Aircraft Maintenance Checks

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Questions and Answers

Why are nicks on propeller blades important to inspect?

  • They enhance blade lubrication.
  • They reduce drag.
  • They improve fuel efficiency.
  • They produce stress concentrations. (correct)

What is a 'lifed item' on an aircraft?

  • An item with unlimited fatigue life.
  • An item that improves with age.
  • An item that never needs replacement.
  • An item with a specific time in service. (correct)

Who typically monitors 'lifed items'?

  • The company technical department. (correct)
  • The passengers.
  • The pilot.
  • The air traffic controller.

Why are light bulbs with important functions often duplicated?

<p>To provide redundancy. (B)</p> Signup and view all the answers

Which aircraft surfaces are particularly susceptible to corrosion?

<p>Magnesium and aluminum alloy surfaces. (C)</p> Signup and view all the answers

Where is corrosion most likely to occur on aluminum and magnesium alloy surfaces?

<p>Along rivet lines and lap joints. (C)</p> Signup and view all the answers

What should be checked in ground runs?

<p>Engine temperatures and pressures. (B)</p> Signup and view all the answers

Which aircraft area is subject to highly corrosive influences?

<p>The exhaust areas. (A)</p> Signup and view all the answers

Why is it important to maintain aerodynamic cleanliness in aircraft?

<p>It reduces fuel consumption. (A)</p> Signup and view all the answers

What should be done if corrosion is discovered around rivets?

<p>Drill out the rivets to determine the extent of corrosion. (B)</p> Signup and view all the answers

What should be checked on moving parts during aircraft maintenance?

<p>All of the above. (D)</p> Signup and view all the answers

What is the purpose of fillet seals on skin joints?

<p>To maintain aerodynamic cleanliness. (C)</p> Signup and view all the answers

Why are door and window seals important in pressurized aircraft?

<p>To maintain cabin pressure. (A)</p> Signup and view all the answers

What is one of the checks that should be made on fluid lines and hoses?

<p>Correct fitting torque. (A)</p> Signup and view all the answers

What can a gap under a rivet head indicate?

<p>Stretching from stress. (A)</p> Signup and view all the answers

What checks should be performed on wiring during aircraft maintenance?

<p>All of the above. (D)</p> Signup and view all the answers

When can chemical methods for removing corrosion be used in situ?

<p>When specified by the manufacturer and of an approved type (A)</p> Signup and view all the answers

What should be done before using a corrosion-removing chemical?

<p>Remove loose corrosion by mechanical means (A)</p> Signup and view all the answers

What are the two main categories of chemical corrosion removers?

<p>Phosphoric acid- or alkaline-based (B)</p> Signup and view all the answers

What must be done after using rust removers?

<p>Thoroughly rinse with clean water and dry the area (D)</p> Signup and view all the answers

What should be done with cadmium-plated steel parts after corrosion removal?

<p>They should be re-plated according to the aircraft manufacturer’s instructions. (B)</p> Signup and view all the answers

What typically happens to paint when magnesium corrodes underneath it?

<p>The paint raises or swells. (C)</p> Signup and view all the answers

Why should metallic tools not be used to remove corrosion from magnesium?

<p>Magnesium is anodic to most commonly used aircraft structure metals. (C)</p> Signup and view all the answers

Which of the following is a specified mechanical method for removing corrosion from magnesium?

<p>Stiff non-metallic brush (C)</p> Signup and view all the answers

What type of batteries are most likely to cause alkali spillage?

<p>Nickel-cadmium (NICAD) batteries (A)</p> Signup and view all the answers

What is the electrolyte in NICAD batteries that leads to alkali spillage?

<p>Potassium hydroxide (A)</p> Signup and view all the answers

What should be used to neutralize an alkali spillage?

<p>Chromic acid solution (C)</p> Signup and view all the answers

What is the primary danger of mercury spillage on aluminum alloys?

<p>Liquid metal embrittlement (C)</p> Signup and view all the answers

What appearance does aluminum splitting, caused by mercury embrittlement under tension stress, have?

