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Materials & Processes > EMC L2 Study Questions > Flashcards

EMC L2 Study Questions Flashcards

1
Q

The Canadian standard for the certification of nondestructive testing personnel is developed and maintained by:
A) the Canadian General Standards Board (CGSB)
B) standard committee composed of representatives from industry working under the auspices of the of CGSB
C) Natural Resources Canada under the auspice of the CGSB
D) a cooperative effort between various Canadian regulatory bodies and Natural Resources Canada

A

B) standard committee composed of representatives from industry working under the auspices of the of CGSB

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2
Q

The levels of certification covered by the CGSB standard on NDT personnel certification are:
A) trainee, L1, L2 and L3
B) apprentice, trainee, L1, L2 and L3
C) L1, L2 and L3
D) none of the above

A

C) L1, L2 and L3

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3
Q

The pickling time will be least for:
A) low carbon steels
B) high carbon steels
C) alloy steels
D) same for all

A

C) alloy steels

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4
Q

Which of the following heat treatments usually follow a hardening treatment in order to make the steel more ductile?
A) annealing
B) tempering
C) spheriodizing
D) normalizing

A

B) tempering

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5
Q

Which of the following statement is correct?
A) alkaline solutions are never used to clean aluminum alloys
B) acid solutions are never used to clean aluminum alloys
C) acid solutions are usually used to clean aluminum alloys
D) alkaline solutions are usually used to clean aluminum alloys

A

D) alkaline solutions are usually used to clean aluminum alloys

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6
Q

Thermal conductivity of a metal is an important factor to consider in making quality weldments because:
A) some metals such as aluminum have low conductivity which result in weld defects due to localized heat build up
B) some metals, such as SS, have high conductivity which results in lack of fusion defects as the heat is quickly removed from the weld zone
C) in some metals, such as aluminum, very high temp gradients, are produced, causing stresses during cooling
D) none of the above

A

D) none of the above

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7
Q

To remove iron from the ore in a blast furnace, the following materials are added to the furnace to generate the desired chemical reactions:
A) coke, ore and oxygen
B) bauxite, ore and air
C) coke, ore, limestone and air
D) coke, ore, limestone and bauxite

A

C) coke, ore, limestone and air

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8
Q

An advantage of using green sand molds over dry sand molds is:
A) green sand molds are stronger than dry sand molds and thus are less susceptible to damage in handling
B) surface finishing of large castings are better when using green sand molds
C) overall the dimensional accuracy of the mold is better with green sand
D) there is less danger of hot tearing of castings when using green sand molds

A

D) there is less danger of hit tearing of castings when using green sand molds

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9
Q

Shielded metal arc welding is a process of joining metals which is:
A) fully automated
B) semi-automated
C) carried out manually
D) all of the above

A

C) carried out manually

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10
Q

In the resistance spot welding of low carbon steel, the heat is generated:
A) concentrated between the positive electrode and the work
B) concentrated at the interface of the two plates to be welded
C) concentrated between the negative electrode and the work
D) evenly distributed in the work between the electrodes

A

B) concentrated at the interface of the two plates to be welded

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11
Q

Which of the flowing is not a brazing process?
A) furnace brazing
B) induction brazing
C) infrared brazing
D) electron beam brazing

A

C) infrared brazing

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12
Q

Completely recrystallized hot rolled steel products have:
A) exactly the same mechanical properties in the longitudinal and transverse direction
B) superior mechanical properties in the direction of rolling
C) superior mechanical properties in the transverse direction
D) inferior mechanical properties than the original cast structure

A

B) superior mechanical properties in the direction of rolling

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13
Q

Bursts are caused by:
A) casting at too low a temperature
B) forging metal which is either too hot or too cold
C) insufficient reduction in size is attempted in one forging operation
D) none of the above

A

B) forging metal which is either too hot or too cold

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14
Q

In which of the following welding processes is filler metal never added?
A) brazing
B) soldering
C) arc welding
D) spot welding

A

D) spot welding

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15
Q

A welding defect that occurs in the root pass and runs parallel with the weld is:
A) incomplete fusion between beads
B) icicle
C) crater crack
D) incomplete joint penetration

