MOHAMED SATHAK ENGINEERING COLLEGE DEPARTMENT OF AERONAUTICAL ENGINEERING AIRFRAME MAINTENANCE AND REPAIR 1.

WELDING IN AIRCRAFT STRUCTURAL COMPONENTS Equipments used in welding shop and their maintenance Ensuring quality welds Welding jigs and fixtures Soldering and brazing. SHEET METAL REPAIR AND MAINTENANCE Inspection of damage Classification Repair or replacement Sheet metal inspection N.D.T. Testing Riveted repair design, Damage investigation reverse technology.
PART A Questions

1. How will you define Airframe? 2. How will you define beam, strut and tie? 3. Define Load Factor. 4. What is Forge welding? 5. What is Fusion Welding? 6. What are the types of fusion welding? 7. What are the different types of joints in welding process? 8. What is the difference between TIG and MIG welding? 9. What is reinforcement in welding? 10. What are the different parts of a weld? 11. Write the components of Oxy-Acetylene welding. 12. Write the safety equipments used in welding process. 13. How will you classify the flames. 14. Write any two characteristics of weld. 15. What is Stagger and Skip welding? 16. Write any 2 advantages of inert gas welding. 17. What is Soldering? 18. What is Brazing? 19. What are the different types of Soldering methods? 20. What is Sweat soldering? 21. What are the different types of Brazing methods? 22. How will you define Sheet metal. 23. What is Stress corrosion? 24. What is NDT? and write the different types of NDT methods. 25. What is Magnetic particle inspection?
PART B Questions

1. Explain briefly about the types of Fusion Welding process. 2. What is Nomenclature? Explain Welding nomenclature.

3. Write short notes on different equipments used in a welding shop. 4. What are the safety equipments used in Welding shop. Explain them. 5. How will you ensure the quality of Weld. 6. Write short notes on welding Jigs. 7. Write short notes in Sheet metal damages and inspection of damages. 8. How will you classify the sheet metal damage. 9. Write notes on dye penetrant, fluorescent penetrant, and magnetic particle inspection. 10. Write notes on Radiography, ultrasonic and Eddy current inspection. 11. Discuss about the various guidelines involved in Rivet repair. 12. Explain briefly about the MIG and TIG welding process with their advantages and disadvantages. 13. Write notes on the following : a. Resistance soldering b. Induction soldering c. Furnace soldering d. Sweat soldering e. Soft soldering 14. Explain the following : a. Torch flame b. Neutral flame c. Carburizing flame d. Oxidizing flame 15. Define the following defects: a. Brinelling b. Burnishing c. Burr d. Corrosion e. Crack f. Dent g. Erosion 2. PLASTICS AND COMPOSITES IN AIRCRAFT Review of types of plastics used in airplanes Maintenance and repair of plastic components Repair of cracks, holes etc., various repair schemes Scopes. Inspection and Repair of composite components Special precautions Autoclaves.
PART A Questions

1. Define plastics? 2. Write two chemical structure of thermoplastics? 3. Write the properties of transparent plastics?

4. Define cracking? 5. What are the precautions are recommended to prevent formation of plastics? 6. Write three techniques are used to remove paint on plastics? 7. Write the repair of crack on welding shield? 8. Define composites? 10.What is Advanced composites? 11.Write the advantages of using composite materials. 12. What is fibre glass? 13. Write the two phase structure of composite metal? 14. How industrial fibres are classified according to the properties? 15. What is carbon fibre? 16. What are hybrid composites? 17. What are the NDT used for composite inspection? 18. Define radiography? 19. What is delamination in composites? 20. Define blister? 21. Define dent. 22. What is crazing? 23. What is the material used in Aircraft wind shield? 24. How will you classify industrial fibres. 25. How will you repair the blister found in composites.
PART B Questions

1. Briefly explain the various types of plastics used in modern aircraft? 2. Briefly explain the maintenance of plastics? 3. How will you repair the cracks in the plastics? 4. How will you repair the holes in the plastics? 5. Briefly explain about the various types of plastics. 6. Briefly explain the composite materials used in the modern aircraft? 7. What are the advantages and disadvantages of composites? 8. Briefly explain the inspection of composites by various NDT? 9. Write the steps involved in composites repair? 10. Write the notes about repair to glass fibre laminates? 11. Write notes on Radiography, ultrasonic and X-ray testing. 12. Explain briefly about acoustic emission, holography and thermography testing. 13. How will you repair the scratches, dent, blister and delamination in glass fibre laminates. 14. Explain briefly about cleaning of plastics. 15. How will you inspect the damages in Plastics and Composites.

