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Emc Practice Flashcards

1
Q

Ultrasonic inspection of casting is difficult due to

A

The grain structure attenuating the sound beam

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2
Q

After solidification of a casting, the “as-cast” structure consists of a chill layer and elongated grains growing in towards the center. The elongated grains are called

A

Columnar grains

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3
Q

In the casting process, pouring the molten metal in through two pour basins can lead to

A

A defect known as cold shut

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4
Q

The bottom portion of a molding flask is called a

A

Drag

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5
Q

An approved model or a “recommended practice” not enforced by law is known as a

A

Standard

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6
Q

A commonly used method of not which utilizes acoustic energy at frequencies above the audible range is

A

Ut

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7
Q

Casting defects are caused by

A

Incorrect metal composite

bad melting or pouring procedures.

Poor pattern design

Incorrect composition of molding and core sand.

Incorrect positioning of runners, risers, gates and poor molding practice. (All of the above)

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8
Q

Trapped gas in a casting mold cavity may cause

A

Porosity

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9
Q

The hardness testing method that utilizes a 120° diamond tip indenter with a 10 kg minor and 150 kg major load is the

A

Rockwell c hardness

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10
Q

The flash in the closed die forging process can fold over and cause

A

A lap

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11
Q

Solidification of a metal occurs in two stages. Those stages are

A

Nuclei formation and grain growth

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12
Q

Ultimately the function of any ndt inspection is to

A

Find all discontinuities that the proper use of the test method is capable of indicating

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13
Q

Cast turbine blades are often inspected with which two ndt methods to detect leading and trailing edge cracks

A

Et and pt

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14
Q

What two ndt methods would best detect a lamination in a ferromagnetic material

A

Ultrasonic inspection and magnetic particle inspection

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15
Q

Discontinuities that result from trapped impurities in a material when it solidifies from molten state are

A

Inherent

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16
Q

Seamless tubing can be automatically inspected at rates up to several hundred feet per minute using which ndt method

A

Eddy current testing utilizing encircling coils

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17
Q

A Crack or fracture in a casting due to the segregation of low melting point impurities in combination with the restraint from the mold is known as

A

Hot tear

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18
Q

Elongated configurations of foreign substances aligned in the direction of working commonly found in lengths of bar stock are called

A

Stringers

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19
Q

Identify a processing method that can effect a materials mechanical properties

A

Welding

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20
Q

Care must be taken not to splash molten steel on the walls of the mold when pouring to prevent formation of surface defects like

A

Cold shots

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21
Q

Slag inclusions in welds are caused by

A

A wide weave pattern and incomplete removal of Slag from previous passes

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22
Q

Where is the most logical place on a casting to look for discontinuities

A

At junctions between light and heavy sections

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23
Q

A wrought iron used in forging process can be called a

A

Bloom, billet or slab

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24
Q

What are the three types of stress

A

Tensile, compressive, shear

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25
Q

Which discontinuities is not normally associated with a casting but found in forging

A

Burst (found in forging)

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26
Q

Bursts are caused by

A

Forging metal which is too hot

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27
Q

A form of localized corrosion that can Penetrate deep into the material is known as

A

Pitting

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28
Q

A welding defect that occurs on each side of the root pass and runs parallel with the Weld is

A

Incomplete joint penetration

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29
Q

Improper cleaning, insufficient preheating of a weldment, moisture on the base metal, or moisture on the filler metal could cause

A

Porosity

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30
Q

The following defect is caused when the internal edge (or land) of the bevel preparation is left and is not incorporated into the root pass

A

Lack of fusion

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31
Q

A common method of ndt used to detect fatigue cracks open to the surface on aluminum aircraft part is

A

Lpi

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32
Q

The ndt method commonly used to inspect thin wall heat exchanger tube is

A

Eddy current inspection

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33
Q

Which of the following heat treatments usually follows a hardening treatment in order to restore toughness and ductility to the steel

A

Tempering

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34
Q

The difference between an annealing and a normalizing is

A

The cooling rate used

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35
Q

What are the three main types of space lattices

A

BCC, FCC, HCP

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36
Q

Carbon steels used to produce plate, pipe and wire with a carbon content between 0.06% and 0.25% are also referred to as

A

Low carbon steel

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37
Q

The two methods of component failure are

A

Fracture and permanent deformation

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38
Q

What happens to atoms when metals solidify

A

Atoms lose mobility and assume fixed positions in the space lattice of the unit cell

