #

2
ans[1] = "b";
ans[2] = "b";
ans[3] = "a";
ans[4] = "c";
ans[5] = "a";
ans[6] = "b";
ans[7] = "b";
ans[8] = "b";
ans[9] = "a";
ans[10] = "c";

explainAnswer[1]="SP series rivets are 100 degree csk.";


explainAnswer[2]="Lead = pitch x starts.";
explainAnswer[3]="Coding such as SP80 means snap head and al.alloy.";
explainAnswer[4]="Read up on steel compositions.";
explainAnswer[5]="See CAAIPs.";
explainAnswer[6]="See CAAIPs.";
explainAnswer[7]="See Jeppesen Advanced Composites.";
explainAnswer[8]="Read up on precipitation heat treatment.";
explainAnswer[9]="Read up on alodizing treatment.";
explainAnswer[10]="Read up on corrosion types.";

For full explanations of all these questions, and for many more new and up-to-date questions, with correct
answers, full explanations, downloadable material and Tutorial Support, please visit
http://www.club66pro.co.uk

2
=========================
This is exam number 15. You've been here 1 times.
--------------------------------------------------------------------------------

1. Corrosion will spread more rapidly when metals are exposed to


a) high temperatures #
b) dry climates
c) cold climates

2. 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

3. 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 #

4. Colour identification of an aluminium rivet is


a) black #
b) violet
c) green

5. 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

6. Joggles in removed rivet shanks would indicate partial

a) bearing failure
b) torsion failure
c) shear failure #

7. The teeth of a gear would normally be

a) nitrided
b) case hardened #
c) tempered

8. 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

9. If a chain is removed for routine maintenance

a) it must be proof checked to ½ max load


b) it must be proof checked to full load
c) it does not have to be proof checked #

10. Magnesium alloy components are protected by

a) an electro process
b) a chemical process #
c) a painted process

2
var score = 0;
ans[1] = "a";
ans[2] = "a";
ans[3] = "c";
ans[4] = "a";
ans[5] = "b";
ans[6] = "c";
ans[7] = "b";
ans[8] = "a";
ans[9] = "c";
ans[10] = "b";

explainAnswer[1]="Higher temperatures always accelerate corrosion.";


explainAnswer[2]="Read up on American material codes.";
explainAnswer[3]="Read up on gear drive types.";
explainAnswer[4]="A pure aluminium rivet is black anodized.";
explainAnswer[5]="Rivet spacing (single row) is 4 x diameter.";
explainAnswer[6]="Read up on rivet failure modes.";
explainAnswer[7]="Hardening right through the gear teeth would make them
brittle and tend to break.";
explainAnswer[8]="5% magnesium rivets are green anodized.";
explainAnswer[9]="See CAAIPs / CAIPs.";
explainAnswer[10]="Read up on corrosion prevention.";

3
=========================
This is exam number 16. You've been here 1 times.
--------------------------------------------------------------------------------

1. 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

2. If it is necessary to remove corrosion from a steel component in-situ, the base of a suitable solution for this
purpose is
a) chromic acid
b) nitric acid
c) phosphoric acid #

3. A type of protection which is applicable to magnesium alloys is the


a) phosphate process
b) coslettising process
c) chromating process ##

4. 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 #

5. 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 #

6. Black streaks running away from a bolt or rivet would indicate

a) fretting corrosion #
b) exfoliation corrosion
c) intergrannular corrosion

7. 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 #

8. On gear teeth, the wear pattern should be

a) the top edge most worn


b) the middle of the tooth most worn #
c) even

9. 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

10. 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

3
ans[1] = "a";
ans[2] = "c";
ans[3] = "c";
ans[4] = "c";
ans[5] = "c";
ans[6] = "a";
ans[7] = "a";
ans[8] = "c";
ans[9] = "a";
ans[10] = "a";

explainAnswer[1]="Read up on corrosion removal.";


explainAnswer[2]="Read up on corrosion removal.";
explainAnswer[3]="Read up on corrosion protection.";
explainAnswer[4]="Read up on corrosion removal.";
explainAnswer[5]="Read up on corrosion types.";
explainAnswer[6]="Read up on corrosion types.";
explainAnswer[7]="Eg 'L32'";
explainAnswer[8]="See Jeppesen Helicopter Maintenance.";
explainAnswer[9]="See Jeppesen Helicopter Maintenance.";
explainAnswer[10]="Read up on corrosion protection.";