A

D) incomplete joint penetration

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16
Q

A burst is discontinuity that may be found in:
A) a forging
B) a rolled product
C) an extrusion
D) any of the above

A

D) any of the above

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17
Q

A hole produced during solidification of metal due to escaping gases is called:
A) burst
B) a cold shut
C) flaking
D) blow hole

A

D) blow hole

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18
Q

Grain boundaries are areas of a metal micro structure:
A) where high melting points constituents are concerned
B) made up of rows of atoms arrayed in straight lines
C) that are not attacked by etchants and generally stand in relief during metallographic examinations
D) where low melting impurities tend to concentrate

A

D) where low melting impurities tend to concentrate

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19
Q

What is the cause of cracks in the HAZ?
A) a thermal cycle that increases hardness and reduces brittleness
B) a thermal cycle that reduces hardness and increases brittleness
C) a thermal cycle that reduces hardness and brittleness
D) a thermal cycle that increases hardness and brittleness

A

D) a thermal cycle that INCREASES hardness and brittleness

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20
Q

The best way to demagnetize a long tube would be:
A) reversing DC with a central conductor
B) pulsating AC with a central conductor
C) a portable yoke
D) passing the tube through an AC coil

A

A) reversing DC with a central conductor

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21
Q

Define pipe: (ingot discontinuity)

A

A shrinkage cavity that results in not enough molten metal reaching the center of the casting

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22
Q

In rolling operations, the flattened and elongated pipe discontinuity becomes what?

A

A lamination

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23
Q

Define segregation: (ingot discontinuity)

A

A non-uniform distribution of alloying elements and impurities

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24
Q

Define killed steel:

A

Steel that has been fully deoxidized prior to being cast into ingots

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25
Q

Define billet: (in regards to castings)

A

A steel shape whose cross-section area is LESS than 36 square inches

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26
Q

Define bloom: (in regards to castings)

A

A steel shape whose cross-section is GREATER than 36 square inches

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27
Q

Define slab: (in regards to castings)

A

A rectangular shape whose width is at least 3x its thickness

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28
Q

What does the term “green” refer to in a green sand casting?

A

The high moisture content used to make the mold shape

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29
Q

What is the main advantage of a dry sand casting over a green sand casting?

A

It’s stronger and less susceptible to handling damage

30
Q

What is the main advantage of a shell mold casting over a sand casting?

A

Greater dimensional accuracy

31
Q

What is the main advantage of a plaster mold casting over a sand or shell mold casting?

A

Best as-cast surface

32
Q

What are the 3 main disadvantages of a plaster mold casting?

A

1) only non-ferrous materials can be cast
2) restricted to relatively small parts
3) mold-making time may be long

33
Q

What does a true centrifugal casting involve?

A

A rotating mold that is used to develop centrifugal force.

34
Q

Describe the mold in a permanent casting:

A

Reusable molds that are made of metal with machined cavities.

35
Q

A die casting also employs reusable metal molds with machined mold cavities. What is the difference between the die casting and the permanent casting?

A

In the die casting, the molten metal is injected into the mold cavity under pressure.

36
Q

There are two types of die castings: hot chamber and cold chamber. Which is high pressure and which is low pressure?

A

Hot chamber = low pressure
Cold chamber = high pressure

37
Q

Define strength:

A

Ability to withstand applied loads/stress prior to failure

38
Q

Define hardness:

A

Resistance to shape change/deformation when external force is applied

39
Q

Define toughness:

A

Ability to deform plastically prior to fracturing or rupturing

40
Q

Ductility:

A

Material softness.

Ability to deform under stresses applied by tension

41
Q

What shape are inclusions?

A

Irregularly shaped to slightly spherical

42
Q

What does shrinkage look like?

A

Sponge-like/brach-like

43
Q

What does micro-shrinkage look like?

A

Feathery/sponge-like

44
Q

Are hot tears trans-granular or inter-granular?

A

Inter-granular

45
Q

Where are cold shots commonly found?

A

On the outside of the casting (can be seen visually)

46
Q

How are hot cracks caused?

A

Internal residual stresses that initiate after solidification and during cooling from high temps

47
Q

What’s another name for a cold crack?

A

A mechanical crack

48
Q

How are cold cracks caused?

