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Materials & Processes Flashcards

1
Q

As hot working progresses (assuming the temperature of the part is held constant), the energy required for further processing:

a. increases.
b. decreases.
c. remain constant.
d. any of the above may be true, depending on the material.

A

a. increases.

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2
Q

A fatigue crack is a service defect that is caused by:

a. cyclic loading of the part above the yield strength of the material.
b. cyclic loading of the part below the yield strength of the material.
c. local overheating of the part.
d. corrosive atmosphere.

A

b. cyclic loading of the part below the yield strength of the material.

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3
Q

The middle portion of a molding flask is called a:

a. cope.
b. drag.
c. cheek.
d. separator.

A

c. cheek.

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4
Q

A cause of gas porosity in welds is:

a. welding at too low temperature.
b. improper cleaning or preheating.
c. the use of insufficient filler metal.
d. restriction of movement of the material.

A

b. improper cleaning or preheating.

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5
Q

In the resistance welding process:

a. two parts to be joined are heated then pressure is applied
b. the pieces to be joined are held firmly together under pressure, followed by the generation of heat at the interface.
c. no heat is applied and the parts are welded by applying pressure only.
d. the parts are heated but not melted and a filler metal is added.

A

b. the pieces to be joined are held firmly together under pressure, followed by the generation of heat at the interface.

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6
Q

In a mold, the runner connects:

a. the pouring basin to the sprue.
b. the downgate to the riser.
c. the sprue to the ingate.
d. the pouring basin to the mold cavity.

A

c. the sprue to the ingate.

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7
Q

Metal forming during rolling results in:

a. plastic flow of the metal.
b. elongation of existing defects perpendicular to the rolling direction.
c. directional properties which are always beneficial for secondary forming operations.
d. the flattening out of defects which makes them more easily detectable by most N.D.T. methods.

A

c. directional properties which are always beneficial for secondary forming operations.

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7
Q

A welding defect that occurs at the root and runs parallel with the weld is:

a. a lack of fusion between beads.
b. an icicle.
c. a crater crack.
d. a lack of penetration.

A

d. a lack of penetration.

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8
Q

Hot working an ingot may produce a product with:

a. fewer defects than in the original ingot.
b. more defects than in the original ingot.
c. the same number of defects as in the original ingot.
d. any of the above may be correct depending on the circumstances.

A

d. any of the above may be correct depending on the circumstances.

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9
Q

A disadvantage of dry sand molds when compared to green sand molds is that:

a. erosion of the mold is more common.
b. castings are more susceptible to hot tears.
c. a surface finish is generally worse.
d. the overall dimensional accuracy is worse.

A

a. erosion of the mold is more common.

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10
Q

A long defect, parallel to the longitudinal axis of a bar and caused by blowholes, cracks or tears introduced in earlier processing and elongated in the direction of rolling or forging is called a:

a. seam.
b. forging lap.
c. lamination.
d. cold shut.

A

a. seam.

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11
Q

Rapid oxidation of metal surfaces during hot working of a mild steel may:

a. produce a carburized surface layer.
b. produce a product which is thicker than originally intended.
c. adversely affect the cooling rate of the newly formed material.
d. adversely affect the application of some non-destructive tests.

A

d. adversely affect the application of some non-destructive tests.

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12
Q

An advantage of shell molding compared to green sand molding is:

a. that larger castings can be produced when using shell molds.
b. the lower cost of production of shell molding.
c. a better surface finish is obtainable.
d. All of the above.

A

c. a better surface finish is obtainable.

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13
Q

A burst is an/a _______________________ discontinuity.

a. inherent
b. processing
c. service
d. All of the above.

A

b. processing

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14
Q

Bursts usually have the following characteristics, they:

a. appear as smooth indentations on metal surfaces.
b. are cavities varying in size from wide open to very tight, usually parallel with the grain.
c. are extremely thin and flat, generally aligned parallel to the work surface of the material.
d. are three dimensional discontinuities having smooth internal surfaces and generally located close to the surface of the wrought material.

A

d. are three dimensional discontinuities having smooth internal surfaces and generally located close to the surface of the wrought material.

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15
Q

In a rolling mill, flattening and elongation of metal is accomplished primarily by:

a. tensile stresses.
b. bending stresses.
c. compressive stresses.
d. high frequency cyclic loads.

A

c. compressive stresses.

