1. What are the 5 basic loading conditions? Tension, Compression, Shear, Torsion, Bending. 2. What is stiffness?

Stiffness is the resistance of an elastic body to deflection by an applied force. 3. What is Strain? The effect of overstressing a part or assembly to the point where a permanent deformation takes place is called Strain. 4. What is stress corrosion? The combined action of corrosive attack and sustained tensile strength upon metal surfaces which can induce cracking. 5. What is a primary structure? Primary structural parts are parts whose failure alone, without requiring a further unusual sequence or combination of events to render the failure serious, would endanger the airworthiness of the airplane or the safety of its occupants or ground crew. They include the basic airframe for wing, empennage and fuselage. Other examples are controls and mechanisms for brakes, external doors, flight control systems, landing gear and latching systems, engine cowling, fuel tanks, wing and tail surface fillets, floors and support structures. 6. What is a Monolithic detail? A complex one piece part that could have been made in several pieces and joined together, but is rather made as one piece through hug-out. 7. What metal has the highest strength to weight ratio? Titanium, followed by Aluminum and Steel. 8. Name corrosion resistant (Stainless or Cres) steels. 301, 302, 303 SE, 304 316L (very good corrosion resistance in marine environment) 321 (used for elevated temperature applications) 347 (Very high resistance to stress corrosion) 17-7 PH (high strength, corrosion resistance and moderate heat resistance) PH 13-8 MO (high strength, corrosion resistance and good fracture toughness) 15-5 PH and 17-4 PH (moderate strength, corrosion resistance and good toughness) A-286 (moderate strength, good corrosion resistance at elevated temperatures up to 1200 deg F) 9. What are the three different groupings of Stainless Steels? Austenitic Austenitic Steels are chromium-nickel and chromium-nickel-manganese alloys. They are Nonmagnetic. They can be hardened by cold working and heat treatment only serves to anneal them. Ferritic Ferritic steels contain no carbon, hence they do not respond to heat treatment. They contain a substantial amount of chromium and may have a small amount of aluminum. They are always magnetic. Martensitic Martensitic steels are chromium alloys and can be hardened by heat treatment. The most widely used stainless steels for general use are those in the 300 series, such as 301, 302, 321 and 347. They are called 18-8 because they contain approximately 18% chromium and 8% nickel. 10. What are some commonly used steel for general aircraft structural purposes? 4130 Chromium-Molybdenum Steel 4140 Chromium-Molybdenum Steel 4340 Nickel-Chromium-Molybdenum Steel 11. What are the Carbon Steels? 10XX Nonsulfurized carbon steel (plain carbon) 11XX Resulfurized carbon steel 12XX Resulfurized and rephosphorized carbon steel 12. What kind of Steel is used for high toughness? HY -TUF, It has high toughness, is heat treatable in thick sections and is weldable. It is heat treated to 220250 KSI.

13. What is the highest strength steel? 300M. It is heat treated to 275 to 305 KSI. 14. What is clad? Clad or Alclad is an extremely thin layer of pure aluminum laminated onto each side of an aluminum sheet to improve corrosion resistance with little impairment of strength. 15. What are the different forms of Aluminum alloys? Sheet, Plate, Forging, Extrusion, Bar, Tubing. 16. What is the basic temper designation for wrought and cast aluminum and aluminum alloys? F --- As fabricated. (No treatment) O --- Annealed. H --- Strain hardened. (Wrought products only) W --- Solution heat treated. T --- Thermally treated. T is always followed by one or more digits to indicate the process applied. 17. What aluminum alloy is weldable? 6061. It may be fusion welded, resistance welded and dip brazed. 18. What is 2024 and its application? Alloy 2024 is a medium strength general purpose material with high toughness and resistance to crack propagation. It should be used for fatigue and fracture critical applications such as fuselage skins, lower wing skins, and control surfaces. 19. What temper in 7075 and 7050 Aluminum alloy provides good exfoliation corrosion resistance? T76. However T76 provides 10% less strength than T6. 20. What are the high strength aluminum alloys? 7075 and 7050. 7050 has higher strength than 7075. 7050 is only available in Plate, extrusion or forging. 7075-T6 is used for maximum strength. 7075-T73 is used for stress corrosion resistance. 7075-T76 is used for exfoliation corrosion resistance. 7050-T74 is used for optimum resistance to stress corrosion cracking. 7050-T76 is used for exfoliation corrosion resistance. 21. Aluminum alloys are designated by a four digit system. What does the first digit signify? It indicates principal alloying element. For example, 2 indicates copper. Here is a list of alloy types: 1100 ----- Pure Aluminum 2014 ----- Copper, Silicon, Manganese, Magnesium 2020 ----- Copper, Lithium 2024 ----- Copper, Manganese, Magnesium 2219 ----- Copper, Manganese, Vanadium, Zirconium 3003 ----- Manganese 4043 ----- Silicon 5052 ----- Magnesium 6061 ----- Magnesium, Silicon 7075 ----- Zinc, Magnesium, Copper, Chromium 22. What are the pure aluminum (1100) and softer alloys (3003 and 5052) used for? They are used for tubing, junction boxes, nonstressed panels or other parts that require considerable loads but are not subjected to high loads. These materials are easily worked and readily weldable. 23. What does Cold Working mean? Cold Working is any process applied at room temperature that stretches, compresses, bends, draws, or otherwise changes the shape of the alloy to any appreciable degree. 24. What are the different forms of titanium alloys? Sheet, Plate, Forging, Extrusion, Bar, Tubing and Wire

