2 MARKS

1. Define Airworthy condition.

2. List the measuring tools used in Aircraft maintenance
3. What is the main function of Rivet?
4. Distinguish between Schematic and Assembled Diagram
5. What are the types of Gears?
6. Write short notes on Belt checking method in transmission unit?
7. What are the disadvantages of Radiography method?
8. Distinguish between Third angle and First angle projection
9. What is the function of fastener and List out any two used in aircraft?
10. Why eddy current and magnetic particle inspection is applicable for all material?
11. What is the use of Ammeter and Ohmmeter?
12. How Steel property is varies with the addition of Carbon
13. Define Quenching.
14. Difference between Soldering and Brazing
15. Distinguish between TIG welding and MIG welding
16. Write the Principal behind the Eddy current testing
17. List out some connector used for electrical cable
18. What is the function of quality control system?
19. What are the disadvantages of Radiography method?
20. Write short notes on Brittle material
21. What is the function of Clamp in Electrical?
22. What is meant by NDT?
23. What are the disadvantage of Ultrasonic Testing?
24. What is Hard time Maintenance?
25. Name some Locking devices.
26. Define Anodizing.
27. Write the use of Ohm meter.
28. What are the uses of workshop tools?
29. Distinguish between Bolt and Screw.
30. What is the Purpose of Calibration?

6 & 10 MARKS

1. Why engineering drawing is needed for the Aircraft Industry?

2. Explain about weight balance control in Aircraft?
3. Explain briefly about electrical equipment used in the Aircraft
4. Explain briefly about measuring tools used for the accuracy.
5. Explain about Anticorrosion treatment of the material?
6. Explain about different weight acts in the aircraft and how balancing control is
achieved
7. Explain about the installation and maintenance procedure of Rivet?
8. Explain in detail about the Ultrasonic testing of material and its types.
9. Explain briefly about Heat treatment of Steel?
10. Explain about types of maintenance procedure in Aircraft to attain Airworthy
condition
11. Explain in detail about Electrical cable maintenance procedure?
12. Explain about different types of clamps used in aircraft electrical cable
13. Explain briefly about the identification of bolts
14. Write short notes on Dye penetrant technique.
15. Explain briefly about repair work of the electrical wires and maintenance
procedure followed for the damage electrical wires.
16. Write short notes about NDT techniques and List out its types.
17. Briefly explain about magnetic inspection process.
18. Explain in detail about the Ultrasonic testing of material and its types.
19. Explain in detail about bearing maintenance procedure?
20. Write short notes on different types of torque wrenches and its types.
21. Explain about maintenance tools used for Aircraft.
22. Why engineering drawing is needed for the Aircraft Industry?
23. Explain about the maintenance procedure in Gear
24. Explain briefly about composite material and its application
25. Explain about heat treatment of Aluminum Alloy.
26. Explain about maintenance tools used for Aircraft
27. Explain in detail about welding and its types.
28. Explain about different weight acts in the aircraft and how balancing control is
achieved.
29. Explain briefly about Eddy current Inspection.
30. explain briefly about composite material and its application
31. Explain about the maintenance procedure of Gear?
32. Explain about different types of Maintenance in Aircraft?
33. Explain briefly about measuring Instruments.
34. Explain in detail about welding and its types
 ANSWERS
2 MARKS
1. Define Airworthy condition.

Airworthiness or Airworthy condition-it is the certification of the aircraft which is

suitable for flight.
It is given by National Aviation Authority

2. List the measuring tools used in Aircraft maintenance.

 Feeler Gauges
 Micrometer
 Telescopic Gauges
 Vernier caliper
 Plug gage
 Ring gage

3. What is the main function of Rivet?

Riveting is the permanent connection of two or more workpieces the rivet being
put as a joint in a predrilled bore hole and formed on one or both ends.
The riveted parts can be connected in a movable, fixed, close or fixed and close
manner.

4. Distinguish between Schematic and Assembled Diagram.

 Schematic diagram is a circuit which shows the connections in a clear and
standardized way. A schematic diagram shows the components and their values
and connections in an understandable manner. It is usually used to communicate
or intended to convey the connections and working of the circuit to other
engineers.