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16
Q

The fuel gas most commonly used in gas welding is:

a. Butane.
b. Propane
c. Acetylene.
d. All of the above.

A

c. Acetylene.

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17
Q

Cold shuts are most likely to be found in:

a. extrusions.
b. forging.
c. castings.
d. sintered parts.

A

c. castings.

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18
Q

Air craft turbine blades are usually processed by:

a. investment casting.
b. shell mold casting.
c. green sand casting.
d. dry sand casting.

A

a. investment casting.

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19
Q

The electrodes used for spot welding are usually made of:

a. Carbon.
b. Mild steel.
c. Tungsten.
d. Copper.

A

d. Copper.

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20
Q

A metal forming operation which allows three dimensional control over the shape of the product is:

a. Rolling.
b. Extruding.
c. Forging.
d. All of the above.

A

c. Forging.

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21
Q

A forming operation which results in the greatest dimensional accuracy is:

a. Cold rolling of sheet.
b. Hot rolling of sheet.
c. Cold rolling of bars.
d. Forging.

A

d. Forging.

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22
Q

In which of the following joining methods will flaws essentially be two dimensional?

a. Gas tungsten arc welding.
b. Gas metal arc welding.
c. Submerged arc welding.
d. Brazing.

A

d. Brazing.

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23
Q

A flaw which can resemble a cold shut is:

a. an undercut in a weld.
b. a hot tear in a casting.
c. a blowhole in a casting.
d. a forging lap.

A

d. a forging lap.

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24
Q

Elements may be added to the filler metal to:

a. control grain growth.
b. increase ductility.
c. assure adequate corrosion resistance.
d. any of the above.

A

d. any of the above.

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25
Q

One of the main causes of cold shuts is:

a. improper preheating of molds.
b. the presence of several sprues or gates in the mold.
c. pouring without a filter.
d. the alloy selection.

A

b. the presence of several sprues or gates in the mold.

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26
Q

An EDM notch formed in 304 stainless steel may cause:

a. a local increase in permeability.
b. the formation of austenite around the notch.
c. an increase in conductivity.
d. all of the above.

A

c. an increase in conductivity.

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27
Q

CHECK FOR CORRECTNESS

Which discontinuity is not normally found in a casting?

a. Misrun.
b. Porosity.
c. Shrinkage.
d. Slugging.

A

d. Slugging.

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28
Q

Non-metallic impurities trapped within the molten metal of a casting are generally called:

a. blowholes.
b. inclusions.
c. cracks.
d. shrink cavities.

A

b. inclusions.

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29
Q

Most manufacturing defects in a tube are:

a. axial in direction.
b. circumferential in direction.
c. on the outside of the tube.
d. subsurface.

A

a. axial in direction.

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30
Q

Increasing test sample temperature normally:

a. increases electrical resistivity.
b. decreases electrical resistivity.
c. does not change electrical resistivity.
d. increases magnetic permeability.

A

a. increases electrical resistivity.

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31
Q

When thick and thin casting sections are adjacent to each other, what discontinuity may result?

a. porosity.
b. inclusions.
c. shrinkage.
d. core shift.

A

c. shrinkage.

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32
Q

Heat exchanger tubes are defect prone at regions:

a. adjacent to support plates.
b. under support plates.
c. in-between support plates.
d. all of the above.

A

d. all of the above.

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33
Q

Which of the following discontinuities is not normally associated with casting?

a. segregation.
b. core shift.
c. misrun.
d. bursts.

A

d. bursts.

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34
Q

Which of the following is identified as a casting insert?

a. chaplet.
b. mold.
c. gate.
d. riser.

A

a. chaplet.

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35
Q

The work metal used for working with a forging hammer is:

a. a bloom.
b. a billet.
c. a bar.
d. any of the above.

A

d. any of the above.

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36
Q

Cold working steel or aluminum results in a decrease in:

a. ductility.
b. hardness.
c. strength.
d. all of the above.

A

a. ductility.

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37
Q

The grain size of a ferrous metal is commonly refined by:

a. elastic deformation.
b. heat treatment.
c. high frequency mechanical vibrations.
d. both a and b.

A

b. heat treatment.

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38
Q

A method commonly used to remove a number of flaws in an ingot prior to forming is:

a. cropping.
b. heat treating.
c. welding.
d. sand blasting.

A

a. cropping.

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39
Q

Which of the following factors can have a negative influence on some non-destructive tests?

a. grain size.
b. grain orientation.
c. grain boundary composition.
d. all of the above.