A

Rough handling, thermal shock, shakeout (mechanically removing sand from a sand mold casting) or during heat treatment

49
Q

Define misrun:

A

When a casting mold is not sufficiently filled with molten metal and fails to meet dimensional requirements

50
Q

What name is given to the bottom part of the mold flask in the casting process?
A) cope
B) drag
C) gate
D) chill

A

B) drag

51
Q

Which of the casting processes listed below uses the ‘’expendable’’ molds?
A) die casting
B) injection mold casting
C) investment casting
D) centrifugal casting

A

C) investment casting

52
Q

What is the name of the metal inserts that are placed inside the mold to aid in uniform cooling between thick and thin sections of the finished casting?
A) chills
B) chaplets
C) cores
D) risers

A

À) chills

53
Q

A discontinuity caused by gas that is released during solidification, or by the evaporation of moisture or volatile material from the mold surface, is indicative of:
A) microshrinkage
B) shrinkage cavity
C) inclusion
D) gas porosity

A

D) gas porosity

54
Q

In a casting mold, what does the runner connect?
A) the pouring basin to the sprue
B) the down gate to the riser
C) the sprue to the ingate
D) the pouring basin to the mold cavity

A

C) the sprue to the ingate

55
Q

Which of the following acts as a reservoir of molten metal that is provided to compensate for the internal contraction of the casting as it solidifies, while also providing the necessary venting of gas or air?
A) riser
B) pouring cup
C) runner
D) sprue

A

À) riser

56
Q

Which of the following statements could be considered a common characteristic of both sand casting and investment casting?
A) both may be used to produce small castings
B) both produce castings of great dimensional accuracy
C) both make use of wooden patterns
D) both make use of reusable molds

A

À) both may be used to produce small castings

57
Q

Blooms, billets and slabs are manufactured in what type of processing?

A

Primary processing

58
Q

Forcing toothpaste from a tube is a common example of what type of process?

A

Extrusion

59
Q

What is the reverse process of extruding?

A

Drawing: PULLING a metal through a die to reduce and lengthen

60
Q

Laminations are caused by what?
A) pipe
B) large porosities
C) blowholes
D) inclusions
E) all of the above

A

E) all of the above

61
Q

Define cupping:

A

A series of internal ruptures that are severe defects common to bar stock rod and wire.
(Shaped like chevrons)

62
Q

Define hydrogen flakes:

A

Short, internal fissures that are extremely thin and are aligned parallel with the grain

63
Q

What is the difference between pickling and etching?

A

Pickling prepares the surface of the metal while etching removes thin layers of surface metal thickness (with chemical acids)

64
Q

Which of the following materials cannot be cold worked at room temperature?
A) aluminum
B) copper
C) silver
D) lead

A

D) lead

65
Q

Which of the following is a discontinuity that might be found in rolled plate stock?
A) shrinkage cracks
B) inclusions
C) forging laps
D) blow holes

A

B) inclusions

66
Q

A rough forging discontinuity has the following characteristics: it can occur on the surface or internally; it is associated with low temp processing; it is often caused by excessive working; and it creates cavities varying in size. How would it be identified?
A) burst
B) shrinkage
C) pipe
D) lamination

A

À) burst

67
Q

Which of the following is a processing discontinuity?
A) blow holes
B) intergranular corrosion
C) forging lap
D) segregation

A

C) forging lap

68
Q

Discontinuities in plate, sheet or strip caused by pipe, inclusions or blowholes in the original ingot, which after rolling are usually flat and parallel to the outside surface, are called:
A) seams
B) laminations
C) cracks
D) laps

A

B) laminations

69
Q

The property of a metal that allows plastic deformation while under tension before fracture is:
A) the endurance limit
B) hardness
C) ductility
D) toughness

A

C) ductility

70
Q

An advantage of hot working over cold working is that:
A) internal cavities may close or weld together during operation
B) the final product has better dimensional tolerances
C) the final product has better mechanical properties
D) the final product has a better surface finish

A

À) internal cavities may close or weld together during the operation

71
Q

What is the name given to the process that involves steps such as bending, die compacting and sintering?
A) press forging
B) powder metallurgy
C) powder forging
D) press alloying

A

B) powder metallurgy

Materials & Processes (3 decks)

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