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39
Q

When a metal is stressed beyond its elastic limit, after the stress is released it has

A

Permanent deformation only

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40
Q

Etching, pickling and plating cracks are all caused by

A

The evolution of hydrogen which permeates the grain boundaries causing cracks

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41
Q

Cold working metals increase their

A

Hardness and strength

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42
Q

Of the following which method produces most of the world’s steel today

A

Basic oxygen furnace

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43
Q

A difference between shielded metal arc welding and gas metal arc welding is that in gas metal arc welding

A

A stream of protective gas is passed through a nozzle which surrounds the electrode

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44
Q

One method of ndt that has been used to monitor the initiation and growth of stress corrosion and hydrogen embrittlement cracks in astenitic stainless steel is

A

Acoustic emission

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45
Q

Recapitalization temperature is the temperature at which

A

A cold worked structure will recrystallize in 1 hour

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46
Q

To remove iron from the ore in a blast furnace, which materials are added to generate the desired chemical reactions

A

Coke, ore, limestone and air

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47
Q

Contrary to fusion welding, resistance welding

A

Requires the application of pressure to achieve complete bonding

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48
Q

A crater Crack may occur when

A

The welder fails to fill the crater before breaking the arc

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49
Q

Shielded metal arc welding is a process of joining two metals and is performed _____

A

Performed manually

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50
Q

Suitable combinations of two different materials, each with specific properties may result in a composite that

A

Has better resistance to heat than the individual materials. Is stronger in tension than the individual materials. Is stiffer per unit weight than the individual materials.

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51
Q

An increased amount of energy at the grain boundaries after cold working leaves them susceptible to a type of intergranular corrosion known as

A

Stress corrosion cracking

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52
Q

A finshing discontinuity that bears no relation to the direction of metal grains is

A

Grinding cracks

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53
Q

A burst is what type of discontinuity

A

Processing (forging)

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54
Q

Where is the most logical place in an “as cast” ingot to look for porosity

A

In the top section

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55
Q

In the submerged arc welding process, Flux is added ______

A

separately and heaped along the joint being welded

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56
Q

The most common method for producing steel seamless tubing involves

A

Piercing round billets with large diameter and short length

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57
Q

Magnetic particle inspection can most effectively be performed on what type of material

A

Any ferromagnetic material

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58
Q

Any interruption in the normal physical structure or configuration of a test part, which may or may not affect the usefulness of the part, is called a

A

Discontinuity

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59
Q

Discontinuities created during the additional processing of metals, such as forging, rolling or welding are categorized as

A

Processing discontinuities

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60
Q

A commonly used method of ndt which utilizes acoustic energy at frequencies above the audible range is

A

Ut

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61
Q

Fracture is one type of material failure. what is another type of material failure

A

Permanent deformation

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62
Q

Ultrasonic inspection can be used to

A

Determine material thickness from one side only

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63
Q

From an engineering and inspection standpoint, what defects is considered the one of the more detrimental

A

Fatigue crack

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64
Q

Eddy current is most commonly used to detect defects in

A

Thin materials

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65
Q

The most frequently used method of ndt is

A

Visual testing

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66
Q

The ndt technique may be selected by the level 2 technician, but the test method, test procedures and instructions to be used are determined by the

A

Level 3

67
Q

One main advantage of Eddy current inspection over the other test methods is

A

It is a very rapid inspection since it does not need to contact the test piece

68
Q

Ultimately the function of any ndt inspection is to

A

Find all discontinuities that the proper use of the test method is capable of indicating

69
Q

A discontinuity that is of such a size, shape, type or location that it creates a substantial chance of material failure is known as a

A

Defect

70
Q

The three main categories of defects are

A

Inherent, processing, service

71
Q

A very effective way to help eliminate or control the human factors that can cause human error is to

A

Properly educate and train new personnel

72
Q

An approved model or a “recommend practice” used in manufacturing, and is not enforced by law is known as a

A

Standard

73
Q

When a technician deems an indication to be relevant, what is the next step

A

Evaluate the indication to a pre-determined acceptance criterion to determine severity

74
Q

The standard used in Canada to certify ndt personal is

A

Can/cgsb 48.9712

75
Q

For fatigue cracking to occur, what type of stress is required

A

Cyclic and tensile

76
Q

Lpi is limited to what type of defect

A

External

77
Q

When one “weak” component fails, and the remaining load must be absorbed by neighboring component a ___________ type fracture may occur