A

d. all of the above.

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40
Q

The principle purpose of risers in molds is to:

a. feed the castings as the metal shrinks.
b. let air escape from the mold.
c. ensure impurities will remain outside the casting.
d. favour directional solidification.

A

a. feed the castings as the metal shrinks.

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41
Q

The process in which a mold is formed from a mixture of sand and a thermosetting resin binder that is placed against a heated metal pattern is called:

a. Dry sand molding.
b. Permanent mold casting.
c. Investment casting.
d. Shell molding.

A

d. Shell molding.

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42
Q

A casting process in which the pattern is not re-usable is called:

a. Shell mold casting
b. Investment casting
c. Sand casting
d. Composite mold casting

A

b. Investment casting

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43
Q

A casting process involving a re-usable mold is called:

a. investment casting.
b. shell mold casting.
c. dry sand casting.
d. die casting.

A

d. die casting.

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44
Q

Which of the following welding processes does not involve melting of the parts to be joined?

a. Arc welding
b. Gas welding
c. Pressure welding
d. Electron beam welding

A

c. Pressure welding

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45
Q

In the shielded metal-arc welding process, the electrode covering may include materials used to:

a. protect the metal from oxidation during melting and transfer across the arc.
b. protect the weld bead as it solidifies and cools to room temperature.
c. alloy the weld metal.
d. all of the above.

A

d. all of the above.

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46
Q

A non-consumable electrode used for arc welding would be made of:

a. Tungsten
b. Steel
c. Copper
d. Titanium

A

a. Tungsten

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47
Q

In gas welding, acetylene is usually burned with which other gas?

a. Oxygen.
b. Hydrogen.
c. Argon.
d. Nitrogen.

A

a. Oxygen.

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48
Q

Which of the following statements is correct?

a. The heat affected zone of a weld is basically a homogenous structure
b. In some areas of the weld heat affected zone, grain size can be smaller than in the unaffected base metal
c. The temperature in the heat affected zone can sometimes exceed the temperature in the fusion zone
d. Transverse cracks do not occur in the heat affected zone

A

a. The heat affected zone of a weld is basically a homogenous structure

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49
Q

A rupture in the material that can be in any direction on the part and is caused by localized stresses that exceed the tensile strength of the material is:

a. A fatigue crack
b. A heat treat crack
c. A seam
d. A stringer

A

a. A fatigue crack

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50
Q

CHECK FOR CORRECTNESS

A manufacturing process based on plastic flow is:

a. Welding.
b. Casting.
c. Forging.
d. All of the above.

A

d. All of the above.

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51
Q

A definite break in the material caused by excessive working of the metal during the forging, rolling or extruding operation is called a:

a. Cold shut
b. Seam
c. Burst
d. Hot tear

A

c. Burst

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52
Q

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

a. Crater cracks
b. Porosity
c. Undercutting
d. Lack of penetration

A

b. Porosity

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53
Q

An inherent defect formed prior to completion of solidification of the casting because of restricted contraction is called a:

a. Hot tear
b. Shrinkage
c. Burst
d. Cold shut

A

a. Hot tear

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54
Q

CHECK FOR CORRECTNESS

An extremely thin discontinuity that is the result of pipes or inclusions flattened and made directional by working is called:

a. a stringer.
b. a lamination.
c. a seam.
d. a cold shut.

A

b. a lamination.

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55
Q

A surface defect caused by cyclical loading of a part below the yield strength of the material is called:

a. Intergranular corrosion
b. A heat treat crack
c. A fatigue crack
d. A hot tear

A

c. A fatigue crack

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56
Q

A cold shut is an inherent defect that may be caused by:

a. gases given off during casting and trapped in the metal.
b. not enough metal available to fill the mold.
c. too low a temperature of the metal poured.
d. the more rapid cooling of thin sections that adjoin heavier masses of metal which are slower to cool.

A

d. the more rapid cooling of thin sections that adjoin heavier masses of metal which are slower to cool.

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57
Q

An advantage of investment casting over green sand casting is:

a. The mold in reusable
b. Larger parts my be cast
c. More complex shapes may be cast
d. The need for cores never arises

A

c. More complex shapes may be cast

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58
Q

The material used for making a pattern depends on:

a. The type of material that will be cast
b. The grain structure desired in the finished casting
c. The expected production quantity
d. All of the above

A

d. All of the above

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59
Q

A green sand mold is:

a. a sand mold coated with a green wash.
b. a sand mold mixture made up of sand, clay and water.
c. a sand mold not yet ready for casting.
d. a sand mold used in the production of cores only.

