Answers - Aircraft Metal Structure Repair

Fill in the Blanks

1. strong, cracks
2. shear, torsion
3. parallel, three
4. bearing, shear
5. parallel, double‐cut
6. shape, half‐round
7. pneumatic, electric
8. stops, underlying
9. bends
10. press, complex
11. feed, curvature
12. deburr, stretching
13. V‐blocks, flanges
14. thickness, temper
15. K‐factor, 90°


1. true
2. false
3. false
4. true
5. false
6. false
7. true
8. false


1‐1. d, 1‐2. c, 1‐3. f, 1‐4. e, 1‐5. a, 1‐6. b, 1‐7. a, 1‐8. f, 1‐9. e, 1‐10. c, 1‐11. b

2‐1. l, 2‐2. c, 2‐3. i, 2‐4. q, 2‐5. f, 2‐6. a, 2‐7. e, 2‐8. o, 2‐9. g, 2‐10. d, 2‐11. p, 2‐12. j, 2‐13. m, 2‐14. r, 2‐15. b, 2‐16. h, 2‐17. n, 2‐18. k

3‐1. d, 3‐2. f ,3‐3. b, 3‐4. g, 3‐5. a, 3‐6. i, 3‐7. e, 3‐8. h, 3‐9. c

4‐1. c, 4‐2. a, 4‐3. e, 4‐4. d, 4‐5. g, 4‐6. b, 4‐7. f

5‐1. e, 5‐2. a, 5‐3. c, 5‐4. f, 5‐5. b, 5‐6. d

Knowledge Application

1. The repair must restore the lost strength and rigidity, and it must not change the aerodynamic shape of the part.

2. The two strengths should be close to each other, but the bearing strength of the sheet should be the greater.

3. A patented fastener that is inserted in the rivet holes and is used to hold two pieces of sheet metal together until they can be riveted.

4. Throatless shears are used to cut mild carbon steel up to 10-gage, and stainless steel up to 12-gage. They can be used to cut irregular curves in the metal.

5. The sight line allows the jaws of a cornice brake to be positioned so the bend made by the brake will start at the bend tangent line.

6. Simple curves with a large radius.

7. Compound curves in sheet metal. 8. The flanges must be stretched for a convex curve and shrunk for a concave curve.

Multiple Choices

1. c
Rivets hold pieces of aircraft skin together, and in a properly designed riveted joint, the rivets support shear loads only.

2. b
Huckbolts and Lockbolts are manufactured to the same Federal Standard. In each case, the tension-type has 4 to 5 locking grooves and the shear-type has 2.

3. b
The 2117-T rivet, known as the field rivet, is used more than any other for riveting aluminum alloy structures. The field rivet is in wide demand because it is ready for use as received, and needs no further heat treating or annealing.

4. a
As a general rule, the rivet diameter should be not less than three times the thickness of the thickest sheet being riveted.

5. a
A properly formed shop head is one-half the shank diameter high, its diameter is one-and-one-half times that of the shank, and it is concentric with the hole.

6. c
The hand tools used for installation of Hi-Loks are an open end wrench and hex key (allen wrench).

7. c
When working with Dzus fasteners, it is worthwhile to know that the body diameter, length, and head type may be identified by the markings found on the head of the stud.

8. c
The length of a Dzus fastener is measured in hundredths of an inch and is the distance from the head of the stud to the bottom of the spring hole.

9. a
The diameter of a Dzus fastener is always measured in sixteenths of an inch.

10. c
Rivnuts are a combination of rivet and nut. A hole is drilled through the skin and the Rivnut, which resembles a hollow rivet with threads inside its shank, is slipped into the hole and upset with a special puller.

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