Assembly Diagram can be used to represent items that consist of more than
one component. They show how the components fit together and may
include, orthogonal plans, sections and elevations, or three-dimensional views,
showing the assembled components, or an exploded view showing the
relationship between the components and how they fit together.
They may be used to show how to assemble parts of a kit such as furniture, how
to assemble a complex part of a building (an assembly), or to show the
relationship between a number of details.

5. What are the types of Gears?

6. Write short notes on Belt checking method in transmission unit?

  Check the belt for signs of exposure to excessive heat. High heat is a belt
killer. Use an infrared thermometer to check the surface temperature of the
belt. Replace the belt if signs of wear are obvious.
 Ensure that the misalignment is not caused by sheaves or sprockets that are
tilted on the shaft due to incorrect installation of the bushings.
 Over- or under-tensioned belts can also cause premature wear and early
failure.

7. What are the disadvantages of Radiography method?

 Trained technician needed

 Radiation hazards
 High cost of equipment
 Power source needed

8. Distinguish between Third angle and First angle projection

9. What is the function of fastener and List out any two used in aircraft?
The purpose of the fastener is to connect all the different parts together in primary
structural areas, secondary structure, pressurized and nonpressurized applications,
and to transfer loads from one part to another in both production and repair
applications.
An interesting statistic is aircraft fasteners make up half of the 6,000,000 parts used
to fabricate a Boeing 747-800 aircraft.
 Bolts
 Nuts
 Washers

10. Why eddy current and magnetic particle inspection is not applicable for all
material?

 Only effective on conductive materials

 It is restricted to ferromagnetic materials - usually iron and steel, and cannot
be used on austenitic stainless steel
 Most methods need a supply of electricity
 It is sometimes unclear whether the magnetic field is sufficiently strong to
give good indications
 The method cannot be used if a thick paint coating is present

11. What is the use of Ammeter and Ohmmeter?

Ammeter:

Ammeter is the device used to measure the current in an electric circuit. It

measures the current in amperes (A).

Ohmmeter:

Ohmmeter is the device used to measure the resistance in an electric circuit. It

measures the resistance in ohms (Ω).

12. How Steel property is varies with the addition of Carbon

 Steel has many properties that are important for a variety of uses and
applications. The percentage of carbon plays a large role in determining these
properties. Steels that are predominantly alloyed with carbon make up 90% of all
steel. Properties include:

 Tensile strength - the amount of load a material can withstand before

breaking.
 Ductility - the ability of a solid material to deform under stress. This
property is characterized by the ability of the material to be stretched into
a wire.
 Thermal conductivity - the ability of a material to conduct heat.

Resistance to corrosion - the ability of a material to resist against

reactions with caustic elements that can corrode or degrade it.

13. Define Quenching.

Quenching is the rapid cooling of a workpiece in water, oil or air to obtain certain
material properties. A type of heattreating, quenching prevents undesired low-
temperature processes, such as phase transformations, from occurring

14. Difference between Soldering and Brazing

S.No SOLDERING BRAZING

.
1. Used in electrical industries to join Used in mechanical industries to join
capacitors, wires etc different metals.
2. It is done below 200oC. It is done above 450oC, but below the
critical temp of the metal.
3. It is weaker than Brazing joint. It forms stronger joint.
4. It is a cheaper process It is a costly process
5. Preheating of the base metal is not Preheating of base metal is needed.
needed.
6. An alloy of Lead and Tin is used as An alloy of Copper and Zinc is used as
solder. filler.
15. Distinguish between TIG welding and MIG welding

TIG welding:

Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG)
welding, is an arc welding process that uses a non-consumable tungsten
electrode to produce the weld.

MIG welding:

Gas metal arc welding (GMAW), also known as MIG (metal inert gas) welding or
MAG (metal active gas) welding, is a process in which an electric arc forms
between an electrode and a metal workpiece, heating the metals and causing
them to melt, and be joined.

16. Write the Principal behind the Eddy current testing

In its most basic form, the single-element ECT probe, a coil of conductive wire is
excited with an alternating electrical current. This wire coil produces an
alternating magnetic field around itself. The magnetic field oscillates at the same
frequency as the current running through the coil. When the coil approaches a
conductive material, currents opposed to the ones in the coil are induced in the
material — eddy currents.

