Aircraft Welding Sample Test
1. Edge notching is generally recommended in butt welding above a
certain thickness of aluminum because it
a. aids in the removal or penetration of oxides on the metal
surface.
b. helps hold the metal in alignment during welding.
c. aids in getting full penetration of the metal and prevents local
distortion.
2. When selecting a welding rod, one of the most important factors
to consider is to ensure that
a. ferrous rods are used on aluminum.
b. nonferrous rods are used on steel.
c. the proper AMS specification number is used.
3. What method of repair is recommended for a steel tube longeron
dented at a cluster?
a. Welded split sleeve.
b. Welded patch plate.
c. Welded outer sleeve.
4. Why are aluminum plates 1/4 inch or more thick usually preheated
before welding?
a. Reduces internal stresses and assures more complete penetration.
b. Prevents corrosion and ensures proper distribution of flux.
c. Reduces welding time.
5. Oxides form very rapidly when alloys or metals are hot. It is
important, therefore, when welding aluminum to use a
a. solvent.
b. flux.
c. filler.
6. A welding torch backfire may be caused by
a. a tip temperature that is too cool.
b. using too much acetylene.
c. a loose tip.
7. Acetylene at a line pressure above 15 PSI is
a. usually necessary when welding metal over 3/8-inch thick.
b. used when a reducing flame is necessary.
c. dangerously unstable.
8. Which statement is true in regard to welding heat-treated
magnesium?
a. Flux should not be used because it is very difficult to remove
and is likely to cause corrosion.
b. The welded section does not have the strength of the original
metal.
c. Magnesium cannot be repaired by fusion welding because of the
high probability of igniting the metal.
9. 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. melting point of the filler metal.
c. temperature of the flame.
10. Cylinders used to transport and store acetylene
a. are pressure tested to 3,000 PSI.
b. are green in color.
c. contain acetone.
11. In gas welding, the amount of heat applied to the material being
welded is controlled by the
a. cutting oxygen valve lever.
b. oxygen-acetylene regulator.
c. size of the tip opening.
12. If too much acetylene is used in the welding of stainless steel,
a. a porous weld will result.
b. oxide will be formed on the base metal close to the weld.
c. the metal will absorb carbon and lose its resistance to
corrosion.
13. When a butt welded joint is visually inspected for penetration,
a. 100 percent of the thickness of the base metal.
b. 50 percent of the thickness of the base metal.
c. 75 percent of the thickness of the base metal.
14. Which statement best describes magnesium welding?
a. Filler rod should be the same composition as base metal.
b. Filler rod should be nickel-steel.
c. Magnesium can be welded to other metals.
15. Annealing of aluminum
a. removes stresses caused by forming.
b. makes the material brittle.
c. increases the tensile strength.
16. Filing or grinding a weld bead is considered to be
a. frequently necessary to avoid adding excess weight to a weld
joint.
b. a way to bring about strength reduction in joint.
c. an acceptable means to achieve a smoother surface.
17. The most important consideration(s) when selecting welding rod
is
a. ambient conditions.
b. current setting or flame temperature.
c. material compatibility.
18. Oxygen and acetylene cylinders are made of
a. steel.
b. seamless aluminum.
c. bronze.
19. Engine mount members should preferably be repaired by using a
a. larger diameter tube with fishmouth and no rosette welds.
b. smaller diameter tube with fishmouth and rosette welds.
c. larger diameter tube with fishmouth and rosette welds.
20. Which of the following can normally be welded without adversely
affecting strength?
1. Aircraft bolts.
2. SAE 4130 chrome/molybdenum tubing.
3. Spring steel struts.
4. Most heat-treated steel/nickel alloy components.
a. 2
b. 2 and 4.
c. 1 and 3.
21. Welding over brazed or soldered joints is
a. permissible for most metals or alloys that are not heat treated.
b. not permitted.
c. permissible for mild steel.
22. 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.
23. Which statement best describes magnesium welding?
a. It can be welded successfully using the same type of joints that
are used for aluminum.
b. It is recommended to use larger welding beads and a slower
welding speed than normal.
c. It has low thermal conductivity, so distortion and cracking
rarely occur.
24. Which statement concerning a welding process is true?
a. 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.
b. The inert-arc welding process uses an inert gas to protect the
weld zone from the atmosphere.
c. In the oxyacetylene welding process, the filler rod used for
steel is covered with a thin coating of flux.
25. The oxyacetylene flame for silver soldering should be
a. oxidizing.
b. neutral.
c. carburizing.
26. How should a welding torch flame be adjusted to weld stainless
steel?
a. Slightly oxidizing.
b. Slightly carburizing.
c. Neutral.
27. A resurfaced soldering iron cannot be used effectively until
after the working face has been
a. polished.
b. fluxed.
c. tinned.
28. Why should a carburizing flame be avoided when welding steel?
a. It hardens the surface.
b. It removes the carbon content.
c. A cold weld will result.
29. What purpose does flux serve in welding aluminum?
a. Minimizes or prevents oxidation.
b. Removes dirt, grease, and oil.
c. Ensures proper distribution of the filler rod.
30. The oxyacetylene flame used for aluminum welding should
a. contain an excess of acetylene and leave the tip at a relatively
low speed.
b. be slightly oxidizing.
c. be neutral and soft.
31. In Gas Tungsten Arc (GTA) welding, a stream of inert gas is used
to
a. prevent the formation of oxides in the puddle.
b. lower the temperature required to properly fuse the metal.
c. concentrate the heat of the arc and prevent its dissipation.
32. When welding or cutting, the acetylene pressure gauge should
never be set higher than
a. 20 PSI.
b. 15 PSI.
c. 25 PSI.
33. A very thin and pointed tip on a soldering copper is undesirable
because it will
a. cool too rapidly.
b. transfer too much heat to the work.
c. have a tendency to overheat and become brittle.
34. 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. helium or argon, or a mixture of helium and argon.
c. nitrogen or hydrogen, or a mixture of nitrogen and hydrogen.
35. Which statement concerning soldering is correct?
a. Joints in electric wire to be soldered should be mechanically
secure prior to soldering.
b. If the soldering temperature is too high, the solder will form in
lumps and not produce a positive bond.
c. Changeable shades of blue can be observed on the surface of a
copper soldering tip when the proper temperature for soldering has
been reached.
36. 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.
37. High pressure cylinders used to transport and store acetylene
must
a. contain acetone.
b. be pressure tested to 3,000 PSI.
c. be green in color.
Answers:
1. - c
2. - c
3. - b
4. - a
5. - b
6. - c
7. - c
8. - b
9. - a
10. - c
11. - c
12. - c
13. - a
14. - a
15. - a
16. - b
17. - c
18. - a
19. - c
20. - a
21. - b
22. - b
23. - a
24. - b
25. - b
26. - b
27. - c
28. - a
29. - a
30. - c
31. - a
32. - b
33. - a
34. - b
35. - a
36. - a
37. - a