2A753 Volume 4 Structural Maintenance Journeyman

65 Questions | Total Attempts: 240

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2A753 Quizzes & Trivia

When an aircraft suffers damage, it’s essential to fix it and get back in the air. A structural maintenance journey man is responsible for repairing physical damage, Aircraft Structural Maintenance specialists maintain the high quality structures of Air Force aircraft. Find out if you're qualified to be a structural maintenance journey man.


Questions and Answers
  • 1. 
    (601) Other assemblies are directly or indirectly attached to what main aircraft structural assembly?
    • A. 

      Wings.

    • B. 

      Nacelles.

    • C. 

      Fuselage.

    • D. 

      Empennage.

  • 2. 
    (601) What reduces sway or yaw about the vertical axis of an aircraft?
    • A. 

      Wings.

    • B. 

      Fuselage.

    • C. 

      Vertical stabilizer

    • D. 

      Horizontal stabilizer

  • 3. 
    (601) When the cockpit control is moved to the right, the right
    • A. 

      And left ailerons move up.

    • B. 

      And left ailerons move down

    • C. 

      Aileron moves up and the left aileron moves down

    • D. 

      Aileron moves down and the left aileron moves up.

  • 4. 
    (601) Which of these is an auxiliary flight control?
    • A. 

      Flap.

    • B. 

      Rudder.

    • C. 

      Elevator.

    • D. 

      Stabilizer.

  • 5. 
    (601) What provides shape, strength, and rigidity to the aircraft fuselage?
    • A. 

      Spars.

    • B. 

      Stringers.

    • C. 

      Longerons.

    • D. 

      Bulkheads.

  • 6. 
    (601) Aircraft reference lines that indicate vertical planes parallel to the plane of symmetry are called
    • A. 

      Waterlines.

    • B. 

      Buttock lines

    • C. 

      Wing stations

    • D. 

      Fuselage stations

  • 7. 
    (602) What symbol do you enter on the Air Force Technical Order (AFTO) Form 781A when an aircraft is considered unsafe or unfit for flight?
    • A. 

      Red X.

    • B. 

      Red Plus

    • C. 

      Red Dash

    • D. 

      Red Diagonal

  • 8. 
    (602) When a new Air Force Technical Order (AFTO) Form 781A is initiated, what kind of discrepancies must not be transferred to the AFTO Form 781K?
    • A. 

      Red X.

    • B. 

      Red Dash

    • C. 

      Red Diagonal

    • D. 

      Discrepancies with a supply document number

  • 9. 
    (602) What block on the Air Force Technical Order (AFTO) Form 781H do you check after entering a Red X discrepancy in the AFTO Form 781A?
    • A. 

      STATUS TODAY

    • B. 

      SYMBOL STATUS

    • C. 

      CURRENT STATUS

    • D. 

      STATUS CONDITION

  • 10. 
    (603) When performing a visual inspection on nicked plastic assemblies, what are you looking for?
    • A. 

      Nicked area is near the edge of the plastic and spreading inward

    • B. 

      White powdered glass is often seen in a chipped area

    • C. 

      Visibility through the nicked area is slight

    • D. 

      Chipped area has a smooth appearance

  • 11. 
    (603) When inspecting for distortions, besides excellent lighting what else do you use?
    • A. 

      A grid made up of horizontal and vertical lines

    • B. 

      Viewing lines through panel at a distance of at least 40ft away

    • C. 

      A dark background placed outside of the panel while viewing from inside

    • D. 

      A dark grid made up of parallel curved lines of varying lengths and thicknesses

  • 12. 
    (604) When classifying damage to a composite structure, a puncture of a fiberglass panel that extends through one facing is which classification?
    • A. 

      Repairable.

    • B. 

      Class III

    • C. 

      Class II.

    • D. 

      Class I.

  • 13. 
    (604) When is it acceptable to have bubbles on a plastic window?
    • A. 

      Bubbles are never acceptable

    • B. 

      They only impair vision along the edges of the panel.

    • C. 

