test – SpaceTEC® – National Science Foundation's Center for Aerospace Technical Education

Please enter the following information.

Student Name*

First

Last

Date*

STE Name*

First

Last

1/5

Select up to two from the list, then proceed to Section 3 - Structures and Assembly Practicals:

W/C-03.003(P)
PAC/Carbon Steel
A. You are going to layout and cut carbon steel using the plasma arc cutting process in accordance to the blueprint (see reference). These are your instructions:
1. Using a square, tape measure, and soap stone, lay out the plate according to the blueprint.
2. Set up the PAC equipment.
3. Inspect parts of the plasma torch.
4. Connect air and adjust the pressure.
5. Set parameters on the plasma arc machine.
6. Perform plasma arc cutting.
7. Shut down plasma arc equipment.
B. I will evaluate you by safe work practices and by visually inspecting the cuts and determining that the plate meets all dimensions on the blueprint from both sides. Do you have any questions?

W/C-04.001(P)
GMAW/T-Joint 2F 3/16” carbon steel plate
A. You are going to perform a GMAW weld on a 3/16” carbon steel plate in the flat position in accordance to the blueprint (see reference). These are your instructions:
1. Clean plates to be welded.
2. Set the parameters on the machine.
3. Tack plates into a T-joint.
4. Position the weldment in the 2F position.
5. Perform welds according to blueprint.
6. Clean welds with a chipping hammer and wire brush.
7. Visually inspect the welds and point-out defects to examiner.
8. Make repairs to visual defects.
9. Make repairs to defects found by dye penetrant.
B. I will evaluate you by safe work practices and by performing a dye penetrant inspection on your product to determine that the weldment meets the standards on the blueprint. Do you have any questions?

W/C-04.008(P)
FCAW/Butt Joint 1G 3/8” carbon steel plate (V-groove with backing)
A. You are going to perform a FCAW weld on a 3/8” carbon steel plate in the flat position in accordance to the blueprint (see reference). These are your instructions:
1. Prepare plates to be welded.
2. Set the parameters on the machine.
3. Tack plates into a butt-joint with backing.
4. Position the weldment in the 1G position.
5. Perform welds according to blueprint.
6. Prepare weld for post weld inspection.
7. Visually inspect the welds and point-out defects to examiner.
8. Make repairs to visual defects.
9. Make repairs to defects found by dye penetrant.
B. I will evaluate you by safe work practices and by performing a dye penetrant inspection on your product to determine that the weldment meets the standards on the blueprint. Do you have any questions?

W/C-05.003(P)
GTAW/ Butt Joint 1GF/ 1/8” aluminum plate (Butt Joint, Open Root) (AC)
A. You are going to perform a GTAW weld on a 1/8” aluminum plate in the flat position in accordance to the blueprint (see reference). These are your instructions:
1. Clean plates to be welded.
2. Set the parameters on the machine.
3. Clamp plates into the testing jig.
4. Position the weldment in the 1G position.
5. Perform welds according to blueprint.
6. Clean welds with a wire brush and alcohol.
7. Visually inspect the welds and point-out defects to examiner.
8. Make repairs to visual defects.
9. Make repairs to defects found by dye penetrant.
B. I will evaluate you by safe work practices and by performing a dye penetrant inspection on your product to determine that the weldment meets the standards on the blueprint. Do you have any questions?

W/C-05.009(P)
GTAW/ Butt-Joint 1G/ 1/8” Carbon Steel (Butt Joint Open Root)
A. You are going to perform a GTAW weld on a 1/8” carbon steel plate in the flat position in accordance to the blueprint. These are your instructions:
1. Clean plates to be welded.
2. Set the parameters on the machine.
3. Clamp plates into the testing jig.
4. Position the weldment in the 1G position.
5. Perform welds according to blueprint.
6. Clean welds with a wire brush and alcohol.
7. Visually inspect the welds and point-out defects to examiner.
8. Make repairs to visual defects.
9. Make repairs to defects found by dye penetrant.
B. I will evaluate you by safe work practices and by performing a dye penetrant inspection on your product to determine that the weldment meets the standards on the blueprint. Do you have any questions?

2/5

Select up to two from the list, then proceed to Section 4 - Manual Machining and Fabrication:

S/A-2.001(P)
Cable Build
A. You are going to manufacture a cable harness in accordance with the attached build sheets and IPC-A-620 (Reference-Training & Certification Program Instructor Guide-provided by examiner). (NOTE: Use wire provided) These are your instructions:
1. Layout and cut wires to proper length; use ONLY wire Nos. J1, J2, 1, 2, 3, 4 & 5
2. Present terminated wires to evaluator prior to connectorization connector assembly
3. Perform continuity check with audible indicator or multimeter
4. Bundle and secure according to IPC A-620
5. Present cable to evaluator for final inspection
6. Perform engineering change as specified by examiner
B. I will evaluate you by the requirements of the applicable sections in IPC-A-620 (latest revision.) Do you have any questions?

