AIRCRAFT WELDING

4-1 E01
In Gas Tungsten Arc (GTA) welding, a stream of inert gas is 4-1. Answer B. JSAT 4-4
used to A stream of inert gas such as argon or helium flows out of
A concentrate the heat of the arc and prevent its dissi- the torch and envelopes the arc to exclude oxygen from the
pation. area and prevent the formation of oxides.
B prevent the formation of oxides in the puddle.
C lower the temperature required to properly fuse the
metal

4-2 E01
Which statement best describes magnesium welding? 4-2. Answer C. JSAT 4-16 (AC65-15A)
The filler rod should be of the same composition as the
A Filler rod should be nickel steel. base metal.
B Magnesium can be welded to other metals.
C Filler rod should be the same composition as
base metal.

4-3 E01
Which statement is true in regard to welding heat-treated
magnesium?
A Magnesium cannot be repaired by fusion welding
because of the high probability of igniting the metal.
B Flux should not be used because it is very difficult to
remove and is likely to cause corrosion.
C The welded section does not have the strength of the
original metal.
4-3. Answer C. (AC43.13-1B) (AC65-15A)
Repair of magnesium by welding is limited by the fact that
if it is used as a structural member, it has probably been
heat treated. As is true with heat treated aluminum,
welding heat treated magnesium does not leave as much
strength as the original metal had.

4-4 E02
The oxyacetylene flame for silver soldering should be 4-4. Answer C. JSAT 4-12 (AC43.13-1B) (AC65-15A)
The oxyacetylene flame for silver soldering should be neu
A carburizing. tral, but may have a slight excess of acetylene. It must be
B oxidizing. soft, not harsh. ....
C neutral.

4-5 E02
Why is it necessary to use flux in all silver soldering
operations?
A To chemically clean the base metal of oxide film.
B To prevent overheating of the base metal.
C To increase heat conductivity.
4-5. Answer A. JSAT 4-12 (AC65-15A)
It is necessary to use flux in all silver soldering operations
because of the necessity for having the base metal chemi-
cally clean without the slightest film of oxide to prevent
the silver solder from coming into intimate contact with
the base metal.
4-2 Building Professional Experience

4-6 E03 4-6. Answer C. (AC43.13-1B) (AC65-15A)

Engine mount members should preferably be repaired by All welding on an engine mount should be of the highest
using a quality, since vibration tends to accentuate any minor
defect. Engine-mount members should preferably be
A smaller diameter tube with fishmouth and rosette repaired by using a larger diameter replacement tube
welds. telescoped over the stub of the original member, using
B larger diameter tube with fishmouth and no fishmouth and rosette welds.
rosette welds.
C larger diameter tube with fishmouth and rosette
welds.

4-7 E03 4-7. Answer A. JSAT 4-17 (AC43.13-1B)

What method of repair is recommended for a steel tube A dent at a cluster should be repaired by welding a specially
longeron dented at a cluster? formed steel patch plate over the dented area and surround-
ing tubes, as shown in the AC43.13-1B.
A Welded patch plate.
B Welded split sleeve.
C Welded outer sleeve.

4-8 E04 4-8. Answer A. (43.13-1B) (AC43.13-1B)

Welding over brazed or soldered joints is Do not weld brazed or soldered parts as the brazing
mixture or solder will penetrate the hot steel and weaken it.
A not permitted.
B permissible for mild steel.
C permissible for most metals or alloys that are not heat
treated.

4-9 E04 4-9. Answer A. JSAT 4-13 (AC65-15A)

Which statement concerning soldering is correct? Joints must be mechanically secure before soldering. If a
soldered joint is subject to vibration, it can fail .
A Joints in electric wire to be soldered should be
mechanically secure prior to soldering.
B Changeable shades of blue can be observed on the sur-
face of a copper soldering tip when the proper tem-
perature for soldering has been reached.
C If the soldering temperature is too high, the solder will
form in lumps and not produce a positive bond.

4-10 E04 4-10. Answer A. JSAT 4-13 (AC65-15A)

A resurfaced soldering iron cannot be used effectively until Without being tinned, heat cannot readily transfer from the
after the working face has been iron to the work.

A tinned.
B fluxed.
C polished.