25. Name common Titanium alloys: Ti 6AL-4V and Ti 6AL-6V-2Sn Ti 6AL-4V is a multiple purpose structural titanium alloy with a good balance of strength and toughness. It is the most commonly used titanium alloy and is realy available in all forms except tubing. Ti 6AL-6V-2Sn is similar to Ti 6AL-4V but has higher strength and lower toughness. It should be considered when strength is the primary consideration and lower fracture toughness can be tolerated. 26. Name some exotic metallic alloys (Special alloys). Inconel 718 (Nickel alloy) Inconel 625 (Nickel alloy) Monel (Nickel alloy) Rene 41 (Nickel alloy) 27. What is Monel and what is it used for? Monel is a nickel alloy of approximately two-thirds nickel and one-third copper and may have small amounts of other metals like iron and manganese. It has high strength and resistance to a range of corrosive media including seawater, hydrofluoric and sulfuric acids, and alkalis. Monel is a registered trademark of Special Metals Corporation. Monel is nonmagnetic. 28. What is Rene 41 used for? Rene 41 is used for structural applications requiring good mechanical properties and oxidation resistance at high temperatures. It has good corrosion resistance and is heat treatable, but very poor fusion weldability. 29. What is the maximum sheet metal thickness for Aluminum, Titanium and Steel? 0.249 for Aluminum, 0.187 for Titanium and Steel. 30. What are the commonly used sheet metal materials for Aluminum? 2014, 2024, 2219, 6061, 7075, 7475. 31. What are the commonly used sheet metal materials for Steel and Stainless Steels? 4130, 300-Series, A-286, 17-7PH, 12-9-2. 32. What are the commonly used sheet metal materials for Titanium? Commercially Pure Titanium, 6Al-4V. 33. What are the commonly used sheet metal materials on special alloys? Inconel 718, Inconel 625. 34. Name some composite materials: Fiberglass, Aramid Fiber (Kevlar), Graphite, Carbon Fiber 35. How are the plies laid in a composite lay-up? In 0, +/- 45 deg and +/- 90 deg angles 36. Name Thermosetting Resins in composites. Epoxies, Phenolics, Polyurethanes, polyesters and silicones. 37. What are the materials for Honeycomb Core? Nomex paper, Aluminum, Aromatic Polyamide paper. 38. What kind of sanding material is used after repair of a composite part to sand the repaired part? 180 grit or finer Silicon Carbide abrasive paper. 39. What are the common methods of trimming sheet metal periphery? Routing, Shearing, Blanking, sawing. 40. What are the common methods of producing holes in sheet metal? Punching, drilling, piercing, and blanking. However, load carrying attachment holes and slots in primary and secondary structures are not punched, blanked or pierced to full size. Planning should allow for a minimum of .020 for clean-up in hole diameter.

41. List the temper / condition at which Aluminum alloys can be formed. 6061 -------- 0, T4, T6 2024 -------- 0, T3, T361, T81 2219 -------- 0 7075 -------- 0, T6, T76 42. List the condition at which Titanium can be formed. Commercially Pure, 6AL-4V and 6AL-4V-2Sn are formed in annealed condition. 43. What is bend allowance? Bend Allowance is the length of sheet metal required to make a bend over a given inside radius (that is, it is the distance from the beginning to the end of the bend). Bend allowance can be calculated by an empirical formula. See design manual.

