Questions and Answers - Aircraft Welding | Aircraft Systems

Questions and Answers - Aircraft Welding

Study Aid Questions

Fill in the Blanks

1. There are 3 types of welding: ________, ________ and, ________ welding.

2. The oxy acetylene flame, with a temperature of ________ Fahrenheit is produced with a torch burning ________ and mixing it with ________.

3. Shielded metal arc welding is the most common type and often referred to as ________ welding.

4. Gas metal arc welding (GMAW) was formerly called ________.

5. When welding mild steel, stainless steel, or titanium the welder setting needs to be set to ________. When welding aluminum and magnesium ________ must be selected.

6. Electric resistance welding, either ________ or ________ welding is typically used to join thin sheet metal components.

7. The gas used with Plasma Arc Welding is ________. The torch also uses secondary gas such as ________ or ________ that assists in shielding the puddle.

8. Argon is ________________________ and nontoxic.

9. The oxygen hose is ________ and has ________ threads indicated by the absence of a groove.

10. The size of the tip opening not ________ determines how much heat is applied to the work.

11. All cylinders should be stored and transported in the ________ position, especially acetylene because they contain an absorbent material saturated with ________.

12. The higher the welding tip number the ________ the hole in the tip.

13. Three flame types flame commonly used for welding are ________________, and ________.

14. The oxidizing flame burns at approximately ________°F and is produced by burning an excess of ________.

15. A ________ may be caused by touching the tip to the work, ________ the tip, by a ________ tip, or by dirt or slag in the end of the tip.

16. Turn off the flame by closing the ________ valve on the torch first. Then close the ________ valve on the torch.

17. Low ________, low ________ steels are the ferrous materials that are gas welded most frequently.

18. As in aluminum welding, ________ is needed to break down surface oxides and ensure a sound weld.

19. The principle use of ________ solder in aircraft work is in the fabrication process of high pressure ________ lines.

20. The heat control of a TIG welder may be preset by a machine setting or variable by use of a ________ or a ________ control.

21. The grinding of a Tungsten electrode used in TIG welding should be done ________, not ________.

22. When welding aluminum the welding machine is set to an ________ output waveform because it causes a ________ that breaks up ________.

23. A good indication and measure of weld quality for titanium is the weld ________. A bright ________ weld indicates that the shielding is satisfactory.

24. What four types of welds commonly used in flat position welding:
________     ________   ________   ________

25. Stresses developed by heating and cooling during welding need to be relieved or ________ and ________ of the sheets will occur.

26. If a partial replacement of a tube is necessary, make an ________ sleeve splice, especially where you want a smooth tube surface.

27. Dents at a cluster weld can be repaired by welding a ________ over the dented area.

28. A damaged tubular section can be repaired using welded ________ reinforcements.

29. The spring‐steel part of a spring‐steel leave is ________ and should not be ________ on.

30. The preferred method to repair an engine mount member is by using a ________ replacement tube.


1. Friction stir welding is one of the most common welding techniques. TRUE/FALSE

2. Gas welding was the most common welding method for thick (over 3/16”) till the 1950s. TRUE/FALSE

3. The temperature generated by SMAW is hotter than gas welding. TRUE/FALSE

4. GMAW (MIG) welding is an improvement over SMAW (stick) welding. TRUE/FALSE

5. GTAW (TIG) uses a consumable rod and a filler. TRUE/FALSE

6. Plasma cutting systems can cut aluminum and stainless steel. TRUE/FALSE

7. The acetylene pressure gauge should never be set higher than 20 psi for welding or cutting. TRUE/FALSE

8. The acetylene hose is red and has left hand threads. TRUE/FALSE

9. The flash back arrestor prevents the reverse flow of gas. TRUE/FALSE

10. A backfire is a momentary backward flow of the gases at the torch tip. TRUE/FALSE

11. Welding eyewear used for gas welding can also be used for arc welding processes. TRUE/FALSE

12. Welding tips have a number of holes and cutting tips have one hole. TRUE/FALSE

13. Open the torch oxygen valve a quarter to a half turn when lightening the torch. TRUE/FALSE

14. The neutral flame burns higher than the carburizing flame. TRUE/FALSE

15. When shutting down the welding equipment the oxygen valve is closed first. TRUE/FALSE

16. For welding thick metals or heavy plate, a technique called backhand welding can be used. TRUE/FALSE

17. Maintain a slight excess of acetylene for most steels, and a neutral flame for stainless. TRUE/FALSE

18. Gas welding of some aluminum alloys can be accomplished successfully. TRUE/FALSE

19. Welding magnesium is done with a slightly carburizing flame. TRUE/FALSE

20. Pure tungsten electrodes have better electron emission characteristics than Thoriated electrodes. TRUE/FALSE

21. When TIG welding aluminum the welding equipment is switched to a AC output waveform. TRUE/FALSE

22. Tig welding of titanium is performed using AC straight polarity. TRUE/FALSE

23. Expansion and contraction caused by heat during the welding process have a tendency to buckle and warp thin sheet metal sheets. TRUE/FALSE