A

b. a sand mold mixture made up of sand, clay and water.

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60
Q

In which of the following casting processes are cores never used?

a. Shell mold casting
b. Investment casting
c. Permanent mold casting
d. None of the above

A

b. Investment casting

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61
Q

The essential difference between permanent mold casting and die casting is:

a. In the first method, molten metal enters the mold by gravity, while the second method, the molten metal enters the mold under pressure
b. The mold in the permanent mold casting is reusable while it is not in the case of die casting
c. The mold in permanent mold casting is made of ceramic while steel is used to make the mold for die casting
d. There are no differences. Both names are used to identify the same process

A

a. In the first method, molten metal enters the mold by gravity, while the second method, the molten metal enters the mold under pressure

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62
Q

When metal solidifies:

a. Atoms become more mobile thus allowing them to migrate to definite positions within a crystal
b. Atoms lose mobility and assume fixed positions in the space lattice of the unit cell
c. A curie point is reached were crystals begin to grow
d. A curie point is reached where grain boundaries begin to form

A

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

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63
Q

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

a. A mixture of large and small grains having random orientation and shape
b. Coarse columnar grains
c. Coarse equiaxed grains
d. Fine equiaxed grains having random orientation and shape

A

d. Fine equiaxed grains having random orientation and shape

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64
Q

What type of grain structure would normally be found at the centre of a heavy walled casting?

a. Fine equiaxed grains of random orientation and shape
b. Columnar grains with a dendritic structure
c. Large equiaxed grains with superior metallurgical characteristics
d. None of the above are correct

A

b. Columnar grains with a dendritic structure

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65
Q

In fusion welding, preheating will result in:

a. A reduced grain size
b. A harder structure
c. A reduced cooling rate
d. An austenitization of the base metal prior to welding

A

c. A reduced cooling rate

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66
Q

Elements may be added to the filler metal to:

a. control grain growth.
b. increase ductility.
c. assure adequate corrosion resistance.
d. all of the above.

A

d. all of the above.

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67
Q

An advantage of electroslag welding, over other methods of welding, is that:

a. A coarse grain structure is formed because of the slow cooling rate
b. It does not require special edge preparation on the base metal sections
c. Weld cracking is never a problem because of the absence of residual stress
d. Very thick sections can be welded easily

A

b. It does not require special edge preparation on the base metal sections

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68
Q

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

a. The electrode is consumable
b. The shielding gas is contained in the flux covering the electrode
c. A stream of protective gas is passed through an inverted cup or a nozzle which surrounds the electrode
d. A slag coating is formed to protect the weld as it cools

A

c. A stream of protective gas is passed through an inverted cup or a nozzle which surrounds the electrode

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69
Q

Submerged arc welding may be performed:

a. In the flat position
b. In the flat and horizontal positions
c. In the vertical position
d. All of the above

A

d. All of the above

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70
Q

Arc welding is usually performed using:

a. Alternating current, low voltage and low amperage
b. Direct current, low voltage and high amperage
c. Direct current, high voltage and low amperage
d. Alternating current, high voltage and low amperage

A

b. Direct current, low voltage and high amperage

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71
Q

Hot tears in a casting may be the result of:

a. Interrupted or too slow metal pouring
b. Excessive gas in the metal poured
c. Insufficient metal poured
d. Improper use of chills

A

d. Improper use of chills

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72
Q

Laminations are produced:

a. When forging with faulty dies
b. When excess metal is folded over during a rolling operation
c. When a pipe or blisters present in the original ingot are made directional by rolling
d. When blowholes introduced in earlier processing are elongated, by extruding, in the direction of working

A

c. When a pipe or blisters present in the original ingot are made directional by rolling

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73
Q

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

a. Continuous hot rolling
b. Super hot rolling
c. Super hot extrusion
d. Continuous casting

A

d. Continuous casting

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74
Q

Inserts which may be found in sand molds are:

a. Chills
b. Chaplets
c. Cores
d. All of the above

A

d. All of the above

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75
Q

The first step in the production of casting is the making of:

a. A mold
b. A pattern
c. A core
d. A cavity

A

b. A pattern

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76
Q

A joining process which occurs without fusion of the base metal is:

a. Arc welding
b. Brazing
c. Spot Welding
d. Gas welding

A

b. Brazing

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77
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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78
Q

