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Welding Week 4 > Inspection Methods > Flashcards

Inspection Methods Flashcards

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1
Q

Methods of weld testing and analysis are used to assure what?

A

The quality and correctness of the weld after it is completed.

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2
Q

Weld testing refers to testing and analysis focused on what?

A

Quality and strength of the weld.

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3
Q

To ensure development of quality weld, what 2 data sources are collected?

A

Qualitative (NDT), Quantitative (Hardness, tensile strength, ductility, toughness, fracture toughness)

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4
Q

What are the 3 stages of inspection?

A

Before, during and after welding.

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5
Q

What are the 2 testing techniques (type)?

A

Destructive and non-destructive.

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6
Q

What are 3 things that must happen before welding?

A
  1. Cleaning, 2. Edge Prep, 3. Baking of electrodes
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7
Q

What must be monitored during welding?

A

Input parameters, current/voltage, welding speed, shielding gas, and head source temp

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8
Q

What are 3 things that must happen after welding?

A

Removal of slag, peening (stress removal), and post welding treatment (heat)

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9
Q

What is destructive testing?

A

Physical damage to w/p and welded joint. Quantitative data obtained.

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10
Q

What is NDT?

A

Without physically damaging the work piece and joint. Qualitative data is obtained.

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11
Q

What is the definition of a destructive test?

A

Damage takes place in the component which is being tested while being observed, until damage reaches an extent that it cannot be used for further targeted application.

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12
Q

Destructive testing can be performed in what 2 places?

A

Workshop, laboratory

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13
Q

What are the types of destructive weld testing?

A

Tensile, Bend, hardness, Toughness, fatigue.

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14
Q

Tensile test is used to check how the weld joint will ______ and under different environments.

A

perform under tensile loading

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15
Q

What is tensile testing?

A

Deformation at different stages and the total elongation of the weld joint till fracture. (Involves modulus of elasticity and yield strength)

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16
Q

What are the two ways tensile properties are obtained?

A
  1. Taking specimen from transverse direction of weld joint consisting base metal - heat affected zone.
  2. All weld metal metal specimen: consists entirely of weld metal, oriented parallel to the weld axis.
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17
Q

Tensile test results must be supported by ______ diagram.

A

stress/strain diagram

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18
Q

What are the two reasons from performing an all weld metal test?

A
  1. qualify a filler metal

2. determine properties of the weld metal in a particular weldment

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19
Q

What are the typical properties of an all weld metal tension test?

A

Tensile strength, yield strength, elongation.

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20
Q

_____ determines ductility, soundness of welded joints in terms of porosity, inclusion, penetration, and other macro size weld discontinuities.

A

Bend Test

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21
Q

The outside of the bend is extensively plastically deformed, why?

A

So that any defect in or embrittlement of the material will be revealed by the premature failure.

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22
Q

Bend of the weld joint can be done from ________ or _____ side depending upong the purpose (whether ____ or ____ side is assessed)

A

face or root

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23
Q

What are the 3 types of bend test?

A

Free bend, Guided bend, loading bend

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24
Q

In _______ test between the two supports, the weld joint is placed and then the compressive load is applied for bending to take place.

A

Free bend

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25
Q

In ______ test, it is performed by placing the weld joint over a die. It offers better controlled conditions of the specimen and of the loading.

A

guided bend

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26
Q

_____ has a load that keeps on increasing until crack starts appearing on the face or root. Angle of bend is considered as measure of ductility.

A

load in Bend test

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27
Q

What am I? it is resistance to indentation or penetration. usually referred as a measure of resistance to abrasion or scratch.

A

Hardness test

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28
Q

Due to applications of heat in welding, materials like hard enable _____ or ______ are subjected to hardening. Materials like aluminum alloys ________.

A

Steel or cast Irons are subjected to hardening, aluminum alloys precipitation enabled become softer.

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29
Q

hardening and softening phenomenon usually occurs at _____.

A

HAZ

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30
Q

What does the hardness test reveal?

A

Micro structural transformation, any embrittlement.

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31
Q

_______ is the ability of a material to resist both fracture and deformation. Simulates service conditions often encountered by components of the system used in transportation, agricultural and construction equipment.

A

Toughness Test

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32
Q

What can be determined by calculating energy absorbed by material before fracture?

A

Toughness

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33
Q

What steel is the strongest?

A

high carbon steel (high stress/low strain)

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34
Q

What steel is the toughest?

A

medium carbon steel (medium stress/medium strain)

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35
Q

What is the most ductile?

A

low carbon steel (low stress/high strain)

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36
Q

What are 2 methods of toughness?