      They are well scattered and within acceptable number, diameter and spacing

    • D. 

      They do not impair vision, are well scattered and within the limitations of the TO.

  • 14. 
    (605) According to the basic principle of repair, when you make any repair your main concern is the original
    • A. 

      Strength.

    • B. 

      Contour.

    • C. 

      Stresses.

    • D. 

      Weight.

  • 15. 
    (605) Before fastening the doubler and filler together for a flush repair, the repair parts must be
    • A. 

      Filled in with aerodynamic smoothing compound

    • B. 

      Curved to the precise contour of the repair area

    • C. 

      Cut into a circular repair patch

    • D. 

      Replaced as soon as practical

  • 16. 
    (606) When repairing damage to an aircraft, the first step in removing the damaged area is to determine
    • A. 

      How much undamaged area should be removed

    • B. 

      If the damage is near a sub-structural member.

    • C. 

      If the damage is in an open area.

    • D. 

      The final size of the patch.

  • 17. 
    (606) When you’re preparing a cutout for an “open area,” you remove all damage and
    • A. 

      Stop-drill all cracks.

    • B. 

      Relieve stress concentrations.

    • C. 

      Make sure the cutout is centered over a sub-structural member.

    • D. 

      Anneal the cutout areas so the area is not work-hardened during the cutout operation.

  • 18. 
    (606) What factors do you consider when selecting a twist drill to use for chain-drilling removal techniques?
    • A. 

      Size and location of the cutout area

    • B. 

      Diameter and head style of repair fasteners

    • C. 

      Material composition and thickness of the cutout area

    • D. 

      Location of existing fasteners within and outside the cutout area

  • 19. 
    (606) You must consider the location of any existing fasteners near a damaged area when determining the
    • A. 

      Overall size of the cutout

    • B. 

      Material thickness of the repair parts

    • C. 

      Number of fasteners required for the repair

    • D. 

      Classification of the repair to be accomplished

  • 20. 
    (606) An angle drill is used to remove damage when
    • A. 

      The damage is in a limited space

    • B. 

      The skin and sub-structural damage cutout are the same

    • C. 

      The skin and sub-structural damage cutout are not the same

    • D. 

      Only the skin is damaged and the sub-structural member is intact

  • 21. 
    (607) Before you develop a rivet layout for a circular flush repair, you must first establish the
    • A. 

      Center point of the cutout area.

    • B. 

      Head style of the rivets to be used

    • C. 

      Rivet spacing required on the filler plate

    • D. 

      Direction of the stress concentrations within the part being repaired

  • 22. 
    (607) If the location of the rivets on the inner and outer rows of a layout pattern on a square flush patch are the same then the
    • A. 

      Wrong measurements were used to develop the rivet pattern

    • B. 

      Rivet spacing and row spacing are identical

    • C. 

      Doubler is twice the size of the filler plate

    • D. 

      Edge distance is beyond acceptable limits

  • 23. 
    (607) Which layout procedure is very important when developing a rivet pattern for a flush skin repair over a substructural member?
    • A. 

      Locating the centerline of the cutout area to use as a starting point

    • B. 

      Measuring edge distance from the outer edges of the substructural member

    • C. 

      Determining the edge distance requirements for the different head styles of the rivets

    • D. 

      Placing the lengths of rivets required in the repair because of the substructural member

  • 24. 
    (607) To properly develop a rivet pattern for a flush skin repair across a substructural member, the rivet spacing used for calculating the row spacing is the
    • A. 

      Existing rivet spacing for the fasteners in the substructural member

    • B. 

      Smallest rivet spacing available regardless of where the cutout area is located

    • C. 

      Strongest rivet spacing possible based on the diameter of the rivets used in the repair

    • D. 

      Rivet spacing used on one side of the cutout, opposite the width of the substructural member

  • 25. 
    (608) When fabricating a doubler for a flush skin repair in an open area
    • A. 

      Select material that is one-gage thicker than the skin

    • B. 

      Position the doubler material inside the cutout

    • C. 

