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Rosette weld hole diameter

Aviation Mechanic Airframe (AMA) practice question 4 of 20 on Metallic Structures. ACS element AM.II.A.K14 · difficulty: recall. Want to answer it in a timed quiz? Use the Aviation Mechanic Airframe (AMA) practice mode.

Question bank updated 2026-09-22

QUESTIONIn a welded repair to steel tubing, what is the typical diameter of the holes drilled in the outer splice for rosette welds?

  1. AOne-fourth the tube diameter
  2. BOne-half the tube diameter
  3. COne and one-half tube diameters
Show the answer and explanation

Correct answer: A. One-fourth the tube diameter

  • A — correct Rosette welds are made in holes typically one-fourth the diameter of the original tube, drilled in the outer splice and welded around the circumference.
  • B — incorrect A hole this large would remove far more of the splice than the handbook calls for.
  • C — incorrect One and one-half tube diameters is the minimum distance a sleeve end must sit from a cut or a crack, not a hole size.

BACKGROUND

Rosette welds are used in many of the standard welded repairs to steel tubing structure. They are holes, typically one-fourth the diameter of the original tube, drilled in the outer splice and then welded around their circumference so the outer member is fastened to the inner replacement tube or to the original structure. They appear in the inside sleeve splice, where the outer and inner replacement tubes are first tacked using rosette welds, and in outer split sleeve repairs, where the handbook notes that rosette welds may be omitted when the sleeves fit tightly. Several dimensions in these repairs are expressed as multiples of tube diameter: sleeve ends must lie at least one and one-half tube diameters from the nearest end of a diagonal cut or from the edge of a crack or dent. Inner sleeve splices also leave a 1/8 inch gap at each end for welding to the original tube stubs.

STUDY TIP

Sort the tubing repair dimensions into two groups: hole sizes as a fraction of tube diameter, and clearances as a multiple of tube diameter.

KEY POINTS

  • Rosette weld holes are typically one-fourth the diameter of the original tube.
  • They are drilled in the outer splice and welded around the circumference.
  • Rosette welds may be omitted on outer split sleeve repairs when the sleeves fit tightly.

SOURCES

  • sources/ama-airframe/ch05.txt "Rosette Welding"
  • sources/ama-airframe/ch05.txt "Tube Splicing with Inside Sleeve Reinforcement"
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SkyDrill is not affiliated with the FAA. This is an original practice item based on FAA-H-8083-31B Aviation Maintenance Technician Handbook – Airframe, and 14 CFR part 43. Regulations and handbooks are revised; confirm details against the current edition.