Variations in the electrical conductivity and magnetic permeability of the

test object, and the presence of defects causes a change in eddy current and a
corresponding change in phase and amplitude that can be detected by
measuring the impedance changes in the coil, which is a telltale sign of the
presence of defects.

ECT has a very wide range of applications. Because ECT is electrical in

nature, it is limited to conductive material. There are also physical limits to
generating eddy currents and depth of penetration (skin depth).

17. List out some connector used for electrical cable

Types of electric connectors:

 1. Terminal blocks
2. Posts
3. Crimp on connectors
4. Insulation displacement connectors
5. Plug and socket connector
6. Component and device connector
7. Blade connector
8. Ring and spade connector

18. What is the function of quality control system?

A quality assurance system and its management are of great importance to

anaviation organization whether it is large or small. The final task of the quality
system is to ensure the technical aircraft maintenance system at a high level of
quality, to ensure airworthiness of the aircraft

19. What are the disadvantages of Radiography method?

The disadvantages of Radiography method are:

1. X-ray equipment is very large in size and its cost is high.

2. It requires power supply and water supply for the functioning of X-ray unit.
3. Defects in thick castings and components with varying thickness are not
easily inspected.
4. A number of castings in one exposure cannot be inspected.
5. Due to larger size, it is not portable.
6. Further, it requires maintenance and servicing.

20. Write short notes on Brittle material

Brittle material:

A material is brittle if, when subjected to stress, it breaks without significant

plastic deformation. Brittle materials absorb relatively little energy prior to
fracture, even those of high strength. Breaking is often accompanied by a
snapping sound.
21. What is the function of Clamp in Electrical?

A clamp is a fasting device used to hold or secure objects tightly together to

prevent movement or separation through the application of inward pressure.

22. What is meant by NDT?

NDT is process of testing a work piece with out causing any damage to it during
the testing process ad also known as Non destructive testing

23. What are the disadvantage of Ultrasonic Testing?

 It is very difficult to use this method for parts which are very thin- for e.g. the
aircraft skin because of the dead zone, though this can be overcome by using
higher frequencies or immersion technique; in most cases of aircraft checks,
this may not be an option. Also, it cannot be used for irregular and non-
homogeneous parts (At-least, not the portable methods).
 The method does not detect flaws that are oriented parallel to the wave
propagation.
 The material must be characterized prior to inspection. As the returning signal
is affected by attenuation within the material, comparisons can be made only
if a similar (defective and good) specimen of same material is characterized
first.
 Usually, Ultrasonic method requires a trained operator for interpretation of
the results.

24. What is Hard time Maintenance?

It is an unintentional landing and effected on account of failure/malfunction of an

aircraft component or system. 3.2 Hard-Time Maintenance : "Hard-
Time"maintenance is the primary maintenance process requiring assembly,
inspection of aircraft and aircraft components at fixed

25. Name some Locking devices.

  Cotter Pins
 Safety Wires
 Tab Washers
 Lock Plate
 Spring Washers
 Check Nuts

26. Define Anodizing.

Anodizing is an electrochemical process that converts the metal surface into a

decorative, durable, corrosion-resistant, anodic oxide finish. Aluminum is ideally
suited to anodizing, although other nonferrous metals, such as magnesium and
titanium, also can be anodized.

27. Write the use of Ohm meter.

.An ohmmeter is an electrical instrument that measures electrical resistance, the

opposition to an electric current. Micro-ohmmeters (microhmmeter or
microohmmeter) make low resistance measurements. Megohmmeters (also a
trademarked device Megger) measure large values of resistance.

28. What are the uses of workshop tools?

HAMMER: Originally employed as a weapon of war, the hammer now-a-days is

used as a kind of divining rod to inadvertently locate expensive parts near to the
object we are actually trying to hit.
AIR CHISEL: A tool that when being used to gently cut into a piece of thin metal,
decides that the "teaser-button" will now go to "full-hammer", shooting the part
out the garage door and into traffic lanes only to get run over by an 18-wheeler.
MECHANIC'S KNIFE: Used to open and slice through the contents of cardboard
cartons delivered to your front door; works particularly well on boxes containing
upholstered items, chrome-plated metal, plastic parts and the hand not holding
the knife.
MECHANIC'S KNIFE: Used to open and slice through the contents of cardboard
cartons delivered to your front door; works particularly well on boxes containing
 upholstered items, chrome-plated metal, plastic parts and the hand not holding
the knife.
HACKSAW: One of a family of cutting tools built on the Ouija board principle: It
transforms human energy into a crooked, unpredictable motion, and the more
you attempt to influence its course, the more dismal your future becomes.

