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Subject area E of 12

Aircraft Materials, Hardware, and Processes

5-10% of the A&P General test, about 3 to 6 of the 60 questions. The FAA's test standard lists 14 knowledge elements and 4 risk management elements for this area. Here is every one, plus sample questions to try.

What the FAA tests

From the aviation mechanic test standard, FAA-S-ACS-1.

Knowledge: what you must know

  • AM.I.E.K1Materials commonly used in aircraft and their general application.
  • AM.I.E.K2Heat treatment and metal working processes.
  • AM.I.E.K3Forces placed on aircraft materials (e.g., tension, compression, torsion, bending, strain, and shear).
  • AM.I.E.K4Hardware commonly used in aircraft (e.g., bolts, nuts, screws, pins, washers, turnlock fasteners, cables, cable fittings, and rigid line couplings).
  • AM.I.E.K5Safety wire and safety clip requirements and techniques.
  • AM.I.E.K6Precision measurement tools, principles, and procedures.
  • AM.I.E.K7Soldering preparation, types of solder, and flux usage.
  • AM.I.E.K8Torquing tools, principles, and procedures.
  • AM.I.E.K9Suitability and compatibility of materials and hardware used for maintenance.
  • AM.I.E.K10Relationship between torque and fastener preload.
  • AM.I.E.K11Identification markings on materials and hardware.
  • AM.I.E.K12Characteristics of acceptable welds.
  • AM.I.E.K13Characteristics of unacceptable welds.
  • AM.I.E.K14Procedures for weld repairs.

Risk management: hazards you must be able to spot and manage

  • AM.I.E.R1Use of personal protective equipment (PPE).
  • AM.I.E.R2Improper torque.
  • AM.I.E.R3Used hardware or suspected unapproved parts (SUPS).
  • AM.I.E.R4Torquing techniques on critical, highly-stressed fasteners.

Try a sample question

Aircraft Materials, Hardware, and Processes ยท AM.I.E.K12

Which of the welds shown best matches the handbook description of a good weld: a smooth seam with evenly spaced ripples, uniform width and thickness, slightly built up and with no spatter around it?

FAA-CT-8080-4G, Appendix 1, Figure 44

Practice all of aircraft materials, hardware, and processes

The full course has questions on every element listed here, with an explanation and FAA source for each.

See the courseFree mock test