A type of defect which propagates along grain boundaries is called:

a. A fatigue crack
b. A transgranular crack
c. A borderline crack
d. A hot tear

A

b. A transgranular crack

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79
Q

Which of the following is a discontinuity that might be found in a forging?

a. Shrinkage cracks
b. Laps
c. Hot tears
d. Insufficient penetration

A

b. Laps

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80
Q

A weld defect formed as a result of shrinkage is called:

a. Undercutting
b. Heat affected zone cracking
c. A crater crack
d. An incomplete sidewall fusion

A

a. Undercutting

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81
Q

CHECK FOR CORRECTNESS

A steel casting suitable for working or remelting is called

a. A bloom
b. A billet
c. An ingot
d. A slab

A

b. A billet

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82
Q

With a forging hammer, the striking force is imposed on the work metal by:

a. The lower die only
b. The upper die only
c. Both dies moving in opposite directions
d. Both b and c

A

b. The upper die only

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83
Q

The factor which must be considered prior to selecting the hammer or press to produce a closed-die forging is:

a. The size of the forging
b. The production quantity
c. The design of the forging
d. All of the above

A

d. All of the above

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84
Q

Which of the following statements is correct?

a. The hardness of the dies for open-die forging is generally higher than the hardness of impression dies for closed-die forging
b. The hardness of dies for open-die forging is generally lower than the hardness of impression dies for closed-die forging
c. The life of dies for open-die forging is less than that of impression dies for closed-die forging
d. Both b and c are true

A

d. Both b and c are true

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85
Q

Prior to forging, steel is usually heated to:

a. Slightly above the curie point
b. Slightly above the melting point
c. Slightly below the melting point
d. Slightly below the first transformation temperature

A

c. Slightly below the melting point

86
Q

The purpose of metal forming is to:

a. Refine the grain structure
b. Improve the mechanical properties
c. Close blow holes which have formed in an ingot
d. All of the above

A

d. All of the above

87
Q

Strain hardening occurs whenever a metal is:

a. Deformed at a temperature below the recrystallization point
b. Deformed at a temperature above the recrystallization point
c. Heat treated
d. Both a and c

A

a. Deformed at a temperature below the recrystallization point

88
Q

Metals which cannot be work hardened are those which:

a. Recrystallize at room temperature
b. Recrystallize at very high temperatures
c. Recrystallize at the curie temperature
d. Recrystallize above the curie temperature

A

a. Recrystallize at room temperature

89
Q

The material used for making a pattern depends on:

a. The type of material that will be cast
b. The grain structure desired in the finished casting
c. The expected production quantity
d. All of the above

A

d. All of the above

90
Q

Patterns made of wood:

a. Are always made in one piece
b. Are always made in two pieces, one for the cope and the other for the drag portion of the flask
c. Are made in one, two, or more pieces depending on the complexity of the casting
d. Never includes the gates and risers if they are made in one piece

A

c. Are made in one, two, or more pieces depending on the complexity of the casting

91
Q

The top portion of a moulding flask is called a:

a. Cope
b. Drag
c. Cheek
d. Separator

A

a. Cope

92
Q

The bottom portion of a molding flask is called a:

a. Cope
b. Drag
c. Cheek
d. Separator

A

b. Drag

93
Q

In a mold, the sprue connects:

a. The runner to the mold cavity
b. The downgate to the riser
c. The downgate to the ingate
d. The pouring basin to the runner

A

d. The pouring basin to the runner

94
Q

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

a. A core
b. A chill
c. A chaplet
d. A spacer

A

c. A chaplet

95
Q

Which of the following methods produces a casting faster and at a lower costs?

a. Green sand casting
b. Dry sand casting
c. Investment casting
d. Shell casting

A

a. Green sand casting

96
Q

Resistance welding differs from fusion welding in that:

a. The use of pressure is indispensable
b. Smaller amounts of filler metal is used
c. Bonding occurs at room temperature
d. There is no fusion of the parent metal

A

a. The use of pressure is indispensable

97
Q

In the shielded metal-arc process, the covering material:

a. Protects the metal from picking-up nitrogen during melting and transfer across the arc
b. Serves as alloying elements to the weld
c. Protects the metal from oxidation during melting
d. All of the above.

A

d. All of the above.