29. Distinguish between Bolt and Screw.

The rod with threads and a head is abolt, and alongside it is a nut.

SCREW: An externally threaded fastner capable of being inserted into the holes
inside assembled parts (now comes thedifference) of mating with a pre formed
internal thread or forming it's own thread is called a screw

30. What is the Purpose of Calibration?

Purpose of instrument calibration.Calibration refers to the act of evaluating and

adjusting the precision and accuracy of measurement equipment.
Instrument calibration is intended to eliminate or reduce bias in an instrument's
readings over a range for all continuous values

6 & 10 MARKS
31. Why engineering drawing is needed for the Aircraft Industry?

An engineering drawing, a type of technical drawing, is used to fully and clearly

define requirements for engineered items.

Engineering drawing (the activity) produces engineering drawings (the

documents). More than merely the drawing of pictures, it is also a language—a
graphical language that communicates ideas and information from one mind to
another.

Engineering drawing and artistic types of drawing, and either may be called
simply "drawing" when the context is implicit. Engineering drawing shares some
traits with artistic drawing in that both create pictures. But whereas the purpose
of artistic drawing is to convey emotion or artistic sensitivity in some way
 (subjective impressions), the purpose of engineering drawing is to convey
information (objective facts).

The process of producing engineering drawings, and the skill of producing those,
is often referred to as technical drawing or drafting (draughting) although
technical drawings are also required for disciplines that would not ordinarily be
thought of as parts of engineering (such as architecture, landscaping, cabinet
making, and garment-making

Traditionally, engineers have hand-drawn a series of two-dimensional line

drawings, or blueprints, for each of the myriad of parts that make up a
modern airplane. Next, the manufacturing operation must use these to create
solid objects. The entire process is streamlined when the engineer creates
three- dimensional representations in the computer. Today's wide-body
commercial airliners have as many as 100,000 structural components. The
engineering description of these components may take as many as 20,000
drawing sheets. With manual techniques, it is almost impossible to achieve
complete design continuity between the sheets. Thus, it is not uncommon for
a significant number of manual drawings to contain some sort of errors.
These are generally not detected until after toolling has been made and parts
are being fabricated in the factory. Therefore, correcting them is quite costly.
By using computer accuracy to eliminate these expensive errors during the
design stage, Boeing is expecting to recover the cost of implementing the
system repidly.

Drawings convey the following critical information:

 Geometry – the shape of the object; represented as views; how the object will look
when it is viewed from various angles, such as front, top, side, etc.
 Dimensions – the size of the object is captured in accepted units.
 Tolerances – the allowable variations for each dimension.
 Material – represents what the item is made of.
 Finish – specifies the surface quality of the item, functional or cosmetic. For
example, a mass-marketed product usually requires a much higher surface quality
than, say, a component that goes inside industrial machinery

32. Explain about weight balance control in Aircraft?

 http://www.ascentgroundschool.com/faa-references/aircraft-weight-and-
balance-handbook/199-chapter-1-weight-and-balance-control

33. Explain briefly about electrical equipment used in the Aircraft

http://www.microair.com.au/admin/uploads/Typicalaircraftelectricalsystems.pdf

34. Explain briefly about measuring tools used for the accuracy.

Refer Maintenance Practice & Tools Pdf

35. Explain about Anticorrosion treatment of the material?

36. Explain about different weight acts in the aircraft and how balancing control is
achieved
Refer weight Pdf

37. Explain about the installation and maintenance procedure of Rivet?

Refer Aircraft Fastener Pdf Or Check below

38. Explain in detail about the Ultrasonic testing of material and its types.
39. Explain briefly about Heat treatment of Steel?