44. Can you Straighten aluminum alloys in the T3 and T4 tempers? No, aluminum alloys are not to be Straightened in the T3 and T4 tempers. 6000 series aluminum alloys in all tempers and 2024 aluminum alloys in T3 and T4 tempers are to be straightened at room temperature. 45. What are the different forming techniques? Break Forming, Press Forming, Roll Forming, Peen Forming, Stretch Forming, Spin Forming, Drop Hammer Forming, Hot sizing. 46. What are the Rivet sizes? Rivets normally come in 1/16, 3/32, 1/8, 5/32, 3/16, 1/4, 5/16 and 3/8. 7/32 and 9/32 rivets are considered as oversize replacements. 47. What is the edge distance on metallic and composite parts? Metallic: 2D+.030 (NGC), 2D+1/16 (Boeing), 1.5D (Lockheed C5) Composites: 2.5D 48. What is pitch and Gauge? Pitch is the distance between the centerlines of fasteners in a single row. Gauge is the distance between rows of fasteners. 49. What is a BJ6 fastener? MS20470AD6 universal head rivet. 50. What is a LZ6 fastener? NAS1097AD6 Flush head (Countersunk head) rivet. 51. What is the first oversize for a 3/16 fastener? Oversize fasteners come in increments of 1/64th of an inch. First oversize for a 3/16 fastener is .1875 + 1/64 = .2031 Second oversize for a 3/16 fastener is .1875 + 2/64 = .2188 Third oversize for a 3/16 fastener is .1875 + 3/64 = .2344 The next size higher will be a .250 fastener.

52. Define MS20470AD4-24 Rivet MS20470 = Basic number for a Universal head or protruding head rivet AD = 2117-T4 Aluminum 4 = Diameter in 1/32nd increment -24 = Grip length in 1/16th increment 53. What are the Blind Rivets used for? Blind rivets are used where the rivet is not accessible from both sides. They have an integral mandrel that permits the formation of an upset on the blind end of the rivet. As the mandrel is pulled into or against the body being riveted it breaks at or near the intersection of the mandrel shank and its upset end. 54. What kind of Nut and Washer is used on an angled hole? Self Aligning Nut assembly with Ball and Seat Washer. Nut Assembly is composed of a Nut and A Seat Washer. Angle is from 0.5 to 8 degrees maximum. 55. What is an acceptable repair if a hole is too close to a radius, not allowing nut, washer, collar, or head of attachment to seat flush? A radius washer may be installed to replace standard washer provided that there is sufficient clearance for installation of fastener head or nut. This repair is not to be used with rivets of any type. 56. What is the maximum allowed shank diameter at bearing in a CSink? It is recommended that 20% of the sheet metal thickness be held for bearing. Never allow sheet metal thickness to fall below .010 at bearing shank diameter. 57. Name some commonly used Lockbolts. S4932867 ------ 100 Degree Crown Flush Rivet Head S4932868 ------ 100 Degree Crown Flush Shear Head S4932869 ------ Protruding Head S4931917 ------ 100 Degree Crown Flush Rivet Head S4931919 ------ 100 Degree Crown Flush Shear Head S4931920 ------ Protruding Head 58. What is a preferred, acceptable and prohibited fastener material on an Aluminum to Aluminum structural joint? Preferred: Anodized Aluminum. Acceptable: Titanium, A286, Inconel, Cadmium plated Steel or Monel. Prohibited: Monel, Copper, and Brass. 59. What is a preferred, acceptable and prohibited fastener material on Carbon Fiber Composite to all alloys in a structural joint? Preferred: Titanium, Inconel. Acceptable: A286, Monel. Prohibited: Cadmium plated Steel or Monel, Aluminum. 60. What is a preferred, acceptable and prohibited fastener material on Titanium to Aluminum structural joint? Preferred: Titanium. Acceptable: A286. Prohibited: Monel, Cadmium plated Steel or Monel. 61. What is maximum unshimmed gap and maximum shim thickness? Maximum unshimmed gap is 0.005 inch, and maximum shim allowed is 0.040 inch. 62. Name various Non-destructive testing methods (NDT or NDI) Radiographic inspection (X-Ray), Magnetic particle inspection, Ultrasonic inspection, Eddy Current, Infrared, Holography, Dye or Fluorescent Penetrant Inspection. 63. What is the purpose of Magnetic Particle Inspection? To find defects like cracks and inclusions on ferrous materials. 64. What is the purpose of Fluorescent penetrant inspection?