<p>An appearance similar to severe exfoliation (C)</p> Signup and view all the answers

What is an effective method for locating small particles of spilled mercury?

<p>X-ray inspection (A)</p> Signup and view all the answers

Spilled mercury needs to be cleaned immediately from aluminum because it causes what?

<p>Corrosion attack (C)</p> Signup and view all the answers

Mercury can penetrate which of the following on a metal structural component?

<p>Any break in the finish (B)</p> Signup and view all the answers

What is the most popular primer due to its maximum corrosion protection?

<p>Epoxy Primer (C)</p> Signup and view all the answers

What color is zinc chromate primer typically?

<p>Olive-green (A)</p> Signup and view all the answers

Which primer can be applied over wash primer for maximum protection?

<p>Epoxy primer (C)</p> Signup and view all the answers

Which of the following is a characteristic of synthetic enamel?

<p>Good gloss finish (B)</p> Signup and view all the answers

What type of primer is used with acrylic lacquer on high-volume production lines?

<p>Two-part wash primer (D)</p> Signup and view all the answers

What action does zinc chromate perform to prevent corrosion?

<p>Ionizes the surface to prevent electrolytic action (D)</p> Signup and view all the answers

Which of the following is a disadvantage of using synthetic enamel as a finish coating?

<p>Nominal chemical resistance (B)</p> Signup and view all the answers

What should be done to a surface before applying zinc chromate?

<p>Clean all fingerprints and traces of oil (D)</p> Signup and view all the answers

What is a primary method for preventing corrosion?

<p>Applying protective coatings (C)</p> Signup and view all the answers

Why is regular aircraft cleaning important?

<p>To protect the surface finish and allow for thorough inspections (B)</p> Signup and view all the answers

What should be done with pitot tubes and static ports before washing an aircraft?

<p>They should be covered. (B)</p> Signup and view all the answers

What should be done if oil spills on an aircraft tire?

<p>Immediately wipe it off with a dry towel, then wash with soap and water (A)</p> Signup and view all the answers

Why should plastic components be rinsed with water before drying?

<p>To prevent surface scratching (C)</p> Signup and view all the answers

What should be done to landing gear and flight controls after washing?

<p>They should be re-lubricated. (D)</p> Signup and view all the answers

What type of cleaners should be used on an aircraft?

<p>Only approved chemical cleaners, following manufacturer’s recommendations (C)</p> Signup and view all the answers

What should be avoided when cleaning rubber de-ice boots?

<p>Stiff brushes or abrasive materials (C)</p> Signup and view all the answers

Flashcards

Blade Seals

Seals that ensure pressurisation in aircraft; critical for serviceability.

Aerodynamic Cleanliness

Maintaining clean surfaces to enhance aircraft performance and reduce drag.

Fillet Seal

Seals at skin joints that help maintain aerodynamic cleanliness.

Lubrication

Applying substances to moving parts to reduce friction and wear.

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Hose Inspection

Checking hoses for leaks, cracks, and secure fittings in fluid lines.

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Wiring Security

Ensuring electrical wires are secure and free from damage.

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Rivet Maintenance

Inspecting rivets for corrosion and ensuring proper installation.

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Powerplant Checks

Inspecting engine security, leak checks, and accessories operation.

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Propeller Inspection

Inspection of nicks, dents, cracks, and cleanliness on the propeller.

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Nicks on Blades

Nicks create stress concentrations that may lead to blade failure.

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Ground Runs

Checks on engine temperatures, pressures, and response to power changes.

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Lifed Items

Components with a finite service time that require monitoring and replacement.

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Corrosion Assessment

Identifying and evaluating corrosion on aircraft surfaces.

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Corrosion-prone Areas

Locations more susceptible to corrosion, like rivet lines and fasteners.

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Light Bulb Checks

Regular inspections to ensure functioning of critical aircraft light bulbs.

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Corrosive Exhaust Areas

Regions subject to corrosive influences in gas turbine and piston engine exhaust paths.

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Chemical corrosion removal

Using chemicals specifically approved for rust removal, as per manufacturer guidance.