Refer Aircraft Materials PDF

40. Explain about types of maintenance procedure in Aircraft to attain Airworthy

condition

Refer Introduction to Aircraft Maintenance PPT (Internal - 1)

41. Explain in detail about Electrical cable maintenance procedure?

 Refer Electrical Cables Pdf

42. Explain about different types of clamps used in aircraft electrical cable
Refer Electrical Cables Pdf,Internet

43. Explain briefly about the identification of bolts

Refer Aircraft Fastener Pdf

44. Write short notes on Dye penetrant technique.

Refer NDF full Notes

45. Explain briefly about repair work of the electrical wires and maintenance
procedure followed for the damage electrical wires
Refer Electrical Cables

46. Write short notes about NDT techniques and List out its types.
Refer NDF full Notes

47. Briefly explain about magnetic inspection process.

Refer NDF full Notes

48. Explain in detail about bearing maintenance procedure?

BEARINGS

When correctly installed and efficiently lubricated, bearings require little but thorough,
attention during service, to ensure a long working life. The majority of bearings used in
aircraft engineering are of the sealed or shielded type. These bearing are designed to
prevent the ingress of foreign matter, which will damage or contaminate the bearing
contact surfaces.

10.1 CLEANING AND INSPECTION OF BEARINGS

Cleaning

Before a bearing can be checked it must be cleaned thoroughly to remove any dirt and
the old lubricating fluid.

The manual will dictate the cleaning process including use of any solvent, but a typical
method is as follows.
 Remove any excess grease with clothes and dry compressed air, whilst ensuring
that the rolling elements remain stationary or only rotate slowly.

Soak the bearing in an approved solvent, such white spirit, to remove the
remaining grease. The solvent may be applied as a forced jet if necessary.

Dry the bearing by using clean warm and dry compressed air, again avoiding fast
rotation of any rolling elements.

Lightly lubricate all bearing surfaces with oil to prevent the onset of corrosion.

Testing

 Testing a bearing is usually restricted to rotational checks and excessive backlash

or free play.
 Slow rotation of the rolling elements and raceway will highlight any roughness
due to damage, corrosion or wear.
 A serviceable bearing should have a smooth actuation.
 Free play should be tested in both a radial and axial direction and is normally
done by using a DTI. S
 some wear is usually permitted and will depend on the grade of fit, but any wear
that leaves excessive backlash in the system is unsatisfactory.
 The rate of this wear depends on the speed the bearing is rotated at, with high
speed bearings failing quicker than those which rotate slowly or through
distances of less than one complete revolution.
 A bearing that has any indication of a fault should be discarded immediately.
 Due to their construction internal inspection of shielded bearings will be
restricted.
 Taper bearings can be dismantled and a thorough inspection of the rolling
elements and raceway surfaces can be completed.

INSPECTION OF BEARINGS

Once clean the bearing should be inspected for signs of failure, some of the more
common being:
1. Normal Fatigue 2. Excessive Loading 3. Installation and Misalignment 4. Loose Fitting
or Spinning 5. Brinelling 6. Overheating and Lubrication Deficiency 7. Contamination and
Corrosion

1) Normal Fatigue
a) Normal fatigue failure is often shown as a fracture of the running surface, with
subsequent removal of small particles of metal and is commonly called spalling.
b) It occurs on both rolling elements and raceways, and is always accompanied by
an increase in vibration. Moderately spalled areas show the bearing has reached
the end of its normal service life.
2) Excessive Loads
a) Excessive loading of a bearing is usually the same as normal fatigue, but the
rolling elements wear path is usually heavier. There is also increased evidence of
overheating with a widespread and deeper fatigue

3) Installation and Misalignment

i) Installation damage is usually the result of an impact that occurs when a

bearing is fitted incorrectly. This may be due to a sharp strike from a drift or
pressing the wrong raceway when mounting the bearing.
ii) Misalignment damage can be seen on the raceway of the non-rotating ring
because the rolling element wear path is not parallel to the raceway edge.
Excessive misalignment can cause high temperatures as well as heavy wear of
the cage.

4) Loose Fit

i) A bearing should always be mounted onto a shaft or housing with an

interference fit.
 ii) If the raceway becomes loose then it will rotate on these surfaces and cause
fretting.
iii) This fretting will remove metal particles, which oxidise and leave a distinctive
brown colour.
iv) It usually occurs when the bearing outer raceway rotates inside a worn
housing.
v) The external surface of the raceway will be scored and discoloured as a result
of a loose fitting bearing.