A

A progressive type fracture may occur

78
Q

The two most used types of sound waves used in industrial ultrasonic inspection are

A

Longitudinal and transverse (shear)

79
Q

Xrf is a method of ndt commonly used for

A

Material identification and sorting, detects relative amounts of alloying elements in metallic alloys, detecting heavy metal content in polymers or coating (all of the above)

80
Q

The three key activities that must be completed in order to become a certified ndt technician in Canada are

A

Apply for certification, complete QWE and vocational training, and pass the certification examinations

81
Q

Two main classification of metals

A

Ferrous and nonferrous

82
Q

Iron has the ability to exist in more than one type of crystal lattice in the solid state. This phenomenon is known as

A

Allotropy

83
Q

After solidification, the structure of the outside surface of a casting usually consists of

A

Fine equiaxed grains having random orientation and shape

84
Q

After solidification of a casting, the “as-cast” structure consists of a chill layer and elongated grains growing in towards the center. The elongated grains are called

A

Columnar grains

85
Q

Solidification of a metal occurs in two stages. Those stages are

A

Nuclei formation and crystal growth

86
Q

Ultimate tensile strength is defined as

A

The maximum stress in a tensile test

87
Q

The initial slope of a stress strain diagram within the elastic region indicates the rigidity of material. This property is referred to as

A

Modulus of elasticity

88
Q

What are the three types of stress

A

Tensile, compressive, shear

89
Q

What are the two types of solid solutions

A

Interstitial and substitional

90
Q

Typically, fine grained metals exhibit better

A

Mechanical properties

91
Q

Yield points indicates

A

Stress value at the beginning of the plastic range

92
Q

Thermosetting polymers have _________ carbon atoms providing a second degree of polymerization making it harder, stronger than commodity thermoplastics

A

Cross linked

93
Q

Which chemical bond is considered to be the strongest

A

The ionic bond

94
Q

What is the primary element in ferrous metals and alloys

A

Iron

95
Q

Ceramics are typically non-metallic solids with good

A

Wear resistance

96
Q

A common example of a composite is

A

Carbon fiber reinforced polymer panels

97
Q

A common use for ceramic material is

A

Refractory brick for insulating the walls of a furnace

98
Q

An alloy is substance composed of

A

Two or more elements, of which at least one Is a metal

99
Q

The characteristic “tree like” pattern that occurs during crystal growth is known as

A

Dendrite

100
Q

The two common isotopes used in gamma rt are

A

Cobalt and iridium

101
Q

Which hardness testing method uses a 120° diamond tipped indenter with a 10 kg minor load and a 150 kg major load

A

Rockwell C hardness testing

102
Q

Plastic deformation refers to

A

The permanent deformation of a specimen

103
Q

Magnetic properties refer to how a material will be influenced by a Magnetic field, and this material property is considered a

A

Physical property

104
Q

When a component is subjected tensile stress below the yield strength of the material

A

That component will fail after a sufficient number of cycles due to fatigue

105
Q

Large casting called ingots must go through primary rolling mills to produce slabs, blooms and billets. Which of these rolled products will have a cross sectional area less than 36 in squared

A

Billet

106
Q

The removal of impurities and flaws from the top section of a cast ingot prior to mill working is called

A

Cropping

107
Q

Carbon steels used to produce plate, pipe and wire with a carbon content between 0.06% and 0.25% are also referred to as

A

Low carbon steels

108
Q

Which ndt technique would be most suitable for the examination of an austenitic stainless steel (304) shaft to detect any fine fatigue cracks on the surface

A

Liquid penetration test

109
Q

a precision casting method used to produce complex aircraft parts generally weighing less than 1 kilogram is

A

Investment casting

110
Q

Which method produces most of the world’s steel today

A

Basic oxygen furnace

111
Q

In a sand-casting mold, the sprue connects the

A

Pouring basin to the runner

112
Q

Which type of corrosion tends to occur at metal-gasket interfaces

A

Crevice corrosion

113
Q

A metal production process which eliminates the need for ingot cropping is

A

Continuous casting

114
Q

When using a green sand mold, the moisture used to bind the sand can lead to what surface discontinuity

A

Porosity

115
Q

A formal of localized corrosion that can penetrate deep into the material is known as