      Develop a fastener layout on the patch plate

    • D. 

      Split the doubler into two parts.

  • 26. 
    (608) When fabricating a filler plate for a flush skin repair in an open area, you determine the overall dimensions of the filler by
    • A. 

      Using the cutout area as a template

    • B. 

      Using the dimensions of a previously installed flush repair

    • C. 

      Measuring the damaged area before making the skin cutout

    • D. 

      Multiplying the length of the damage by the width of the damage, and adding the edge distance requirements

  • 27. 
    (608) In which situation is a fastener layout more than likely done on the patch instead of the repair part?
    • A. 

      Open area with existing fasteners.

    • B. 

      Blind area with existing fasteners.

    • C. 

      Open area with no existing fasteners.

    • D. 

      Blind area with no existing fasteners

  • 28. 
    (608) In addition to the amount of damage to each member, what other factor must you consider when determining the size of the cutout for a combination repair?
    • A. 

      Type of cutting tools to use

    • B. 

      Location of existing fasteners

    • C. 

      Thickness of the parts being repaired

    • D. 

      Material composition of the damage parts

  • 29. 
    (609) As it applies to the installation of repair parts, what is a primer and when is it applied?
    • A. 

      Cleaning solvent; applied before painting

    • B. 

      Precleaning agent; applied before using an approved solvent

    • C. 

      Corrosion preventative; applied before the installation of repair parts.

    • D. 

      Bonding agent; applied on repair parts to provide a base for a corrosion preventative

  • 30. 
    (609) Before applying an aerodynamic smoothing compound to repair seams
    • A. 

      Smooth the edges with sandpaper

    • B. 

      Clean the area with distilled water

    • C. 

      Smooth the edges with a rotary file.

    • D. 

      Clean the area with an approved solvent

  • 31. 
    (609) The method you use to remove excess aerodynamic smoothing compound from seams depends on the
    • A. 

      Hardness of the material sealed

    • B. 

      Hardness of the compound surface

    • C. 

      Amount of heat used to cure the compound

    • D. 

      Temperature and relative humidity at the time the compound was applied

  • 32. 
    (610) When welding thermocouples follow the
    • A. 

      Equipment manufacturer’s instructions

    • B. 

      Technical Order (TO) 1–1–690

    • C. 

      Thermocouple manual

    • D. 

      Aircraft specific TO

  • 33. 
    (611) When performing a routing operation on a tapered surface, the minimum length of the required wedge blocks is
    • A. 

      3"

    • B. 

      4"

    • C. 

      5"

    • D. 

      6"

  • 34. 
    (611) When drilling aramid composite materials, how can you minimize fiber fuzz?
    • A. 

      Use a dagger spade or brad point bit

    • B. 

      Use a high speed, low-feed when drilling

    • C. 

      Use a Carbide or diamond-coated drill bit

    • D. 

      Use a split helix bit with either two or four helical flutes

  • 35. 
    (612) What cardinal rule must be followed when removing damage from a composite structure?
    • A. 

      Remove a minimum of sound material

    • B. 

      Make the cutout to a round configuration

    • C. 

      Use the scarf method to make an oval cutout

    • D. 

      Use the step-joint method to make a square cutout

  • 36. 
    (612) What is your first step when fabricating a patch for a composite repair?
    • A. 

      Create a patch drawing

    • B. 

      Make a cutting template

    • C. 

      Layout a stacking template

    • D. 

      Draw orientation lines on the repair patch

  • 37. 
    (613) When selecting a resin to repair laminated fiberglass assemblies, what must you know besides the method of curing?
    • A. 

      Overall size of repair

    • B. 

      Number of plies being replaced

    • C. 

      Resin used by the manufacturer

    • D. 

      Curvature of the area being repaired

  • 38. 
    (614) To provide a more uniform bondline thickness when making a metal-bonded honeycomb repair, you use a
    • A. 

      Film adhesive

    • B. 

      Foam adhesive

    • C. 

      Paste adhesive

    • D. 

