Sheet Metal Structures, FAA Airframe
Prepware Questions and Answers
Graded A+
What is the primary advantage of aluminum alloy in aircraft sheet metal structures?
✔✔Aluminum alloy is lightweight, strong, and resistant to corrosion, making it ideal for aircraft
structures.
Why are aircraft skins often riveted rather than welded?
✔✔Riveting is used because it maintains the structural integrity of thin sheets without deforming
the metal due to heat, unlike welding.
What is a joggle in sheet metal work?
✔✔A joggle is an offset formed on the edge of a sheet metal part to allow clearance for another
part or fastener.
Why is it important to remove burrs after drilling holes in sheet metal?
✔✔Burrs can cause stress concentrations, which may lead to cracks or weakened joints over
time.
1
,What is the purpose of a doubler in sheet metal structures?
✔✔A doubler reinforces areas subjected to high stress or where additional strength is required,
such as near cutouts or holes.
How do you prevent corrosion between dissimilar metals in aircraft construction?
✔✔Corrosion is prevented by using proper insulation, coatings, or sealants between dissimilar
metals to prevent galvanic corrosion.
What is the function of a stringer in an aircraft structure?
✔✔A stringer provides longitudinal reinforcement to the fuselage or wing skin, helping maintain
its shape and strength.
Why are some rivets used in aircraft sheet metal structures installed "blind"?
✔✔Blind rivets are used when only one side of the structure is accessible for installation.
What is the significance of edge distance when installing rivets in sheet metal?
✔✔Proper edge distance ensures that the rivet does not weaken the surrounding metal or lead to
cracks.
2
, How are cracks typically stopped in sheet metal components?
✔✔Cracks are often stopped by drilling a small hole at the end of the crack, known as a "stop-
drill" hole, to prevent further propagation.
Why are flush rivets commonly used in aircraft construction?
✔✔Flush rivets are used to reduce drag by maintaining a smooth aerodynamic surface.
What is the purpose of a backing bar during riveting?
✔✔A backing bar is used to support the rivet tail while it is being driven, ensuring a proper
shape and secure installation.
How are sheets of metal typically joined when they need to be extended or reinforced?
✔✔Sheets are joined using lap joints, butt joints with doublers, or by riveting overlapping sheets
together.
What tool is used to check the grip length of a rivet before installation?
✔✔A grip gauge is used to measure the thickness of the material to ensure the correct rivet
length is selected.
3
Prepware Questions and Answers
Graded A+
What is the primary advantage of aluminum alloy in aircraft sheet metal structures?
✔✔Aluminum alloy is lightweight, strong, and resistant to corrosion, making it ideal for aircraft
structures.
Why are aircraft skins often riveted rather than welded?
✔✔Riveting is used because it maintains the structural integrity of thin sheets without deforming
the metal due to heat, unlike welding.
What is a joggle in sheet metal work?
✔✔A joggle is an offset formed on the edge of a sheet metal part to allow clearance for another
part or fastener.
Why is it important to remove burrs after drilling holes in sheet metal?
✔✔Burrs can cause stress concentrations, which may lead to cracks or weakened joints over
time.
1
,What is the purpose of a doubler in sheet metal structures?
✔✔A doubler reinforces areas subjected to high stress or where additional strength is required,
such as near cutouts or holes.
How do you prevent corrosion between dissimilar metals in aircraft construction?
✔✔Corrosion is prevented by using proper insulation, coatings, or sealants between dissimilar
metals to prevent galvanic corrosion.
What is the function of a stringer in an aircraft structure?
✔✔A stringer provides longitudinal reinforcement to the fuselage or wing skin, helping maintain
its shape and strength.
Why are some rivets used in aircraft sheet metal structures installed "blind"?
✔✔Blind rivets are used when only one side of the structure is accessible for installation.
What is the significance of edge distance when installing rivets in sheet metal?
✔✔Proper edge distance ensures that the rivet does not weaken the surrounding metal or lead to
cracks.
2
, How are cracks typically stopped in sheet metal components?
✔✔Cracks are often stopped by drilling a small hole at the end of the crack, known as a "stop-
drill" hole, to prevent further propagation.
Why are flush rivets commonly used in aircraft construction?
✔✔Flush rivets are used to reduce drag by maintaining a smooth aerodynamic surface.
What is the purpose of a backing bar during riveting?
✔✔A backing bar is used to support the rivet tail while it is being driven, ensuring a proper
shape and secure installation.
How are sheets of metal typically joined when they need to be extended or reinforced?
✔✔Sheets are joined using lap joints, butt joints with doublers, or by riveting overlapping sheets
together.
What tool is used to check the grip length of a rivet before installation?
✔✔A grip gauge is used to measure the thickness of the material to ensure the correct rivet
length is selected.
3