3. AIRCRAFT JACKING, ASSEMBLY AND RIGGING Airplane jacking and weighing and C.G. Location. Balancing of control surfaces Inspection maintenance. Helicopter flight controls. Tracking and balancing of main rotor.
PART A Questions

1. Write the four controls used in helicopter? 2. What is the purpose of collective pitch control? 3. What is the purpose of throttle control? 4. What is the purpose of anti torque pedals? 5. What is the purpose of cyclic pitch control? 6. Define rigging. 7. What is the purpose of measuring cable tension? 8. What is the role of Rulers? 9. What is the purpose of rigging checks? 10. What are the alignment checks? 11. How will you carry out dihedral checks? 12. Define checking incidence? 13. What is the principle of symmetry check? 14. What is blade tracking? 15. What is the principle of balancing? 16. Define the scale method of balancing? 17. What are the sources used to obtain the weight and balance data? 18. Define datum. 19. Define centre of gravity? 20. What is useful load?
PART B Questions

1. Briefly explain the collective pitch control and thrust control of the modern aircraft? 2. Write the brief notes about cycle pitch control with neat sketch? 3. Explain the aircraft rigging and its components? 4. Briefly explain the structural alignment of aircraft structural component? 5. Write the procedure of helicopter blade tracking? 6. Briefly explain the principle of balancing? 7. Briefly explain the aircraft weighing and C.G. location? 8. Write down notes on 1. Aircraft leveling means 2. Mean aerodynamic Chord 3. Weighing points. 4. REVIEW OF HYDRAULIC AND PNEUMATIC SYSTEM Trouble shooting and maintenance practices Service and inspection. Inspection and maintenance of landing gear systems. Inspection

and maintenance of air-conditioning and pressurisation system, water and waste system. Installation and maintenance of Instruments handling Testing Inspection. Inspection and maintenance of auxiliary systems Fire protection systems Ice protection system Rain removal system Position and warning system Auxiliary Power Units (APUs)
PART A Questions

1. 2. 3. 4.

Define trouble shooting. What is the purpose of flushing? What is the purpose of draining? What are the conditions to be checked for replacement of component? 5. What are the physical conditions for aircraft pneumatic system? 6. What is the purpose of dehydrator? 7. How will you check the leaks of pneumatic system? 8. What is the purpose of retraction test? 9. What is oleo pneumatic strut? 10. What is the function of pressure controller? 11. What is the purpose of discharge valves used in the pressure controller? 12. What is the purpose of testing of pressurization system? 13. What is the role of drier? 14. What is the maintenance for air conditioning system? 15. Write the two fire detector system? 16. What is EGT? 17. Write any two inspections carried out on APU? 18. What is surge control valve? 19. What is the maintenance checks required for pump in the Icing system? 20. What are the power supplies for gyroscope instruments? 21. Write the various engine instruments? 22. Define thermocouple? 23. What is the purpose of electrical pressure gauges?
PART B Questions

1. Briefly explain the testing and routine maintenance of Hydraulic system. 2. Describe the routine inspection of Pneumatic system? 3. What are the inspections for Oleo Pneumatic strut and write the retraction test of a landing gear? 4. Briefly explain the testing of pressurization system? 5. Briefly explain the leak rate test? 6. Describe the maintenance required or APU. 7. Describe the maintenance required or Air Conditioning system.

8. Briefly explain the proof test of fire extinguisher. 9. What are the main checks required for thermal de-icing system? 10. Briefly explain the inspections of instruments in the modern airliner? 11. Briefly explain the inspections required for pitot-static system? 12. What inspections / maintenance required for manifold pressure gauge, EPR, thermocouple? 5. SAFETY PRACTICES Hazardous materials storage and handling, Aircraft furnishing practices Equipments. Trouble shooting - Theory and practices.
PART A Questions

1. Write the flammable / combustible materials in the aviation industry? 2. What are corrosive materials? 3. Define Toxins. 4. Define Reactives. 5. Define Physical hazards. 6. What is MSDS? 7. Write the physical data for hazardous materials? 8. Define flash point? 9. What is the indication of color for diamond coding system? 10. What is the ultimate object of troubleshooting in aviation? 11. What is the use of trouble shooting charts? 12. What are the formats used to display troubleshooting logic? 13. What is the use of Binary logic chart? 14. What is called truth table?
PART B Questions

1. Briefly explain the generally recommended personal safety equipment? 2. Explain Biological hazards and write fire basic requirements of a hazard communication program? 3. Briefly explain the material safety data sheet. 4. Describe the labeling of hazardous materials. 5. Describe the disposal and accidental release of hazardous material? 6. Briefly explain the trouble shooting process? 7. Write about trouble shooting charts?