A

Charpy impact, izod impact

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37
Q

An izon sample is held _____ on an anvil as a cantilever.

A

vertically

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38
Q

An izon holding, cantilever type and ______ the pendulum.

A

notch faces

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39
Q

A charpy sample is held _____ on anvil as simply supported beam.

A

horizontally

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40
Q

A charpy holding simply supported type and notch is ____ side of pendulum impact (not facing to pendulum)

A

opposite

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41
Q

What is the most common fracture toughness test used by industry.?

A

Charpy

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42
Q

What am I? A notched specimen is broken by a swinging pendulum and the amount of energy required to break the specimen is recorded in foot-pounds or joules. this is determined by __________.

A

Charpy impact; how far the pendulum swings upwards after it fractures the specimen.

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43
Q

At ____ temp the material is more brittle and impact toughness is low.

A

low

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44
Q

At ___ temp the material is more ductile and impact toughness is higher.

A

high

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45
Q

What is an important consideration in the selection of material for toughness test?

A

The transition temperature of the boundary between brittle and ductile behavior.

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46
Q

_____ is generally carried out with the specimens at room temp since the time required to accurately place it in the machine allows its temp to increase. (This can introduce a significant error when conducting tests at various temperatures)

A

Izod Impact

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47
Q

______ standard for preparing specimen. Can be determined by endurance limit and number of load ccles that joint can withstand.

A

Fatigue Test

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48
Q

A fatigue test must include

______ - axial pulsating, reverse bending or tension compression.
______ - ratio of minimum stress to maximum stress.
_________ (ambient/vacuum/corrosive)
________

A

type of loading, stress ratio, temp/environment, type of sample

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49
Q

For plotting stress to number of cycles curve (s-n curve) fatigue test is conducted with _______________ to determine number of load cycle required for fracture.

A

maximum applied tensile load corresponding to 0.9 times of yield strength.

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50
Q

________ is a wide group of analysis techniques used in science and tech industry to evaluate the properties of a material, component or system without causing damage.

A

Non-Destructive testing

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51
Q

What are some uses of NDE methods?

A
  • flaw detect and eval
  • leak detect
  • location determination
  • dimensional measure
  • structure and micro-structure characterization
  • estima of mechanical/physical prop
  • stress/strain and dynamic response measure
  • material sort and chemical comp determination
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52
Q

Why nondestructive?

A

test piece too precious, needs to be reused, is in service, quality control purpose

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53
Q

What NDT methods used for surface flaw?

A

VT, MT, PT

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54
Q

What NDT methods used for internal flaw?

A

RT, UT, ET

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55
Q

What is the most basic and common inspection method?

A

VT

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56
Q

What is the most widely used NDE method?

A

PT… I don’t agree with this

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57
Q

Why is PT popular?

A

Ease of use and its flexibility

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58
Q

You can’t use PT on ______ surfaces.

A

rough or porous

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59
Q

Materials that are commonly inspected with PT include…

A

metals, glass, ceramic, rubber, plastic

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60
Q

PT is a method that is used to reveal surface breaking flaws by ____ of a colored or fluorescent dye from the flaw.

A

bleedout

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61
Q

The technique is based on the ability of a liquid to be drawn into a clean surface breaking flaw by ________.

A

capillary action

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62
Q

After a period of time for pt is called ______, where excess surface penetrant is removed and a developer is applied.

A

dwell

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63
Q

What acts as the blotter and draws the penetrant from the flaw to reveal its presence?

A

developer

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64
Q

_______ require good white light.

A

colored (contrast) penetrants

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65
Q

Fluorescent penetrants need to be used in darkened condition with an _______.

A

ultraviolet black light

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66
Q

____- can be used in non-ferromagnetic materials and even non-metals.

A

PT

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67
Q

Modern PT methods can reveal cracks ___ um wide

A

2

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68
Q

What are 2 ways that a penetrant inspection process makes flaws more easily seen?

A
  1. flaw indication that is much larger and easier for the eye to detect than the flaw itself.
  2. PT produces a flaw indication with a high level of contrast between the indication and the background
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69
Q

What is the basic steps for PT?

A

cleaner, penetrant+dwell, developer, dwell

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70
Q

One of the most critical steps of a liquid penetrant inspection is the ____ preparation

A

surface

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71
Q

the surface must be free of oil, grease, water, or other contaminants _______.

A

that may prevent penetrant from entering flaws.

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72
Q

Sanding or grit blasting may cause ______, thus closing the defects.

A

metal smear

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73
Q

penetrant material is applied by ___, ___, or ___

A

spraying, brushing, immersing the parts in a penetrant bath

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74
Q

dye must provide ______ against the developer

A

good contrast

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75
Q

What is red liquid against white developer?