      Liquid adhesive

  • 39. 
    (614) How do paste adhesives compare with other types as far as strength is concerned?
    • A. 

      Lower in strength

    • B. 

      Higher in strength

    • C. 

      Lower in strength only when the paste adhesive is a two-part mixture.

    • D. 

      Higher in strength only when the paste adhesive is a two part mixture

  • 40. 
    (615) When storing advanced composite materials in cold storage, what is the maximum temperature permitted?
    • A. 

      0ºF

    • B. 

      32ºF

    • C. 

      60ºF

    • D. 

      72ºF

  • 41. 
    (616) How do you apply uniform pressure to laminated fiberglass repairs?
    • A. 

      C-clamps.

    • B. 

      Pressure tape

    • C. 

      Pressure plates

    • D. 

      Vacuum pressure

  • 42. 
    (617) When making a step-joint repair to an aramid honeycomb composite panel, you make the replacement plies
    • A. 

      At right angles to each ply in the original panel

    • B. 

      To match each ply in the original panel

    • C. 

      At 30° to each ply in the original panel.

    • D. 

      At 45° to each ply in the original panel

  • 43. 
    (617) What procedure is used in a step-joint removal method?
    • A. 

      Fit the innermost patch (largest) to the area first

    • B. 

      The first ply is cut so at least ½″ overlaps the inner edges

    • C. 

      The first ply is cut so at least ¼″ overlaps the outer edges

    • D. 

      The edges of the patch are butted to the existing bond ply

  • 44. 
    (617) What is the first step in a scarf repair?
    • A. 

      Find the center point of the damage

    • B. 

      Remove the top damaged ply

    • C. 

      Find the edges of the damage

    • D. 

      Remove any paint

  • 45. 
    (618) When drilling holes in a delaminated area of a metal-bonded honeycomb panel for injecting adhesive,
    • A. 

      Pilot-drill all holes to avoid drilling into cells walls

    • B. 

      Step-drill all holes to ensure proper adhesive injection

    • C. 

      Drill holes first at the top and bottom of the delaminated area

    • D. 

      Drill deep enough into the core material to permit the adhesive flow to remove any moisture present.

  • 46. 
    (618) What step must be taken when doing a partial-through repair that is not done on a full core replacement repair?
    • A. 

      Install a 0.010″ aluminum sheet shim

    • B. 

      Cut the replacement core larger than the cutout

    • C. 

      Cut one disk of adhesive film to the size of the cutout

    • D. 

      Ensure the overlap of the patch plate is a minimum of 2″.

  • 47. 
    (619) How many thermocouples are used and how are they positioned on a wet laminate when removing moisture?
    • A. 

      One; 2″ from the edge of the heat blanket

    • B. 

      Two; 2″ from the edge of the heat blanket.

    • C. 

      Three; equally spaced around the damaged area.

    • D. 

      Four; equally spaced around the damaged area

  • 48. 
    (619) How do you determine if water has been removed or has migrated to another location when removing moisture from a honeycomb composite panel?
    • A. 

      Use a tap hammer

    • B. 

      Visually inspect area

    • C. 

      Re-inspect area using a borescope

    • D. 

      Re-inspect area using nondestructive inspection (NDI).

  • 49. 
    (620) What important factor must be known before polishing out a scratch on an acrylic assembly?
    • A. 

      If any distortion caused by the scratch will be removed when the scratch is removed

    • B. 

      The thickness the acrylic plastic assembly will be after polishing

    • C. 

      If the assembly can be annealed after the polishing operation

    • D. 

      The exact width of the scratch

  • 50. 
    (620) The sanded area of a scratch is washed down after each sandpaper grit is used to
    • A. 

      Cool off the sanded area

    • B. 

      Prevent the area from crazing

    • C. 

      Keep the sanded area lubricated

    • D. 

      Wash away the previously used sandpaper grit

  • 51. 
    (621) When disassembling a transparent plastic assembly, what is the value of drawing a diagram on cardboard showing the location of the fasteners?
    • A. 