4-11 E04 4-11. Answer A. (AC43.13-1B)

Which of the following can normally be welded without You must be very careful about using welding as a repair
adversely affecting strength? procedure. Generally materials, or weldments, which have
1. Aircraft bolts. been heat treated after fabrication are not candidates for
field welded repairs. 4130 steel tubing is commonly used
2. SAE 4130 chrome/molybdenum tubing. both during fabrication and repair.
3. Spring steel struts.
4. Most heat-treated steel/nickel alloy components.
A 2.
B 2 and 4..
C 1 and 3.
Aircraft Welding 4-3

4-12 E04 4-12. Answer C. JSAT 4-26 (AC43.13-1B)

In selecting a torch tip size to use in welding, the size of
the tip opening determines the
A melting point of the filler metal.
B temperature of the flame.
C amount of heat applied to the work.
The size of the tip used on an oxyacetylene torch will
determine the amount of heat applied to the work. The
thickness of the metal will determine which tip size is
required.

4-13 E04 4-13. Answer A. JSAT 4-23 (AC65-15A)

Why should a carburizing flame be avoided when welding Care must be taken when welding steel, to ensure that a
steel? carburizing (reducing) flame is not used. This flame is one
with an insufficient supply of oxygen to ensure complete
A It hardens the surface. combustion of the acetylene, and it allows carbon to
B It removes the carbon content. escape unburned. This carbon will combine with the steel
C A cold weld will result. during the welding operation and cause it to become hard
and brittle.

4-14 E04 4-14. Answer B. JSAT 4-26 (AC43.13-1B)

The most important consideration(s) when selecting weld- When selecting a welding rod, ensure that it is compatible
ing rod is/are with the materials to be welded.
A current setting or flame temperature.
B material compatibility.
C ambient conditions.

4-15 E04 4-15. Answer A. JSAT 4-15

The oxyacetylene flame used for aluminum welding The flame use for welding aluminum should be soft and
should neutral or slightly carburizing, to be sure that there will
be no possibility of the metal being oxidized from the
A be neutral and soft. welding.
B contain an excess of acetylene and leave the tip at a
relatively low speed.
C be slightly oxidizing.

4-16 E04 4-16. Answer C. JSAT 4-13 (AC65-15A)

A very thin and pointed tip on a soldering copper is
undesirable because it will
A transfer too much heat to the work.
B have a tendency to overheat and become brittle.
C cool too rapidly.
The tip on a soldering copper should be blunt and the
entire head should be fairly wide. These features allow the
soldering copper to retain its heat for a long enough period
of time to perform its intended function.

4-17 E04 4-17. Answer B. (AC43.13-1B)

Filing or grinding a weld bead Filing or grinding of a weld will reduce its strength.
A may be performed to achieve a smoother surface.
B reduces the strength of the joint.
C may be necessary to avoid adding excess weight or to
achieve uniform material thickness.

4-18 E04 4-18. Answer A. JSAT 4-22

Acetylene at a line pressure above 15 PSI Acetylene becomes unstable at pressures of 15 psi or higher.
At 30 psi it becomes so unstable that the slightest amount
A is dangerously unstable. of heat generated by the friction of acetylene against the
B should be used when a reducing flame is necessary. atmosphere will cause it to explode.
C is usually necessary when welding metal over
3
/8-inch thick.
4-4 Aircraft Welding

4-19 E04 4-19. Answer B. JSAT 4-22 (AC65-15A)

Cylinders used to transport and store acetylene Under low pressure at normal temperatures, acetylene is a
stable compound. But when compressed in a container to
A are green in color. pressures greater than 15 PSI, it becomes dangerously
B contain acetone. unstable. For this reason, manufacturers fill the acetylene
C are pressure tested to 3,000 PSI. storage cylinders with a porous substance and saturate
this substance with acetone. Since acetone is capable of
absorbing approximately 25 times its own volume of
acetylene gas, a cylinder containing the correct amount of
acetone can be pressurized to 250 PSI.

4-20 E04 4-20. Answer B. JSAD 47 (AC65-15A)

A welding torch backfire may be caused by
A using too much acetylene.
B a loose tip.
C a tip temperature that is too cool.
A backfire may be caused by touching the tip against the
work, overheating the tip, a loose tip or head, or dirt or
slag in the end of the tip.

4-21 E05 4-21. Answer A. JSAT 4-4 (AC65-15A)