A

Dye penetrant

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76
Q

What is liquid contain additives to give fluorescence under uv

A

fluorescent penetrants

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77
Q

Method A-

A

water washable

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78
Q

method B

A

Post Emulsifiable, Lipophilic (gets composed with solvent)

79
Q

Method C

A

Solvent Removable

80
Q

Method D

A

Post Emulsifiable, Hydrophilic (dissolve in water)

81
Q

Based on the ______ of the indication that is produced for a number of very small and tight fatigue cracks, penetrants can be classified into 5 sensitivity levels.

A

strength or detectability

82
Q

level 1/2 -

A

ultra low sensitivity

83
Q

level 1

A

low sensitivity

84
Q

level 2

A

medium sensitivity

85
Q

level 3

A

high sensitivity

86
Q

level 4

A

ultra high sensitivity

87
Q

What is the role of developer?

A

To pull the trapped penetrant material out of defects and to spread the developer out on the surface of the part so it can be seen by an inspector

88
Q

What does fine developer particles?

A

Both reflects and refracts the incident ultraviolet light, allowing more of it to interact with the penetrant, causing more efficient fluorescence.

89
Q

Developer allows more light to be emitted through the same mechanism, that is why ______ are brighter than the penetrant itself under UV.

A

indications

90
Q

Developers that create a white background have a greater degree of ____ between the indication and the surrounding background.

A

contrast

91
Q

______ is the least sensitive but inexpensive developer type

A

dry powder developer

92
Q

____ consist of a group of chemicals that are dissolved in water and form a developer layer when the water is evaporated away.

A

water soluble

93
Q

______ consist of insoluble developer particles suspended in water.

A

Water suspendible

94
Q

_______ suspend the developer in a volatile solvent and are typically applied with a spray gun.

A

nonaqueous

95
Q

Using dye and developer from different manufacturers should be ______.

A

avoided

96
Q

Which method has a high sensitivity to small surface discontinuities.

A

PT

97
Q

What NDT method is most widely utilized.

A

MT

98
Q

The only requirement for MT, is tha.t____

A

components being inspected must be made of a ferromagnetic material like iron, nickel, cobalt, or some of their allows.

99
Q

________ materials are materials that can be magnetized to a level that will allow the inspection to be effective.

A

ferromagnetic

100
Q

Examples of MT use are

A

structural steel, automotive, petrochemical, power generation, and aerospace

101
Q

Mt is a mix of

A

magnetic flux leakage and visual testing

102
Q

The pole where a magnetic line of force exits the magnet is called the _____ pole.

A

north

103
Q

A pole where a line of force enters the magnet is called the _____ pole.

A

south

104
Q

What is a diamagnetic metal?

A

very weak and negative susceptibility to magnetic fields. (slightly repelled by a magnetic field and the material does not retain the magnetic prop when the external field is removed)

105
Q

What is a paramagnetic metal?

A

Small and positive susceptibility to a magnetic field. These materials are slightly attracted by a magnetic field and the material does not retain the magnetic prop when the external field is removed.

106
Q

What is a ferromagnetic material?

A

large and positive susceptibility to an external magnetic field. They exhibit a strong attraction to magnetic fields and are able to retain their magnetic prop after the external field has been removed.

107
Q

Ferromagnetic materials become magnetized when the magnetic domains within the material are _____.

A

aligned

108
Q

The more domains that are aligned the ______ the magnetic field is in the material.

A

stronger

109
Q

When all the domains are aligned, the material is said to be magnetically _____.

A

saturated

110
Q

When a material is magnetically saturated, ______ amount of external magnetization force will cause an increase in its internal level of magnetization.

A

no additional

111
Q

It is common to classify the magnetizing methods as either ____ or ______.

A

direct or indirect

112
Q

Direct magnetization is ______.

A

current

113
Q

Indirect magnetization uses a _________ to establish a magnetic field within the component.

A

a strong external magnetic field

114
Q

Magnetic lines of force ____ cross one another.

A

never

115
Q

Magnetic lines of force will follow the path of ______ resistance between opposite magnetic poles.

A

least

116
Q

The ______ decreases when lines of force move from an area of higher permeability to an area of lower permeability.

A

density

117
Q

Their density ______ with increasing distance from the poles.

A

decreases

118
Q

Flow goes from the south pole to the north pole within the ______ and north pole to south pole in _____.

A

material, air

119
Q

When a bar magnet is broken in the center of its length, what happens?

A

Two complete bar magnets with magnetic poles on each end of each piece will result.