Fluorescent penetrant (Zyglo) inspection is used for nonmagnetic materials to find surface defects like cracks or other discontinuities. 65. What is the purpose of dye-penetrant inspection? To reveal cracks or other defects. The dye-penetrant process involves the use of a highly penetrating dye which seeps into cracks or other defects. A white developer is applied, and the dye coming out of the defect through the film of developer reveals the defects as a bright red spot or line. 66. What is the purpose of Ultrasonic inspection? To reveal sub-surface flaws in metal parts. 67. What is the purpose of Eddy-Current inspection? Eddy-current inspection is used to reveal flaws inside the parts in a manner similar to ultrasonic inspection except that electromagnetic waves are used to penetrate the material rather than sound waves. 68. What is the purpose of X-Ray inspection? X-ray inspection, or radiography, is often used for the inspection of metal parts. Avery powerful X-ray machine is used to produce the rays necessary to penetrate metal. The rays pass through the metal and impinge upon a photographic plate. Flaws in the metals will be revealed as shadows in the picture of the part. 69. What is DFMA and what is its intent? Design for Manufacture & Assembly. The intent is to accomplish a design that allows the most effective and efficient manufacturing methods without compromising the performance of the finished part. Design has to be coordinated with producibility to ensure practicality of manufacturing. An example is closed angle flanges on machined parts. Designer has to make sure that when installing fasteners, tools do not interfere with adjacent structure or fasteners. 70. Name commonly used welding methods. Fusion welding, Oxy-Hydrogen welding, Gas Tungsten Arc welding, Gas Metallic Arc welding, Shielded Metallic Arc welding, Electron Beam welding, Resistance welding, Spot welding, Seam welding, Orbital Tube welding, Flash welding, Inertia welding, Capacitor Discharge Stud welding, Pressure Gas welding. 71. Draw welding symbol for fillet weld all around.

72. What is Spotface? A shallow circular or cylindrical recess, machined on part to offer a flat face against which to seat a fastener; a shallow counterbore. 73. What is Chem Milling? Chemical Milling is a process that uniformly removes metals from an entire part or from selected areas by chemical etching of exposed surfaces. Unexposed surfaces are protected by a rubberized maskant that is applied by spaying, dipping or brushing. 74. What is the purpose of Cad Plating? Cadmium Electroplating is a soft ductile coating which provides corrosion prevention for parts made of steel and copper alloys. It reduces the dissimilar metal effect between steel and copper in contact with aluminum and magnesium. It has no effect on the fatigue strength of the base metal. 75. What is the purpose of Chromium Plating? To provide a hard and wear resistant surface for steel parts and to reduce friction. Chrome plating causes some loss of fatigue strength and ductility in the base metal. 76. What is the purpose of Electrolytic Nickel Plating? To provide a wear resistant surface for light and medium loads. Electrolytic Nickel Plating also provides good corrosion prevention either by itself or when overplated with chromium.