98
Q

In which of the following arc welding processes is the electrode non-consumable?

a. Shielded metal-arc welding
b. Gas tungsten-arc welding
c. Gas metal-arc welding
d. Submerged arc welding

A

b. Gas tungsten-arc welding

99
Q

The following gas is used intensively for shielding in the gas tungsten-arc welding process:

a. Radon
b. Oxygen
c. Argon
d. Hydrogen

A

c. Argon

100
Q

WRONG

In the submerged arc welding process:

a. Flux is supplied by the electrode covering
b. Flux is added separately and heaped along the joint to be welded
c. A liquid flux is applied
d. No flux is needed

A

d. No flux is needed

101
Q

REMOVE

Identify the welding process shown in figure 3.

a. Shielded metal arc welding
b. Gas tungsten-arc welding
c. Gas metal-arc welding
d. Submerged arc welding

A

a. Shielded metal arc welding

102
Q

A process in which multiple electrodes are most commonly used in various arrangements to deposit metal more rapidly is:

a. Shielded metal-arc welding
b. Gas tungsten-arc welding
c. Gas metal-arc welding
d. Submerged arc welding

A

d. Submerged arc welding

103
Q

In gas welding, a reducing flame is produced when:

a. There is no excess oxygen or acetylene in the flame
b. There is excess acetylene in the flame
c. There is excess oxygen in the flame
d. There is excess oxygen and acetylene in the flame

A

b. There is excess acetylene in the flame

104
Q

As cold working progresses, assuming the temperature of the part is held constant, the energy required for further processing:

a. Increases
b. Decreases
c. Remains constant
d. Any of the above may be true depending of the material

A

a. Increases

105
Q

Lack of penetration may be the result of:

a. Too slow a welding rate
b. Too large a welding rod
c. Too high a welding current
d. Improper use of chills

A

b. Too large a welding rod

106
Q

A forging defect caused by the metal being folded over and forced into the surface but not welded to form a single piece is called:

a. A hot tear
b. A Forging lap
c. A burst
d. A forging crack

A

b. A Forging lap

107
Q

Grinding cracks can be caused by:

a. Lack of, or poor coolant
b. Dull, or improper grinding wheel
c. A too heavy cut
d. All of the above

A

d. All of the above

108
Q

A crater crack may occur when:

a. The welder fails to fill the crater before breaking the arc
b. The root face of the joint does not reach fusion temperature before weld metal is deposited
c. Cleaning or preheating of the plates is improperly done before welding
d. Excessive current and excessive welding speed are used

A

a. The welder fails to fill the crater before breaking the arc

109
Q

A forging lap may occur if:

a. Faulty dies are used for forging
b. The metal is either too hot or too cold during the forging operation
c. The metal is forced to flow too fast
d. All of the above

A

d. All of the above

110
Q

Heat treat cracks may be caused by:

a. Unequal heating or cooling of the material
b. Localized stresses below the tensile strength of the material
c. Too high a heat-treatment temperature
d. Use of the part at high temperature

A

a. Unequal heating or cooling of the material

111
Q

A service defect that appears as a series of small micro-openings with no definite pattern and extend in any direction following the grain boundaries is:

a. A fatigue crack
b. A fillet crack
c. Hydrogen embrittlement
d. Intergranular corrosion

A

d. Intergranular corrosion

112
Q

Fine lines, likely to occur in groups caused by non-metallic impurities present in the original ingot and extruded lengthwise are called:

a. Stringers
b. Seams
c. Laminations
d. Laps

A

a. Stringers

113
Q

A burst is a processing defect that may be caused by:

a. The dies not being set-up properly in the hammer or press
b. Excessive working of the metal during the forging or extruding operation
c. Localized stresses set up by unequal heavier masses of metal
d. Thin sections adjoining heavier masses of metal

A

b. Excessive working of the metal during the forging or extruding operation

114
Q

A generally smooth indication of a cast surface resulting from the meeting of two streams of metal coming from different directions and failing to fuse is called:

a. A stringer
b. A hot tear
c. A cold shut
d. A lap

A

c. A cold shut

115
Q
A
116
Q

Spot welding is usually performed using:

a. A very low current passed for a very short time
b. A very high current passed for a very short time
c. A very low current passed for a very long time
d. A very high current passed for a very long time

A

b. A very high current passed for a very short time

117
Q

Materials of low ductility are best forged with:

a. Gravity drop hammers
b. Power drop hammers
c. High energy rate forging hammers
d. Hydraulic presses