5) Brinelling

i) Brinelling marks on a bearing raceway resemble the indentations that result

from a Brinell Hardness Test. They are described as being either True Brinell or
False Brinell marks.

ii) True Brinelling occurs when loads on the bearings raceway exceed the elastic
limit of the raceway material. Brinell marks are indentations on the rolling
element caused by an excessive static or dynamic loads.

iii) The indentations can be seen on the raceways and will increase bearing noise
and vibration, which leads to the bearings premature failure. The damage is
often caused by dropping the bearing or installing it incorrectly.
 iv) False Brinelling occurs when there is only small relative motion between the
rolling elements and raceways during non-rotation periods. It is characterised
by elliptical wear marks in the axial direction at each rolling element position
(Refer Fig. 3 Right).
v) If the bearing is not turning then an oil film cannot be formed to prevent
raceway wear. False Brinelling marks are normally perpendicular to the line of
motion, well defined and maybe surrounded by debris.

6) Overheating and Lubrication Failure

i) Excessive heating of a bearing manifests itself as discoloration of the rings,
rolling elements and cages from gold to blue. Excessive temperatures will
usually be in excess of 400°C. In extreme cases the rolling elements and
raceways will deform. A blue/black colour indicates an area close to the heat
source and changes to a silver/gold discoloration the further you move away.

ii) Failure or lack of lubrication often has similar signs as overheating because
good lubrication should cool the material and transfer away any heat
produced during rotation. Restricted flow and excessive temperatures can
also degrade the chemical composition of the oil, making it ineffective and
increase wear rates.

iii) The outcome of either overheating or lubrication failure will always result in
the eventual failure of the bearing.
7) Contamination and Corrosion
i) Contamination is one of the leading causes of premature bearing failure. The
symptoms are dents or scratches embedded in the bearing raceway and
rolling elements, resulting in bearing vibration and wear.
ii) The contaminant would be an abrasive substance that gets into the bearing,
such as sand, grit or dust. The principal sources are dirty tools, contaminated
work areas, dirty hands and foreign matter in the lubricant or cleaning
solutions.
iii) Corrosion is usually the result of a chemical attack on the bearing material by
an incompatible fluid such as moisture. It manifests itself as either black
pitting marks or red/brown rust coloured areas on the rolling elements,
raceways, or cages. It usually results in increased vibration followed by wear.
SAFETY PRECAUTIONS

The cleaning of bearings for inspection normally involves the use of solvents, so the
appropriate PPE should be worn. This will include respiratory, eye and skin protection
by using breathing masks, goggles and inspection gloves. The moisture from the
human hand may contaminate a bearing surface, as easily as the lubricant can cause
damage to the skin through dermatitis.

STORAGE

If a bearing is to be used immediately after inspection, it should be lubricated with

correct lubricant and installed. If there is liable to be a delay before installation, then
the bearing should be coated in rust-preventing inhibiting oil, wrapped in
greaseproof paper, boxed and labelled. The bearing should always be stored
horizontally, in a clean dry atmosphere.

49. Write short notes on different types of torque wrenches and its types.
Refer Introduction to Aircraft Maintenance PPT (Internal - 1)

50. Explain about maintenance tools used for Aircraft.

Refer Tools Pdf

51. Explain about heat treatment of Aluminum Alloy.

Refer Aircraft Materials PDF

52. Explain in detail about welding and its types.

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

53. Explain about different weight acts in the aircraft and how balancing control is
achieved.
Refer Weight Pdf

54. Explain briefly about Eddy current Inspection.

Refer NDF full Notes

55. explain briefly about composite material and its application

Refer Aircraft Materials PDF

56. Explain about the maintenance procedure of Gear?

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

57. Explain about different types of Maintenance in Aircraft?

Refer Introduction to Aircraft Maintenance PPT (Internal - 1)

58. Explain briefly about measuring Instruments.

Refer Introduction to Aircraft Maintenance PPT (Internal - 1)

MADE BY :

Satya Kumar
Haasith
Bhavana Reddy