Which statement concerning a welding process is true?
A The inert arc welding process uses an inert gas to
protect the weld zone from the atmosphere.
B I n the oxyacetylene welding process, the filler rod
used for steel is covered with a thin coating of flux.
C In the metallic arc welding process, filler material, if
needed, is provided by a separate metal rod of the
proper material held in the arc.
4-22 E05
Where should the flux be applied when oxyacetylene weld-
ing aluminum?
A Applied only to the welding rod.
B Painted on the surface to be welded and applied to
the welding rod.
C Painted only on the surface to be welded.
4-23 E05
What purpose does flux serve in welding aluminum?
A Removes dirt, grease, and oil.
B Minimizes or prevents oxidation.
C Ensures proper distribution of the filler rod.
4-24 E05
Why are aluminum plates V 4 inch or more thick usually
preheated before welding?
A Reduces internal stresses and assures more complete
penetration.
B Reduces welding time.
C Prevents corrosion and ensures proper distribution of
flux.
In gas-shielded arc welding, a gas is used as a covering
shield around the arc to prevent the atmosphere from
contaminating the weld.
4-22. Answer B. JSAT 4-15 (AC65-15A)
Aluminum welding flux is designed to remove the
aluminum oxide by chemically combining with it. The
flux can be painted directly on the top and bottom of the
joint if no filler rod is required; if filler rod is used, it can
be coated.
4-23. Answer B. JSAT 4-3 (AC65-15A)
Using the proper flux when welding aluminum is
extremely important. Aluminum welding flux is designed
to remove the aluminum oxide by chemically combining
with it.
4-24. Answer A. JSAT 4-27 (AC43.13-1B) (AC65-15A)
Preheating of aluminum before welding lessens the strain
caused by the large coefficient of expansion of this metal.
Preheating also assures a more complete weld penetration,
since the high conductivity of aluminum causes heat to be
drawn away from the weld.

4-25 E05 4-25. Answer C. (AC65-15A)

How should a welding torch flame be adjusted to weld A slightly carburizing flame is recommended for welding
stainless steel? stainless steel. The flame should be adjusted so that a
feather of excess acetylene, about V16 long, forms around
A Neutral. the inner cone.
B Slightly oxidizing.
C Slightly carburizing.
Aircraft Welding 4-5

4-26 E05 4-26. Answer C. JSAT 4-3 (AC65-15A)

Oxides form very rapidly when alloys or metals are hot. It Using the proper flux when welding is extremely important.
is important, therefore, when welding aluminum to use a Aluminum welding flux is designed to remove the alu-
minum oxide by chemically combining with it.
A filler.
B solvent.
C flux.

4-27 E05 4-27. Answer C. JSAT 4-26 (AC43.13-1B) (AC65-15A)

In gas welding, the amount of heat applied to the material
being welded is controlled by the
A distance the tip is held from the work.
B amount of gas pressure used.
C size of the tip opening.
The nature of the weld, the material, the experience of the
welder, and the position in which the weld is to be made,
all determine the correct size of the tip opening. The size
of the tip opening, in turn, determines the amount of heat
applied to the work.

4-28 E05 4-28. Answer C. JSGT 13-6 (AC65-15A)

Oxygen and acetylene cylinders are made of Oxygen and acetylene cylinders used in welding operations
are made of seamless steel.
A bronze.
B seamless aluminum.
C steel.

4-29 EOS 4-29. Answer B. JSAT 4-6 and JSAT 4-9 (AC65-9A)
When inspecting a butt welded joint by visual means, If it is properly done, the penetration in a butt weld should
be 100% of the thickness of the base metal.
A look for evidence of excessive heat in the form of a
very high bead.
B the penetration should be 100 percent of the thickness
of the base metal.
C the penetration should be 25 to 50 percent of the
thickness of the base metal.

4-30 E05 4-30. Answer C. JSAT 2-9 (AC65-9A)

Annealing of aluminum
A increases the tensile strength.
B makes the material brittle.
C removes stresses caused by forming.
When aluminum alloy is being formed, it will become
strain hardened, and often before the forming can be
completed, the metal must be annealed to relieve the
stress.

4-31 E05 4-31 Answer A. JSAT 4-7 (AC65-15A)

Edge notching is generally recommended in butt welding
above a certain thickness of aluminum because it
A aids in getting full penetration of the metal and
prevents local distortion.
B helps hold the metal in alignment during welding.
C aids in the removal or penetration of oxides on the
metal surface.
Edge notching is recommended in aluminum welding
because it aids in getting full penetration and also prevents
local distortion. All butt welds in material over .135 thick
are generally notched in some manner to achieve full
penetration of the weld.

4-32 E05 4-32. Answer C. (AC65-15A)

If too much acetylene is used in the welding of stainless Too much acetylene will add carbon to the metal and
steel, cause it to lose its resistance to corrosion.

A oxide will be formed on the base metal close to the

weld.
B a porous weld will result.
C the metal will absorb carbon and lose its resistance to
corrosion.
4-6 Aircraft Welding

4-33 E05 4-33. Answer B. JSAT 4-4

The shielding gases generally used in the Gas Tungsten Arc Argon or helium are used to exclude oxygen from the
area(GTA) welding of aluminum consist of of the molten metal to prevent oxidation.
A a mixture of nitrogen and carbon dioxide.
B helium or argon, or a mixture of helium and argon.
C nitrogen or hydrogen, or a mixture of nitrogen and
hydrogen.