24. Tack welding at intervals of the joint could control the expansion of the sheets that are welded. TRUE/FALSE

25. A damaged tubular section can be repaired using a formed steel patch plate. TRUE/FALSE

Knowledge Application Questions

1. What is the preferred method of welding magnesium?

2. What is a safety hazard associated with welding magnesium?

3. What must be done in the weld zone to successfully weld titanium?

4. Why is it necessary to use flux in all silver soldering?

5. What type of flame is used for silver soldering?

6. What type of repair could be made for a dented steel tube cluster joint?

7. What method can be used to insert a tight fitting inner sleeve into a tubular repair?

8. How is a soft flame obtained without reducing thermal output?

9. What is the most extensively used method of welding aluminum?

10. What valve should be turned off first when extinguishing a torch?

11. What procedure will control expansion when welding a joint?

12. What safety precaution should be taken when gas welding has been completed?

13. What must be done with heat‐treated aluminum alloys after a welding repair has been made?

14. What is the result of insufficient penetration?

15. What type of welding causes less buckling and warping than gas welding?

16. What is gas shielded arc welding?

17. What are some advantages of gas shielded arc welding?

Multiple Choices Questions

1. Edge notching is generally recommended in butt welding above a certain thickness of aluminum because it:
a. helps hold the metal in alignment during welding
b. aids in the removal or penetration of oxides on the metal surface
c. aids in getting full penetration of the metal and prevents local distortion

2. 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. 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
c. In the oxyacetylene welding process, the filler rod used for steel is covered with a thin coating of flux

3. Where should the flux be applied when oxyacetylene welding aluminum?
a. Painted only on the surface to be welded
b. Painted on the surface to be welded and applied to the welding rod
c. Applied only to the welding rod

4. 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

5. Why are aluminum plates 1/4 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

6. How should a welding torch flame be adjusted to weld stainless steel?
a. Slightly carburizing
b. Slightly oxidizing
c. Neutral

7. Oxides form rapidly when alloys or metals are hot. So it is important when welding aluminum to use a:
a. solvent
b. filler
c. flux

8. In gas welding, the amount of heat applied to the material being welded is controlled by the
a. amount of gas pressure used
b. size of the tip opening
c. distance the tip is held from the work

9. The shielding gases generally used in the Gas Tungsten Arc (GTA) welding of aluminum consist of
a. a mixture of nitrogen and carbon dioxide
b. nitrogen or hydrogen, or a mixture of nitrogen and hydrogen
c. helium or argon, or a mixture of helium and argon

10. Acetylene at a line pressure above 15 PSI is
a. dangerously unstable.
b. used when a reducing flame is necessary.
c. usually necessary when welding metal over 3/8‐inch thick.

11. If too much acetylene is used in the welding of stainless steel,
a. a porous weld will result
b. the metal will absorb carbon and lose its resistance to corrosion
c. oxide will be formed on the base metal close to the weld

12. In Gas Tungsten Arc (GTA) welding, a stream of inert gas is used to:
a. prevent the formation of oxides in the puddle
b. concentrate the heat of the arc and prevent its dissipation
c. lower the temperature required to properly fuse the metal

13. When a butt welded joint is visually inspected for penetration?
a. the penetration should be 25 to 50 percent of the thickness of the base metal
b. the penetration should be 100 percent of the thickness of the base metal
c. look for evidence of excessive heat in the form of a very high bead

14. 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

15. A welding torch backfire may be caused by:
a. a loose tip
b. using too much acetylene
c. a tip temperature that is too cool

16. Which statement best describes magnesium welding?
a. Magnesium can be welded to other metals
b. Filler rod should be nickel steel
c. Filler rod should be the same composition as base metal

17. Engine mount members should preferably be repaired by using a:
a. larger diameter tube with fishmouth and no rosette welds
b. larger diameter tube with fishmouth and rosette welds
c. smaller diameter tube with fishmouth and rosette welds

18. What method of repair is recommended for a steel tube longeron dented at a cluster?
a. Welded split sleeve
b. Welded outer sleeve
c. Welded patch plate

19. Welding over brazed or soldered joints is:
a. not permitted
b. permissible for mild steel
c. permissible for most metals or alloys that are not heat treated

20. A resurfaced soldering iron cannot be used effectively until after the working face has been:
a. fluxed
b. polished
c. tinned

21. In selecting a torch tip size to use in welding, the size of the tip opening determines the:
a. amount of heat applied to the work
b. temperature of the flame
c. melting point of the filler metal

22. Why should a carburizing flame be avoided when welding steel?
a. It removes the carbon content
b. It hardens the surface
c. A cold weld will result

23. The most important consideration(s) when selecting welding rod is:
a. current setting or flame temperature
b. material compatibility
c. ambient conditions

24. 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

25. Which statement is true in regard to welding heat‐treated magnesium?
a. The welded section does not have the strength of the original metal
b. Flux should not be used because it is very difficult to remove and is likely to cause corrosion
c. Magnesium cannot be repaired by fusion welding because of the high probability of igniting the metal