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Mechanical corrosion removal

Removing loose corrosion using tools or manual techniques before chemical application.

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Phosphoric acid

A common type of chemical used for corrosion removal; often effective on rust.

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Magnesium corrosion characteristics

Corrosion products from magnesium take up more space, causing expansion and swelling.

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Approved tools for magnesium

Tools like non-metallic brushes and abrasive pads recommended for magnesium work to avoid damage.

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Re-protection of cadmium-plated steel

Re-plating cadmium-coated parts following specific manufacturer instructions to protect from corrosion.

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Cleaning technique for magnesium

Using a non-fluffy cloth to apply approved corrosion preventative solutions on magnesium areas.

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Rinsing and drying after treatment

Thoroughly rinsing corroded areas with clean water and drying them post-treatment to prevent further corrosion.

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Epoxy Primer

A two-component primer providing maximum corrosion protection on various surfaces.

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Zinc Chromate

An olive-green, slightly porous primer that inhibits corrosion by releasing chromate ions.

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Synthetic Enamel

An older finish for metal aircraft, applied over zinc chromate, giving good gloss but lower abrasion resistance.

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Acrylic Lacquer

A fast-applied coating for aircraft finishes that allows quick production line processing.

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Finish Coating Types

The four basic types of finish coatings: synthetic enamel, acrylic lacquer, polyurethane, and acrylic urethanes.

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Wash Primer

A two-part primer applied before coatings like acrylic lacquer for better adhesion.

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Corrosion Prevention

Techniques used in coatings like epoxy and zinc chromate to minimize rust and degradation.

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Surface Preparation

Cleaning surfaces before applying primers and coatings to ensure proper adhesion.

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Surface Cleaning Importance

Regular cleaning helps inspect and protect surfaces from corrosion and defects.

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Effects of Dirt Accumulation

Accumulated dirt can hide defects, trap moisture, and add weight to the aircraft.

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Non-Metal vs Metal Cleaning

Different cleaning techniques are required for non-metallic and metallic components.

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Cleaning Rubber Tires

Oil and fluid spills on tires should be wiped off immediately and washed with soap and water.

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Surface Cleaning Materials

Use only approved chemical cleaners and follow manufacturer instructions while cleaning.

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Post-Wash Procedure

Re-lubricate bearings and fittings after washing to ensure smooth operation.

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Pitot Tube Precautions

Cover pitot tubes and static ports during washing to avoid contamination.

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Alkali Spillage

Spillage of potassium hydroxide from NICAD or Ni-Fe batteries, requiring neutralization.

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Chromic Acid Neutralization

Process used to neutralize alkali spills with chromic acid crystals in water.

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Mercury Corrosion

Rapid corrosion of aluminium caused by spilled mercury leading to pitting and embrittlement.

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Amalgam Formation

Formation of a mercury-aluminium alloy leading to severe structural damage.

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Liquid Metal Embrittlement

Failure of materials due to the presence of liquid metal, such as mercury.

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X-ray Inspection for Mercury

Using X-ray to locate small mercury particles due to its density.

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Mercury Spill Management

Immediate action to isolate and recover mercury spilled in aircraft.

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Preventing Mercury Damage

Steps taken to prevent corrosion and embrittlement from mercury exposure.

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Study Notes

Module 7: Maintenance Practices - Structural

  • Document Details: Category B2 Licence, CASA B2-07d, Aviation Australia, Module 07. Copyright © 2020.
  • Controlled Document - For training materials only.

Knowledge Levels

  • Level 1: The applicant is familiar with the basic elements of the subject. A simple description of the subject utilising common words and examples. Use of typical terms.
  • Level 2: General knowledge of the theoretical and practical aspects of the subject. Ability to apply that knowledge, including typical examples, mathematical formulas, drawings and schematics. Practical application using detailed procedures.
  • Level 3: Detailed knowledge of theoretical and practical aspects. Logical, comprehensive combining and application of all separate knowledge elements. Specific knowledge of the subject theory and its relation to other subjects, ability to use appropriate mathematical formulas and to interpret drawings and schematics. Practical application including manufacturer's instructions, results from different data sources and measurements, and application of corrective actions.

