aircraft rigging and controls mechanic Interview Questions and Answers

1. What is the primary responsibility of an aircraft rigging and controls mechanic?

   • Answer: The primary responsibility is ensuring the safe and reliable operation of an aircraft's flight control systems by installing, inspecting, maintaining, repairing, and adjusting all flight control components, ensuring they meet manufacturer specifications and airworthiness standards.

2. Explain the difference between primary and secondary flight controls.

   • Answer: Primary flight controls (ailerons, elevators, rudder) directly control the aircraft's attitude and direction. Secondary flight controls (flaps, slats, spoilers) augment the primary controls, enhancing performance and control at various flight regimes.

3. Describe the process of rigging an elevator.

   • Answer: Rigging an elevator involves adjusting control surface travel, ensuring proper free play, and verifying correct hinge moments and control system balance to meet manufacturer's specifications. This includes checking for proper cable tension, pushrod alignment, and bellcrank movement.

4. What tools and equipment are commonly used in aircraft rigging and controls work?

   • Answer: Common tools include torque wrenches, dial indicators, micrometers, feeler gauges, control surface travel indicators, rigging scales, cable tension gauges, various hand tools, and specialized control system testing equipment.

5. How do you ensure proper cable tension in a flight control system?

   • Answer: Cable tension is checked and adjusted using cable tension gauges and following manufacturer's specifications. Proper tension is crucial for control response and prevents slack or over-tightening which can damage components.

6. What are the safety precautions you take when working on aircraft flight controls?

   • Answer: Safety precautions include lockout/tagout procedures, wearing appropriate personal protective equipment (PPE), following proper grounding procedures, using correct tools and techniques, working with a partner when necessary, and thoroughly inspecting all components before and after maintenance.

7. Explain the importance of control surface free play.

   • Answer: Free play is the allowable slack in the control system. It is essential to prevent binding and to ensure smooth and responsive control operation. Too much free play results in sluggish response, while too little can lead to binding and jamming.

8. How do you troubleshoot a control system malfunction?

   • Answer: Troubleshooting involves systematically checking all components of the control system, starting from the control column/pedals and working through to the control surface. This may include checking cables, pulleys, pushrods, bellcranks, actuators, and the control surface itself for damage, wear, binding, or misalignment. Using relevant technical manuals and schematics is crucial.

9. What are the common types of control system components?

   • Answer: Common components include control columns, yokes, rudder pedals, cables, pulleys, pushrods, bellcranks, control surface hinges, actuators (hydraulic or electric), and various control system linkages and fairleads.

10. Describe your experience with different types of aircraft control systems (e.g., mechanical, hydraulic, fly-by-wire).

    • Answer: [Candidate should describe their experience with each system, detailing specific tasks and troubleshooting experiences. This answer will vary based on the candidate's experience.]

11. How familiar are you with aircraft maintenance manuals and technical publications?

    • Answer: [Candidate should describe their experience using manuals, including interpreting schematics, diagrams, and maintenance instructions. They should mention familiarity with specific aircraft types if applicable.]

12. What is your understanding of airworthiness directives (ADs)?

    • Answer: ADs are mandatory maintenance actions issued by aviation authorities to address safety concerns. I understand the importance of complying with all applicable ADs and ensuring all necessary work is completed according to the specified procedures.

13. How do you maintain accurate records of your work?

    • Answer: I maintain accurate and detailed records using logbooks, work orders, and other documentation required by the maintenance facility, ensuring all work is properly documented, including part numbers, dates, and specific actions taken. I am meticulous in following all regulatory requirements for record-keeping.

14. Describe a time you had to troubleshoot a complex rigging problem.

    • Answer: [Candidate should describe a specific situation, explaining the problem, their troubleshooting steps, the solution, and what they learned from the experience. This showcases problem-solving skills.]

15. What are the potential consequences of improper rigging?

    • Answer: Improper rigging can lead to control surface malfunction, reduced aircraft controllability, pilot workload increase, and ultimately, an accident. It can also cause premature wear on components, leading to costly repairs and downtime.

16. How do you stay updated on the latest regulations and maintenance procedures?

    • Answer: I stay current through ongoing professional development, attending seminars and workshops, reviewing industry publications, and actively pursuing continuing education opportunities to maintain my certifications and knowledge of the latest regulations and best practices.

17. What is your experience with different types of aircraft (e.g., fixed-wing, rotary-wing)?

    • Answer: [Candidate should detail their experience with various aircraft types, highlighting their familiarity with specific models and systems. This answer will be tailored to their experience.]

18. Explain your understanding of load factors and their influence on flight control rigging.

    • Answer: Load factors are the multiples of the force of gravity acting on an aircraft. Understanding load factors is crucial for proper rigging because control systems must withstand these forces during maneuvers without failure. Rigging must account for these stresses to ensure safe operation.

19. What are your salary expectations?

    • Answer: [Candidate should provide a realistic salary range based on their experience and research of industry standards.]

20. Why are you interested in this position?

    • Answer: [Candidate should express their genuine interest in the position, highlighting relevant skills and experience, and demonstrating enthusiasm for the role and the company.]

21. What are your strengths and weaknesses?

    • Answer: [Candidate should provide honest and thoughtful responses, highlighting relevant strengths like attention to detail, problem-solving skills, and teamwork, and addressing weaknesses constructively, showing self-awareness and a willingness to improve.]

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