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1. The diameter of a metal wire is 3.0 mm and 2.5 m long. A force of 16 Newton is applied to it and
it stretches 0.4 mm. Assume the material is elastic. Determine the following;

i. The stress in the wire, .

ii. The strain in the wire, .
2. Define the requirements for a repair to a piece of sheet metal structures.
3. Describe briefly the steps of making a riveted repair to an aircraft sheet metal structure
including its safety precautions involved.
4. State the stress acting upon the aircraft structure during flight and on ground condition and its
5. Define all the function of the hand tools used while performing a riveted repair.
6. Describe briefly the steps required for layout and forming a bend on a sheet metal.
7. Sheet metal can withstand specific amounts of tensile stress depending on the type and
thickness of the materials. Assume that you want to join two pieces of material 2117 T4 with
the same thickness of 0.040. The size 4.5 X 5 as the patch and the other one sized 6.0 X 6.0
as the skin. Based on the chart 1 given below, prepare a complete calculation for a sample rivet
layout pattern with crack length is about 1.98.You may sketch a drawing to support your

Chart 1: No. 0f 2117-T4 (AD) Protruding Head Rivets Required/Inch of Width (W)
Thickness(in) No. 0f 2117-T4 (AD) Protruding Head Rivets
Required/Inch of Width (W)
Rivet Size
0.020 3/32 1/8 5/32 3/16 1/4
0.025 6.5 4.9 3.9 -- --
0.032 6.9 4.9 3.9 -- --
0.036 8.9 4.9 3.9 3.3 --
0.040 10.0 5.6 3.9 3.3 2.4
0.051 11.1 6.2 4.0 3.3 2.4
0.064 -- 7.9 5.1 3.6 2.4

8. Establish the procedures involved during removal of a bad solid rivet after driven.
9. Explain with your own words, what determine whether a piece of sheet metal should be
dimpled or countersunk when installing flush rivet?
10. Describe joggling repair on a sheet metal.


1. Establish the painting procedures using spray gun including its safety precautions as per
standard maintenance practices.
2. Establish the cleaning procedures of a spray gun.
3. Define the steps of corrosion removal and assessment.
4. List down all the corrosion that usually occurs on metallic aircraft structure.
5. Define the following methods of surface protection.
a. Chromating
b. Anodizing
c. Alodizing
d. Painting