For full explanations of all these questions, and for many more new and up-to-date questions, with correct
answers, full explanations, downloadable material and Tutorial Support, please visit
http://www.club66pro.co.uk

3
=========================
This is exam number 17. You've been here 1 times.
--------------------------------------------------------------------------------

1. 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

2. 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

3. Aluminium alloy with primarily magnesium is numbered

a) 5025 #
b) 2025
c) 1025

4. Heat treatment is shown on an aluminium alloy by a

a) letter code #
b) number code
c) letter and number code

5. Bevel gears are

a) all over case hardened#


b) toe is hardened
c) heel is hardened

6. Nitriding is

a) case hardening#
b) anodising
c) tempering

7. Alloy rivets are heat treated by

a) annealing
b) anodising
c) solution treating #

8. 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 #

9. 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

10. Oxide on exposed silver plated wires is


a) non corrosive
b) an insulator #
c) a conductor

3
ans[1] = "a";
ans[2] = "a";
ans[3] = "a";
ans[4] = "a";
ans[5] = "a";
ans[6] = "a";
ans[7] = "c";
ans[8] = "c";
ans[9] = "b";
ans[10] = "b";

explainAnswer[1]="Cable control systems are strong and light.";


explainAnswer[2]="Pop rivets and blind rivets cannot be used in place of solid rivets.";
explainAnswer[3]="Read up on American material specifications.";
explainAnswer[4]="Eg L32.";
explainAnswer[5]="Bevel gears are all over case hardened.";
explainAnswer[6]="Nitriding is a form of case hardening.";
explainAnswer[7]="Al.Alloy rivets are solution heat treated.";
explainAnswer[8]="Read up on age hardening.";
explainAnswer[9]="Fireproof - 15 minutes, fire resistant - 5 minutes.";
explainAnswer[10]="Any metal oxide is an insulator.";

3
=========================
This is exam number 18. You've been here 1 times.
--------------------------------------------------------------------------------

1. Turnbuckles depending on type are locked by

a) locknuts and wire #


b) stiffnuts
c) castleated nuts and splitpins

2. 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

3. 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

4. Flexible pipes are identified by

a) diameter
b) length
c) material #

5. A pipe carrying lubricant would be identified by the colour

a) white
b) white and yellow
c) yellow #

6. 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

7. Medium carbon steels have a carbon content of


a) 0.3 - 0.5 %
b) 0.5 - 0.8 % ##
c) 0.8- 1.05 %

8. Brinell hardness testing measures

a) depth
b) diameter #
c) area

9. 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

10. Impact resistance measures the


a) material toughness #
b) material hardness
c) material ductility

3
ans[1] = "a";
ans[2] = "b";
ans[3] = "a";
ans[4] = "c";
ans[5] = "c";
ans[6] = "a";
ans[7] = "b";
ans[8] = "b";
ans[9] = "b";
ans[10] = "a";

explainAnswer[1]="See CAAIPs / CAIPs.";


explainAnswer[2]="See CAAIPs / CAIPs.";
explainAnswer[3]="See CAAIPs / CAIPs.";
explainAnswer[4]="See CAAIPs / CAIPs.";
explainAnswer[5]="Read up on pipeline identification markings.";
explainAnswer[6]="See CAAIPs / CAIPs.";
explainAnswer[7]="Actually, medium carbon steel is 0.25 - 0.8% - so b) is closest.";
explainAnswer[8]="In a Brinell hardness test, the diameter of the indent is used to indicate the hardness.";
explainAnswer[9]="The material is tested to full destructions.";
explainAnswer[10]="'Toughness' is resistance to impact.";