A

d. Hydraulic presses

118
Q

The following defect is caused by the melting away of the sidewalls of the welding groove at the edge of a layer of weld metal and runs parallel to the weld bead:

a. Lack of penetration
b. Lack of fusion
c. Undercutting
d. Surface shrink crack

A

c. Undercutting

119
Q

A large semi-finished hot rolled product, approximately square in cross section, and whose cross-sectional area is usually not less that 36 sq. in. is called:

a. A bloom
b. A billet
c. An ingot
d. A slab

A

a. A bloom

120
Q

Forming a taper, or a reduction of metal products such as rod and tubing, by forging is called

a. Swaging
b. Upsetting
c. Punching
d. Drawing

A

a. Swaging

121
Q

Possible effects of metal forming are:

a. refining the grain structure
b. improving the mechanical properties.
c. closing blow holes which have formed in an ingot.
d. all of the above.

A

d. All of the above

122
Q

In gas welding, a reducing flame is produced when:

a. there is no excess oxygen or acetylene in the flame
b. there is excess acetylene in the flame
c. there is excess oxygen in the flame
d. there is excess oxygen and acetylene in the flame

A

b. there is excess acetylene in the flame

123
Q

Cold shuts are most likely to be found in:

a. Extrusions
b. Forgings
c. Castings
d. Sintered parts

A

c. Castings

124
Q

Which of the following can be classified as processing defects?

a. Laminations
b. Grinding cracks
c. Fatigue cracks
d. Cold shuts

A

b. Grinding cracks

125
Q

Grinding cracks are usually caused by:

a. Heat treatment
b. Grinding soft metal surfaces
c. Grinding hard metal surfaces
d. Too slow feeding rates

A

c. Grinding hard metal surfaces

126
Q

A cause of gas porosity in welds is:

a. Welding at too low a temperature
b. Improper cleaning or preheating of the plates to be welded
c. The use of insufficient filler metal
d. Restriction of movement of the metal during heating or welding

A

b. Improper cleaning or preheating of the plates to be welded

127
Q

CHECK FOR CORRECTNESS

Which of the following generally requires the most extensive technique development the NDT?

a. A rolled product
b. A forged product
c. An extruded product
d. All of the above usually require about the same degree of NDT technique development prior to inspection

A

b. A forged product

128
Q

A common characteristic of sand casting and investment casting is:

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 re-usable molds

A

a. Both may be used to produce small castings

129
Q

Usually, seamless tubing is produced by:

a. Extrusion
b. A welding process which requires filler metal
c. Resistance welding
d. Seamless welding

A

a. Extrusion

130
Q

Patterns used to prepare molds for casting are made of:

a. Wood
b. Aluminum alloy
c. Epoxy resin
d. Any of the above

A

d. Any of the above

131
Q

Bursts are caused by:

a. Working at too low or too high a temperature
b. Excessive grinding
c. The presence of hydrogen in the metal
d. Localized heat-affected zones

A

a. Working at too low or too high a temperature

132
Q

One of the main causes of cold shuts is:

a. Improper preheating of molds
b. The presence of several sprues or gates in the mold
c. Pouring without a filter
d. The alloy selection

A

b. The presence of several sprues or gates in the mold

133
Q

The reason an ingot used as forging stock is subjected to more than the minimum hot working required to develop contour is to:

a. Remove evidence of cast structure
b. Refine grain structure
c. Impose a more desirable grain direction
d. All of the above

A

d. All of the above

134
Q

Wrought products invariably exhibit:

a. High susceptibility to corrosion
b. Lower strength than their cast counterparts
c. Directional properties
d. Poor weldability

A

c. Directional properties

135
Q

A metal insert imbedded in the surface of a sand mold to increase the cooling rate at that point is called:

a. A chill
b. A heat sink
c. A chaplet
d. A core

A

a. A chill

136
Q

A riser in a mold is there to:

a. Feed the castings as the metal shrinks before and during solidification
b. Let air escape from the mold
c. Ensure that impurities will segregate outside of the casting proper
d. All of the above

A

a. Feed the castings as the metal shrinks before and during solidification

137
Q
A
138
Q

In spot resistance welding, pressure used may be:

a. Mechanical
b. Pneumatic
c. Hydraulic
d. Any of the above

A

d. Any of the above

139
Q

Usually, the most serious types of flaws in metals are:

a. Porosity
b. Cracks
c. Inclusion
d. Laminations

A

b. Cracks

140
Q
A
141
Q

Pressure welding can be accomplished with pressure alone, but what else is usually added?