120
Q

If the magnet is just cracked but not broken completely in two, what happens?

A

A north and south pole will from at each edge of the crack.

121
Q

The magnetic field exits the ____ pole and reenters at the _____ pole.

A

north, south

122
Q

The magnetic field spreads out when it encounters the small _____ created by the crack because the ____ cannot support as much magnetic field per unit volume as the magnet can.

A

air gap, air

123
Q

When the field ______ it appears to leak out of the material and thus it is called a ______.

A

spreads out, flux leakage field

124
Q

If iron particles are sprinkled on a cracked magnet, the particles will be ___________ not only at the poles at the ends of the magnet but also at the poles at the edges of the crack.

A

attracted to and cluster

125
Q

The magnetic flux line close to the surface of a ferromagnetic material tends to __________________.

A

follow the surface profile of the material.

126
Q

_______ (cracks or voids) of the material perpendicular to the flux lines cause fringing of the magnetic flux lines.

A

discontinuities

127
Q

The leakage field can attract other ________ particles

A

ferromagnetic

128
Q

The magnetic particles form a ridge may times _____ than the crack itself.

A

wider

129
Q

Cracks just below the surface __________ for MT

A

can also be revealed

130
Q

MT is not ______ to shallow and smooth surface defects.

A

sensitive

131
Q

The effectiveness of MT depends strongly on the orientation of the crack related to the flux lines.
True or false

A

true

132
Q

what is the testing procedure of MT?

A
  1. pretreatment
  2. magnetization
  3. apply magnetic particles
  4. observation
  5. detect crack/flaw
  6. post-treatment
133
Q

_______ involves the use of penetrating gamma or x-radiation to examine materials and products defect and internal features.

A

radiography

134
Q

________ shows the internal features and soundness of a part in RT.

A

shadowgraph

135
Q

________ and ____ changes are indicated as lighter or darker areas on the film.

A

material thickness and density changes

136
Q

The ______ areas in the radiograph below represent internal voids in the component

A

the darker areas

137
Q

x-rays are part of the ________ spectrum, with wavelengths shorter than visible light.

A

electromagnetic

138
Q

______ are produced whenever high-speed electrodes collide with a metal target.

A

x-rays

139
Q

a source of electrons is hot W filament, a ____________ (30-50kv) between the cathode (w) and the anode and a metal target.

A

high accelerating voltage

140
Q

The anodes is a ______.

A

water-cooled block of Cu containing desired target metal.

141
Q

X-rays are electrode magnetic radiation with very _____ wavelengths

A

short

142
Q

the x-ray photon with wavelength 1 A has energy of

A

12.5keV

143
Q

Emitted gamma radiation is one of the 3 types of ______ radioactivity. It is also the most energetic form of electromagnetic radiation, with a very short wavelength of less than one-tenth of a nano-meter.

A

natural

144
Q

______ are essentially very energetic x-rays emitted by excited nuclei.

A

gamma rays

145
Q

Man made sources are produced by introducing an extra ____ to atoms of the source material. As the material rids itself of the _____, energy is released in the form of gamma rays.

A

neutron

146
Q

What are the 2 more common industrial gamma-ray sources?

A

Iridium 192 and cobalt 60.

147
Q

The part tested is place between what?

A

the radiation source and the piece of film.

148
Q

_______ area will stop more of the radiation.

A

thicker and more

149
Q

the film _______ density will vary with the amount of radiation reaching the film through the test object.

A

darkness

150
Q

The first subjective criteria for determining radiographic quality is radiographic _____.

A

contrast

151
Q

What is radiographic contrast?

A

the degree of density difference between adjacent areas on a radiograph.

152
Q

It is essential that sufficient contrast exist between the defect of interest and the____.

A

surrounding area

153
Q

The radiographic definition of quality is the ______________.

A

abruptness of change in going from one density to another.

154
Q

y-ray from Co-60 can penetrate up to ____ mm of steel

A

150

155
Q

In Rt the operator must have access to both sides of an object. true or false?

A

true

156
Q

Cracking can be detected in a radiograph on the crack is propagating in a direction that produced a change in thickness that is _____ to the x-ray beam.

A

parallel

157
Q

In Rt ____ will appear as jagged and often very faint irregular lines. They can also so appear as tails on inclusions or porosity.

A

cracking

158
Q

______ (icicles) results when too much heat causes excessive weld metal to penetrate the weld zone. lumps of metal sag through the weld creating a thick globular condition on the back of the weld.

A

burn through

159
Q

_____ burn through appears as dark spots surrounded by light globular areas.

A

burn through

160
Q

_____ or ____ are cause by accumulated gas or air which is trapped by the metal. These discontinuities are usually smooth-walled rounded cavities of a spherical, elongated or flattened shape.