77. What is the purpose of Electroless Nickel Plating? Electroless Nickel Plating is used on ferrous materials. It has good corrosion resistance up to 1000 deg F and moderate abrasion and wear resistance. Plating thickness should be 0.0015 to .002 inches. 78. What is CC coating and what is it used for? Colorless Conversion coating. It is used on the exterior of clad and low alloy aluminum skins. 79. What is MC coating and what is it used for? Multi-Colored Chemical Conversion Coating. It provides a suitable surface for paint for all aluminum alloys. 80. What is the purpose of hard anodizing? Hard anodizing is an electrolytic process which produces a hard abrasion and corrosion resistant coating on most aluminum alloys. 81. What are the different types of Anodize and what are they used for? Chromic Acid Anodize It provides corrosion resistance and a good surface for paint adhesion. It is used for all non-clad structural aluminum parts. It produces a coating thickness of 0.00005 to 0.0002 inch. Sulfuric Acid Anodize It provides more corrosion protection than chromic acid anodize. However it can decrease the fatigue strength of a part. It produces a coating thickness of 0.0003 to 0.0005 inch. 82. What is honing? Honing is a low speed surface finishing process for producing uniformly high accuracy and fine finish holes. It produces a surface smoothness beyond that achievable by standard machining or grinding processes. 83. Describe your knowledge of GD & T. Describe what you know about Positional tolerance, Flatness, Straightness, Cylindricity, Perpendicularity, Parallelism, Profile of a surface, Profile of a line, Concentricity and Symmetry. 84. What is MMC? Maximum Material Condition. 85. What is the consequence if the load path is wrong but you have a positive margin in sizing? (One word answer) Overweight. Part will end up becoming overweight. (Goodrich question) 86. What is Power Copy in CATIA? (Goodrich question) 87. What is the difference between Extract and Extrude in CATIA? (Goodrich question) Extract function will extract a line or surface from a solid, but extrude function will use a 2D geometry and extrude it to make a 3D solid. 88. If you are already working on one part and your boss approaches you and asks you to do something more, what do you do and how do you handle the stress? (Goodrich question) This is called Multi-tasking. Explain how you are capable of performing several tasks at the same time. 89. What is the difference between R&D/Conceptual design and Production design? (Goodrich question) During conceptual design you virtually have an open hand and many factors that affect the design are unknown but during production design all the elements that affect the design are known such as interfacing parts, ED, pitch, etc. 90. Can you explain how you designed a part from conceptual phase all the way through release? (Goodrich question) Explain all the steps you took to design a part from conceptual phase through release. 91. How do you determine your datums? (Goodrich question) 92. Explain how you interface with ME. (Goodrich question) Explain all your interactions with ME during design of a part / assembly.

93. In your sizing what thickness do you start with and explain the interaction process with Stress. (Goodrich question) We start with minimum thickness, for example 0.040 on a web thickness, and increase the thickness after FEM determines final thickness. 94. How do you resolve Cost vs. Schedule? (Goodrich question) No right or wrong answer. Depends on the situation. 95. Explain a trade study on Sizing. (Goodrich question) Pick an example of a part that you designed and go over the process. 96. In sequence of importance, put a number of 1 thru 7 in front of each item: (Goodrich question) Primary Structure Cost Inspectabilit y Maintainabil ity Performanc e Producibility Reliability Weight Secondary Structure

97. Describe a time when you were working on a team project and you had to motivate your teammates to accomplish their tasks. What was the situation? What role did you play? What was the outcome? (Boeing question) 98. Tell me about a time when you had to meet multiple deadlines. What was the situation? What did you do? How did you handle this situation and what was the result? Explain multi-tasking jobs that you performed. (Boeing question) 99. What are some typical finishes on surfaces of aircraft parts? 125, 63, 32, 16, 4 100. What is Elox and some of its uses? The Elox Electron Drill removes metal by the electrical discharge machining method. Elox electron drills are useful in the rework of parts and assemblies by providing a method of removing broken taps, drill, and other metal parts which can not be removed mechanically. 101. What do you know about manufacturing process? (Boeing question) 103. As you know Boeing has had some issues with ethical practices. To you, what is integrity? (Boeing question) 104. How do you handle difficult people? (Boeing question) 105. Describe a situation when you had a conflict (in design, process, etc) with a supplier. What actions did you take and how you resolved the conflict? (Boeing question) 106. Do you prefer to work by yourself or in a team environment? (IPT concept) (Boeing question) 107. Explain how you designed a part from concept through release. (Boeing question) 108. What Air force manuals are you familiar with? (Boeing question)

Aircraft Illustrated Parts Catalog, Mil Hand Book 5, etc 109. Which is more important? Quality, Cost, Schedule? How do you resolve the conflict? (Boeing question) 110. What do you do when another engineer disagrees with your disposition / Design? (Boeing question) 111. Describe how you interact with other disciplines such as Stress, ME, etc? (Boeing question) 112. What is Local and absolute axis system in CATIA? Which one do you use to model a part? (Boeing question) 113. What do you know about Lean Process or Lean Manufacturing? (Boeing question) 114. What different types of aircrafts have you had experience on? (Boeing question) 115. Name some aircraft fasteners. (Hilocks, Lock blots, rivets, nut plates, washers). (Boeing question) 116. What ED and Pitch do you use for fasteners? (Boeing question) 117. Are you familiar with PSDS, IDEA and REDARS? (Boeing question) 118. Why do you want to come here? (Boeing question) 119. Describe your knowledge of Liaison Engineering. What is it all about? (For Liaison Engineering jobs) (Boeing question)