Table of Contents

  • Aircraft Defects, Corrosion Inspection, Assessment Techniques and Reprotection (7.18.1) (page 7) - Learning Objectives
  • Aircraft Defects (page 8) - General defects, External Damage, Inlets and Exhausts, Liquid Systems, Gaseous Systems, Visual Inspection Techniques, Dimensions, Tyres, Wheels, Brakes, Landing Gear Locks, Indicators, External Probes, Handles and Latches, Panels and Doors, Emergency System Indication, Pressurised Structure, Other Inspections, Locations of Corrosion, Prevention of Corrosion, Corrosion Removal, Paint Removal, and Aluminium and Aluminium Alloys.
  • Using a Dial-Type Depth Gauge (page 34)
  • Metal Parts (page 35)
  • Rubber, Fabric, Glass Fibre and Plastic Parts (page 40)
  • Control System Components (page 41) - Cables, chains, pulleys, rods and tubes.
  • Electrical Components (page 42) - Actuators, alternators, generators, motors, relays, solenoids and contactors.
  • External Damage, Inlets and Exhausts (page 43) - Damage to areas, contacting other items/personnel, Inlets and Exhausts (possible obstructions).
  • Liquid Systems (page 44) - Checking quantities, externally leaking systems, internal leaks, and maintenance guidelines.
  • Gaseous Systems (page 45) - Leaks from oxygen systems dangers, and how to treat pneumatic systems.
  • Visual Inspection Techniques (page 46) - Dimensions (tyres, wheels, and brakes), and Inspections.
  • Corrosion Identification, Assessment and Handling, and Locations of Corrosion (page 47)
  • Bilge and Water Entrapment Area (page 48) - Areas, potential corrosion and prevention, and recesses in flaps and hinges.
  • Control Cables (page 49), Prevention of Corrosion (page 50).
  • Corrosion Removal (page 51)
  • Paint Removal (page 52), Aluminium and Aluminium Alloys (page 53), Alclad (page 54), Assessment for Serviceability (page 55), Ferrous Metals (page 56), High-Stressed Steel Components(page 57), Galvanising (page 58), Metal Spraying (page 59), Paint and Primer, Wash Primer, Epoxy Primer (page 60), Zinc Chromate (page 61), Protective Finish Coating (page 62)
  • Acid and Alkali Spillage (page 63)
  • Metallic Mercury Corrosion on Aluminium Alloys (page 64) - Procedures, methods, and dangers.
  • Disassembly, Inspection, Repair and Assembly Techniques (page 65), etc...
  • Small Part and Component Identification (page 66), Discarding Parts (page 67),etc..
  • Troubleshooting Techniques (page 68), etc...
  • Non-Destructive Testing (page 69) - Learning Objectives, Non-Destructive Inspection Techniques, Selection of NDI Technique, etc...
  • Visual Inspection (page 70), Borescopes (page 71), Liquid Penetrant (page 72), Developers (page 73), Magnetic Particle Inspection (page 74) and additional techniques.
  • Electronic Inspection -Eddy Current (page 75), Absolute Method (page 76), Comparison Method (page 77), Ultrasonic Inspection (page 78), Pulse Echo Ultrasonic Inspection (page 79), Radiography (page 80), and Gamma Radiation Camera (page 81)
  • Disassembly and Re-Assembly Techniques (page 82) - Complete Airframes, major components and modules, etc... other minor components. Re-assembly procedures, correct tools, safety precautions and other general issues.
  • Basic Disassembly and Re-Assembly (page 83), the importance of correct tools (page 84).
  • Use of Correct Tools (page 85).
  • Troubleshooting Techniques and General Troubleshooting Process (page 86), identifying the defect (page 87), Conducting a Visual Inspection (page 88), Operational Checks (page 89), Classify the Defect (page 90), Isolating the Defect (page 91), Locating the Defect (page 92), Correcting the Defect (page 93), and conducting a final operational check (page 94).

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