3
=========================
This is exam number 19. You've been here 1 times.
--------------------------------------------------------------------------------

1. A ferrous metal contains


a) iron #
b) aluminium
c) magnesium

2. What is Alumina?

a) Aluminium ore
b) A ceramic oxide of aluminium #
c) An alloy of aluminium

3. Non heat treatable materials

a) by annealing
b) can be hardened strain hardening or cold working #
c) cannot be hardened

4. 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

5. 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

6. Corrosion at the grain boundaries is called

a) filiform
b) intergrannular #
c) fretting

7. What does MSDS stand for?


a) Maximum Structural Design System
b) Material Safety Data Sheet #
c) Metal Surface Dimension Sector

8. Which of these is a common coz for corrosion?

a) Water in fuel
b) Spilled battery acid #
c) Untreated metal

9. Most commonly used thread form in aviation is

a) round thread
b) buttress
c) V thread #

10. 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

3
ans[1] = "a";
ans[2] = "b";
ans[3] = "b";
ans[4] = "b";
ans[5] = "b";
ans[6] = "b";
ans[7] = "b";
ans[8] = "b";
ans[9] = "c";
ans[10] = "a";

explainAnswer[1]="'Ferrous' is from the Latin for iron.";


explainAnswer[2]="Alumina ia aluminium oxide - a ceramic.";
explainAnswer[3]="All materials but a few (eg lead) can be hardened by cold working.";
explainAnswer[4]="The anode loses electrons.";
explainAnswer[5]="See Jeppesen Advanced Composites.";
explainAnswer[6]="Read up on corrosion types.";
explainAnswer[7]="MSDS - Material Safety Data Sheet.";
explainAnswer[8]="Spilled battery acid is sure to cause corrosion.";
explainAnswer[9]="V thread is the most commonly used thread form.";
explainAnswer[10]="Pitch is crest to crest.";

For full explanations of all these questions, and for many more new and up-to-date questions, with correct
answers, full explanations, downloadable material and Tutorial Support, please visit
http://www.club66pro.co.uk

3
=========================
This is exam number 20. You've been here 1 times.
--------------------------------------------------------------------------------

1. A bolt with a raised dash is


a) AN standard
b) Corrosion Resistant Steel #
c) close tolerance

2. A rivet with no marking has the material code

a) A #
b) AD
c) D

3. A dowel will take what loads?

a) shear #
b) tensile
c) torsion

4. The advantage of circlips is

a) cheap
b) can be used for both inner and external applications
c) Both a and c #

5. Rivet MS 20426 has what head type?

a) Round
b) Universal
c) CSK #

6. Cable tension is maintained by

a) a cable tension regulator #


b) a grommet
c) a fair lead

7. Which material are hydraulic fluid hoses made from


a) Butyl
b) Teflon ##
c) Rubber

8. What load are spring hooks subjected to?

a) tension
b) compressive
c) bending #

9. Where are needle roller bearings used

a) where there are space restrictions #


b) high speed operations
c) Where is fluid damped bearing used

10. Loads on tapered roller bearings


a) axial only
b) thrust only
c) axial and thrust #

3
ans[1] = "b";
ans[2] = "a";
ans[3] = "a";
ans[4] = "c";
ans[5] = "c";
ans[6] = "a";
ans[7] = "c";
ans[8] = "c";
ans[9] = "a";
ans[10] = "c";

explainAnswer[1]="A raised dash indicates a CRS bolt.";


explainAnswer[2]="Read up on American rivet codes.";
explainAnswer[3]="A dowel takes shear loads.";
explainAnswer[4]="Circlips are cheap and can be used for internal and external applications.";
explainAnswer[5]="Read up on American rivet codes.";
explainAnswer[6]="A cable tension regulator maintains cable tension.";
explainAnswer[7]="See CAAIPs / CAIPs.";
explainAnswer[8]="Spring hooks are under bending stress.";
explainAnswer[9]="Needle roller bearings are used where there are space restrictions.";
explainAnswer[10]="Taper roller bearings can take axial and thrust loads.";

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