A

gas porosity or blow holes

161
Q

_____________ and ____ are nonmetallic oxides, appearing on the radiograph as irregular, dark blotches.

A

sand inclusions and dross

162
Q

______ is high-frequency sound waves are transmitted into a material to detect imperfections or to locate changes in material properties.

A

ultrasonic testing

163
Q

The most commonly used ultrasonic testing technique is _______, whereby sound is introduced into a test object and reflections (echoes) from internal imperfections or the parts geometrical surface are returned to a receive.

A

pulse echo

164
Q

the _______ between the transmission and reception of pulse give clues to the internal structure of the material.

A

time interval

165
Q

____ has high frequency sound wave introduced into a material and thy are reflected back from surfaces or flaws.

A

pulse echo

166
Q

reflected sound energy is displayed versus time and inspector can visualize a cross section of the specimen showing the ____ of features that reflect sound.

A

depth

167
Q

______ transducers are used for converting electrical pulses to mechanical vibrations and vice versa.

A

piezoelectric

168
Q

commonly used piezoelectric materials are _____, and ______.

A

quartz, polarized ceramics

169
Q

Usually transducers generate ultrasonic waves with frequencies in range ___ or ___ mhz

A

2.25 to 5.0

170
Q

The active element of the most accoustic transducer is ______ ceramic.

A

piezoelectric

171
Q

A thin wafer vibrates with a wavelength that is twice its thickness, therefore, piezoelectric _____ are cut to a thickness that is 1/2 the desired radiated wavelength.

A

crystals

172
Q

_______ matching is achieved by a matching layer with thickness 1/4 wavelength

A

optimal impedance

173
Q

______ waves: similar to audible sound waves. The only type of wave which can travel through liquid.

A

longitudinal waves

174
Q

_____ waves: generated by passing the ultrasonic beam through the material at an angle. Usually a plastic wedge is used to couple the transducer to the materials.

A

shear

175
Q

__________ does not contact the component. These transducers are designed to operate in a liquid environment and all connects are watertight. Wheel and squirter transducers are examples of such immersion applications.

A

immersion

176
Q

_______ contains two independently operating elements in a single housing. One of the elements transmits and the other receives. _____ element transducers are very useful when making thickness measurements of thing materials and when inspecting for near surface defects.

A

dual element

177
Q

____ and wedges are typically used to introduce a refracted shear wave into the test material. they are used to generate surface waves for use in detecting defects on the surface of a component.

A

angle beam

178
Q

______ or a _____ is needed for effective transmission of ut from the transducer to the material

A

fluid couplant or a fluid bath

179
Q

Straight beam contact search unit projects a beam of ultrasonic vibrations _____ to the surface.

A

perpendicular

180
Q

_____ contact units send ultrasonic beam into the test materials at the predetermined angle to the surface.

A

angle beam

181
Q

When the geometry of the part is relatively uncomplicated and the orientation of a flow is well known, the length of a crack can be determined by a technique known as _______.

A

tip diffraction

182
Q

One common application of the diffraction technique is to determine the length of a crack originating form on the backside of a _____.

A

flat plate

183
Q

______ is a function of the ultrasound velocity in the material, the _______ and the difference in arrival times between the two signal

A

crack height, incident angle

184
Q

What are the 3 most common formats for data presentation in UT?

A

A-scan, b-scan and c-scan

185
Q

_____ displays the amount of received ultrasonic energy as a function of time.

A

a-scan

186
Q

______ presentations is a profile cross-sectional view of the a test specimen. TOF of the sound energy is displayed along the vertical and linear position of the transducer is along the horizontal axis.

A

b-scan

187
Q

_____ provides a plan-type view of the location and size of test specimen features. the plane of the image is parallel to the scan pattern of the transducer.

A

c-scan

188
Q

electrical currents are generated in conductive material by an induced alternating magnetic field. the electrical currents are called ____ because the flow in circles at and just below the surface of the material.

A

eddy current

189
Q

the strength of the secondary field depends on the electrical and magnetic properties, structural integrity of the test object. true or false

A

true

190
Q

The changes in the secondary field will be a _____ to the primary coil and affect the primary current

A

feedback

191
Q

the depth as which eddy current density has decreased to 1/e or about 37% of the surface density, called the standard depth of _____.

A

penetration

192
Q

What are the 3 types of ET probes?

A

surface, internal bobbin, encircling probe

193
Q

What is on the y and x axis of the eddy current impedance plane response?

A

inductive reactance, resistance

Welding Week 4 (10 decks)

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