      Loss of fasteners is reduced

    • B. 

      Proper placement of fasteners is ensured

    • C. 

      Missing or broken fasteners can be easily ordered.

    • D. 

      Torquing requirements can be determined for each size and type of fastener

  • 52. 
    (621) Before installing a plastic assembly into its retaining frame, clean the frame with
    • A. 

      A mild soap and water solution

    • B. 

      An approved solvent

    • C. 

      A high detergent soap

    • D. 

      Alcohol.

  • 53. 
    (622) When using an original door as a template, you must make sure the original door has
    • A. 

      A hinge.

    • B. 

      The proper fit.

    • C. 

      All paint removed

    • D. 

      All attaching hardware

  • 54. 
    (622) What should you do to an aircraft panel before you fine finish the edges?
    • A. 

      Alodine the panel.

    • B. 

      Fit test the panel

    • C. 

      Prime the panel

    • D. 

      Paint the panel

  • 55. 
    (622) When trimming aircraft panels or doors, you make a template out of plastic when
    • A. 

      Time is critical

    • B. 

      You need to see through the template

    • C. 

      There isn’t a piece of metal to be found

    • D. 

      The original panel is missing or badly damaged

  • 56. 
    (623) Which balancing method is accomplished on the aircraft?
    • A. 

      Scale/trial-error.

    • B. 

      Trial weight

    • C. 

      Component.

    • D. 

      Calculation.

  • 57. 
    (623) Which balancing method requires you to know the weight of the material removed from the repair area?
    • A. 

      Component.

    • B. 

      Calculation.

    • C. 

      Trial weight

    • D. 

      Scale/trial-error.

  • 58. 
    (623) What method of balancing control surfaces allows components to be interchangeable?
    • A. 

      Calculation.

    • B. 

      Component.

    • C. 

      Trial weight

    • D. 

      Scale/trial-error.

  • 59. 
    (624) You can detect aircraft sealant defects within a pressurized area by
    • A. 

      Performing a tack-free test while the area is pressurized

    • B. 

      Checking the adhesion of the seal by removing small sections

    • C. 

      Passing a listening device along the seams while the area is pressurized

    • D. 

      Applying a water-soap mixture to all seams while the area is pressurized and watching for bubbles.

  • 60. 
    (624) Your first step when repairing a defective fillet seal is to
    • A. 

      Cut the faulty section from the fillet

    • B. 

      Select the proper sealant cutting tools

    • C. 

      Cut around the seal and at the base of the fastener

    • D. 

      Grasp the seal with pliers and pull it away from the structure

  • 61. 
    (625) In order to use premixed frozen sealant, you should
    • A. 

      Use a heat gun to thaw the sealant

    • B. 

      Simply thaw the sealant and use it

    • C. 

      Use a heat lamp to thaw the sealant

    • D. 

      Allow the sealant to thaw overnight

  • 62. 
    (625) To clean dirt and grease from a surface to be sealed, you use
    • A. 

      Soapy water

    • B. 

      Alkaline cleaner

    • C. 

      An approved solvent/cleaner

    • D. 

      A high pressure water blaster.

  • 63. 
    (625) When cleaning a surface before applying a sealant, you can consider the cleaning operation completed
    • A. 

      When the cleaner dries on the surface

    • B. 

      When there is no discoloration on a clean drying cloth

    • C. 

      Only after the surface being cleaned meets tack-free requirements

    • D. 

      When no discoloration is picked up by one of your fingers touching the area

  • 64. 
    (625) What do you do if one-part sealant does not go on smoothly, easily, and evenly when applying it to an area?
    • A. 

      Add thinner

    • B. 

      Discard the sealant

    • C. 

      Add more accelerators

    • D. 

      Whip air into the sealant

  • 65. 
    (625) When preparing to mix a two-part sealant, you mix the sealant in accordance with the
    • A. 

      Job guide

    • B. 

      Technical order

    • C. 

      Shop operating instructions

    • D. 

      Manufacturer’s instructions