A

Pitting

116
Q

Where is the most logical place to look for a hot tear on a casting

A

At junction between light and heavy sections

117
Q

In the casting process, pouring the molten metal in through two pour basins can lead to

A

The defect known as cold shut

118
Q

The two major categories of aluminum alloys are

A

Wrought alloys and cast alloys

119
Q

All forging methods can be categorized into two major groups. They are

A

Open die forging and closed die forging

120
Q

During metal forming, metals will develop higher strength in the direction of rolling due to strain hardening. This unequal strength of the grains is known as

A

Anisotropic properties

121
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, limestone, and air

122
Q

The term “pipe” refers to

A

The central shrinkage cavity in an ingot

123
Q

When a casting requires more than one parting section, a middle section is added between the upper and lower halves of the casting mold. These three sections are called

A

Cope, check, and drag

124
Q

The controlled heating and cooling of a metal, in solid state, to achieve desired properties is called

A

Heat treating

125
Q

Hydrogen accumulating in a steel structure can cause the steel to fail in a brittle fashion. This phenomenon is known as

A

Hydrogen induced cracking

126
Q

A metal support for holding cores in place within a sand mold is called

A

A chaplet

127
Q

In galvanic corrosion, the least noble metal (the anode) in the metal will

A

Corrode

128
Q

A casting mold may be designed to contain external risers and internal risers. The main purpose of these risers is to

A

Supply liquid metal as needed to compensate for shrinkage before solidification is complete

129
Q

To help eliminate or control the cooling rate of “hot spot” in a casting

A

Chills may be placed inside the mold to help control cooling rates

130
Q

List 6 discontinuities

A

Cracks
Voids
Inclusions
Desalination’s
Dis-bond’s
Corrosion

131
Q

Difference between the terms “method” and “technique” when used in relation to ndt

A

Method- the collection of the inspection techniques, based the inspection energy used
Technique- the specific way in which that the inspection energy is applied or detected

132
Q

What is two limitations of pt, Mt, rt

A

Pt- surface condition and pre-cleaning techniques greatly effect test results as the penetrant mist have some way of entering the discontinuity( temperature limitation)
Mt- part geometry, material limitation and the need to demagnetize after inspection
Rt- access to both sides of the piece is required. Density and the orientation of the discontinuity is crucial to detection. Safety

133
Q

List four benefits of using ndt to inspect a manufactured product

A

Avoids failure and prevent accidents by ensuring product Integrity and reliability
Ensure costumer satisfaction and maintain the manufacturer reputation
Aid in product design and control manufacturing process
Lower manufacturing costs and make more profit for user

134
Q

What is a inherent discontinuitie

A

These discontinuities are related to the solidification of the molten metal. They may be formed during the original solidification of the ingot or during the melting, casting and solidification of metal later in the fabrication process

135
Q

What is a processing discontinuity

A

These discontinuity are related to or occur during the various manufacturing process. This group generally has two sub categories. Primary processing discontinuities and secondary processing discontinuity

136
Q

What is a service discontinuity

A

Related to various service conditions to which the part is subject to eg fatigue stress corrosion and erosion

137
Q

What is a relevant indication

A

Indication formed because of a discontinuity present in the test object

138
Q

What is non-relevant indication

A

Indication that is un related to a flaw in the test object. Formed by some other factor. The Indication could be due to part geometry, surface condition or a change in metallurgical structure

139
Q

What is a false indication

A

Indication formed by misappropriation of the test method or technique

140
Q

Identify and describe the 4 types of crystal imperfections that are influential on a metals ductility

A

Vacancy- the lattice has atoms missing or has extra atoms

Interstitial’s- tend to push the surrounding atoms farther apart and distort the lattice planes resulting in increased resistance to plastic deformation

Edge dislocation- atoms above the dislocation line are compressed, while those below are forced apart

Screw dislocation- the lattice is distorted down through the lattice in a spiral format

141
Q

Iron is an allotropic metal. Which crystal structure would iron be in for 20°c-912°c, 912°c-1394°c, 1394°c-1538°c and above 1538°c

A

20°c-912°c: bcc
912°c-1394°c: fcc
1394°c-1538°c: bcc
Above 1538°c: liquid

142
Q

Explain the purpose of impact testing and identify the two types of temperatures being determined during Impact testing

A

It is used to determine the materials susceptibility to undergo brittle fracture (toughness).