S/A-2.003(P)
Pull Testing
A. You are going to perform a pull testing procedure. These are your instructions:
    1. Ensure crimping tools are calibrated by inspecting with Go/No Go gage
    2. Cut and strip 6 pieces of wire (3 each 20 AWG, 3 each 22 AWG). Strip length is to be 0.100”.
    3. Crimp contacts onto wires as follows:
        a. Crimp 3 each 20 AWG contacts onto 20 AWG wire.
        b. Crimp 3 each 22 AWG contacts onto 22 AWG wire.
     4. Pull test all 6 contacts and record the results on the data sheet provided. Be sure to include force required to break the connection and the resulting type of break in accordance with IAW NASA 8739.4B.
B. I will evaluate you using the rubric on the bottom of the Applicant Instructions. This evaluation includes how you use your tools, prepare the wire, terminate the wire, perform the pull test, and identify and record the results on the Tensile Test Log provided. Do you have any questions?

S/A-3.001(P)
Drill holes, install rivet
A. You are going to drill 4 holes and install round head type AD rivets. These are your instructions:
    1. Layout 4 holes, locations to be 0.250 from each edge on all 4 corners.
    2. Measure rivet to determine correct drill bit to use
    3. Drill the holes and install the rivets.
    4. Make sure that the formed rivet head meets aircraft standards for size.( button of rivet must be 1 ½ Ø of rivet, height of button must be ½ Ø of rivet ).
    5. Dimensions to be measured to ±0.030
    6. Properly remove a rivet without damaging the hole
B. I will evaluate you on safety and aircraft standards for rivets. Do you have any questions?

S/A-3.002(P)
Drill holes, install hylok fasteners
A. You are going to drill 4 holes and install hylock fasteners. You have one chance to repair improperly inserted fastener if needed. These are your instructions:
    1. Layout 4 holes, locations to be centered on the 3 x 3 plates
    2. Select drill for correct hole size
    3. Drill the holes and install the fasteners.
    4. Remove a fastener with minimal damage to hole if needed.
B. I will evaluate you on safety and aircraft standards for rivets. Do you have any questions?

S/A-4.001(P)
Disassemble, clean and reassemble a spray gun and demonstrate operation
A. You are going to disassemble, clean and reassemble gun and demonstrate proper operation.
B. These are your instructions:
    1. Take apart spray gun
    2. Use Q-tips to clean where fluid enters and exits gun
    3. Remove spring and needle and clean
    4. Remove fluid nozzle and clean
    5. Remove and clean seal
    6. Reassemble spray gun
    7. Demonstrate to examiner how gun operates using water
C. I will evaluate you on safety practices and ability to clean, disassemble, and reassemble spray gun. Do you have any questions?

S/A-5.002(P)
Install strain gage & solder wires
A. You are going to install a strain gage with M Bond 200 (see reference), centered on the aluminum plate and solder ribbon cable. These are your instructions:
    1. Layout strain gage for installation
    2. Prepare base surface for strain gage attachment
    3. Lay strain gage on to base material and bond
    4. Inspect for bubbles
    5. Read resistance prior to soldering
    6. Solder wires
    7. Read resistance after soldering and at end of ribbon.
B. I will evaluate you on safety practices and functionality of bonded strain gage. Do you have any questions?

S/A-6.002(P)
Composite Layup and Cure
A. You are going to layup an 8 layer 4 inch square of prepeg material and cure at 200F ̊ for 1 hour in a vacuum per instructions of examiner. (strength or flexibility)
These are your instructions:
    1. Layup 6 layers prepreg in proper direction.
    2. Layup carbon fibers on outside and seal the edge.
    3. Make vacuum bag
    4. Use proper bleeding ply’s
B. I will evaluate you on the layup and making a vacuum bag, and outcome of final product. Do you have any questions?

S/A-7.001(P)
Heat resistant coating, prepare special mix and prepare surface for coating
A. You are going to prepare and coat a 6 inch square coupon, to withstand 1400 ̊ F heat.
    1. Bead blast aluminum material
    2. Perform a water brake test to check for cleanliness
    3. Mix coating material (see reference) provided
    4. Material and thinner (see reference) will be at a 4 to 1 ratio
    5. Coupon to be coated with 2.5 to 3.0 mil material
B. I will evaluate you on proper bead blast technique, water break test technique and mixing of materials and proper cleaning of equipment. Do you have any questions?

3/5

Select up to one from the list, then proceed to Section 5 - CNC Machining and Fabrication:

M/F 01.001(P)
Machine C-Clamp 2” using Manual Mill & Manual Lathe
A. You are going to machine a 2” C-Clamp complete to drawing specifications (see reference) using a standard vertical knee mill and standard engine lathe. These are your instructions:
    1. Machine mill piece to finish dimensions
    2. Perform layout
    3. Finish machining pocket, angle
    4. Drill & tap hole deburr
    5. Face turn & thread screw, drill & ream handle hole per drawing.
B. I will evaluate you by safe work practices and by visually inspecting the face turn, counter bore cap, and threaded screw to finished dimensions per specification.
C. Tolerances
    Decimals
    .X = ± .030”
    .XX = ± .010”
    .XXX = ± .005”
    Fractions = ± 1/64”
    Angles = ± 1 degree
Do you have any questions?

4/5

Select up to one from the list, then click Submit to proceed:

CNC-1.001(P)
Note: Is currently being developed at Calhoun CC-will be added later

5/5