The two types of temperatures are:

fracture appearance transition

temperature and energy criteria transition temperature.

143
Q

What are four effects that solid solution strengthening could have on the properties of a material

A

Corrosion resistance

Strength at high temperatures

Ductility of alloys is lower

Solidification temperature can be significantly changed

Increased electrical conductivity

144
Q

Steel is defined as

A

Iron with a small amount of carbon introduced creates steel

145
Q

Explain the difference between thermosetting and thermoplastic polymers

A

Thermoplastic polymer- higher in toughness, they have lower strength and hardness (Vander bond)
Thermosetting polymers- high hardness, high strength, good corrosion (covalent bond)

146
Q

Explain the difference between a material yield strength and ultimate tensile strength

A

Yield strength- is the stress required to produce a specific amount of plastic strain
Ultimate tensile strength- is the maximum stress reached in the tensile test

147
Q

What are the 4 major categories of corrosion and give examples of each

A

Uniform corrosion- rust on cars

Localized corrosion- galvanic, cervice, pitting, integranular and de-alloying

Erosion corrosion- on metal tubes contacting water

Environment cracking- metals under stress causing hairline cracks

148
Q

Describe the following discontinuities
Cold shut

A

Molten metal is poured from two directions, allowing the mold to be filled at a faster rate.where the two flowing channels meet, there is a chance one is cooler than the other and complete fusion does not take place

149
Q

What is a hot tear

A

Uneven cooling in thin or on corners that adjoin to heavier masses of metal can result in hot tears if a section begins to shrink while still hot and there is not sufficient supply of liquid metal, the internal stress tear the metal apart.

150
Q

What is inclusion

A

These are normally oxides or sulfides that are nonmetallic in nature and are located within the solid metal structure and are extremely brittle, which can cause the formation of cracks if stresses are impose on the casting

151
Q

What Is a rolling seam

A

Open continues lines that run along the length of the metal and caused by under filling in the rollers. Seams can also occur when cracks on the slab billet are stretched out and lengthened during the rolling process (rolling discontinuities)

152
Q

What is a lamination

A

A discontinuity normally aligned parallel to the rolling direction and surface of the plate. Maybe the result of Pipe, blister or inclusion that are thinned and spread out by the flattening action of rolling (rolling discontinuities)

153
Q

What is a flash line tear

A

As the dies close in the final stages of the forging process, the flash must be removed by trimming dies. If the trimming is not done properly, cracks or tears can occur along the flash line where the two die halves meet. (Forging discontinuities)

154
Q

What is core shift and how can it be detected by nde?

A

Core shifting during casting process. usually defects can be found using rt

155
Q

How does grain structure (grain size, grain orientation and grain boundary composite) affect some ndt methods such as RT and UT

A

Large grain structure can cause diffraction effects wich reduce image quality.
Course grain structure makes UT inspection a challenge

Reflection off the grain boundaries and attention caused by large grains can make interpretation of results extremely difficult and may lead to false indications
One challenge of UT and not for rt is the rough surface often present on casting can make coupling difficult.

156
Q

What is the sprue in a casting mold

A

The mold Chanel the pouring basin with the runner. In a sand mold an opening in the sand that is made by a spruce pin that’s on the top surface

157
Q

What is a runner in a casting mold

A

An internal Chanel that will allow unrestricted access for the passage of the molten metal

158
Q

What is the gate in a casting mold

A

The portion of the runner in a mold through which molten metal enters the mold cavity

159
Q

What is a riser in a casting mold

A

Also called a feeders, are reservoirs located in the sand mold that provide additional metal to the parts of the casting that freeze last of all

160
Q

What is a core in a casting mold

A

When a hole or cavity is required in a sand casting, it is usually made by inserting a specially made sand core

161
Q

What is a chaplet in a casting mold

A

Whenever a core is either long or fragile, a chaplet is inserted. A chaplet is designed to support the core, and this is made of the metal that is being cast

162
Q

What is a chill in a casting mold

A

Often large changes in thickness cannot be avoided. Therefore controlling the cooling rates must be accomplished to ensure product quality. To assist with controlling the cooling rates, chills may be incorporated into the casting itself or in the mold.

163
Q

Explain two advantages of cold working versus hot working a metal

A

Good surface finish with no oxide scale.

Extremely close dimensional tolerance due to no thermal shrinkage

Emc Practice (1 decks)

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