a. Heat
b. Filler material
c. Oxides
d. Adhesives

A

a. Heat

142
Q

The millworking process performed principally on flat products and bars that improve hardness, strength, surface finish and dimensional accuracy is:

a. Cold rolling
b. Hot rolling
c. Forging
d. Extrusion

A

b. Hot rolling

143
Q

The acronym EDM refers to:

a. Engineering design materials
b. Energy discharge machines
c. Electro dynamic machining
d. Electric discharge machining

A

d. Electric discharge machining

144
Q
A
145
Q

An alloy is a substance composed of:

a. At lease three elements, two of which are metals
b. At least three elements, one of which must be a non-metal
c. Two or more elements, of which at least one is a metal
d. Two or more elements, of which at least one is a non-metal

A

c. Two or more elements, of which at least one is a metal

146
Q

Which of the following measurements indicates the smoothest surface finish?

a. 250 micro inches
b. 0.0002 inches
c. 0.00015 inches
d. 100 micro inches

A

d. 100 micro inches

147
Q

The internal bores of fastener holes on aircraft are an important source of cracking caused by:

a. Fatigue
b. Stress corrosion
c. Overloading
d. Both a and b

A

b. Stress corrosion

148
Q

The machining process which can produce the best surface finish is:

a. Turning
b. Planing
c. Grinding
d. Milling

A

d. Milling

149
Q

Amorphous materials include:

a. Copper
b. Steel
c. Aluminum
d. None of the above

A

d. None of the above

150
Q

Which of the following is an inherent discontinuity?

a. Lamination
b. Heat-treat crack
c. Fatigue crack
d. Lap

A

d. Lap

151
Q

Electroplating sometimes decreases the fatigue strength of highly stressed parts largely as a result of:

a. Corrosion of the surface under the plating due to entrapped electrolyte
b. Hydrogen embrittlement
c. Improper cleaning of the part after electroplating
d. The build up of stresses in fillets

A

b. Hydrogen embrittlement

152
Q

Which material is considered ferromagnetic is:

a. Nickel
b. Cobalt
c. Iron
d. All of the above

A

d. All of the above

153
Q

A metal stressed below its elastic limit will return to its original shape:

a. Upon heating the metal to its curie point
b. Only upon application of an equivalent stress in the opposite direction
c. Upon removal of the stress
d. All of the above

A

c. Upon removal of the stress

154
Q

Polishing is a surface finishing operation which results in:

a. The removal of metal
b. Plastic working of the surface
c. The deposition of a protective layer to prevent corrosion
d. Both a and b

A

c. The deposition of a protective layer to prevent corrosion

155
Q

Electroplating complex parts results in:

a. Uniform plate thickness
b. Reduced plate thickness at outside corners and increased plate thickness at inside corners
c. Reduced plate thickness at inside corners and increased plate thickness at outside corners
d. Increased plate thickness at outside corners and increased plate thickness at centre areas

A

a. Uniform plate thickness

156
Q

Cracks or fractures formed in a casting prior to completion of solidification, because of restricted contracting are indicative of a:

a. shrinkage cavity
b. hot tear
c. misrun
d. cold shut

A

a. shrinkage cavity

157
Q

The millworking process used most to form metals into three dimensional shaped is:

a. Casting
b. Cold rolling
c. Welding
d. Forging

A

d. Forging

158
Q

Machinability and fatigue resistance are improved in metals that have been:

a. Hot worked
b. Cold worked
c. Heat treated
d. Cast

A

c. Heat treated

159
Q

Galvanizing is a process of applying to iron and steel products a protective layer of:

a. Tin and tin compounds
b. Zinc and zinc compounds
c. Aluminum and aluminum compounds
d. Copper and copper compounds

A

b. Zinc and zinc compounds

160
Q

During in-line (manufacturing) inspection of components, defective areas are often automatically marked to:

a. Allow removal of defects after the inspection, if desired
b. Allow destructive examination of defective areas after the inspection, if desired
c. Pass rejectable material after the inspection, if desired
d. Both a and b

A

d. Both a and b

161
Q

As a metal’s hardness increases:

a. Its ability to deform is increased
b. Its strength in tension is increased
c. Its strength in compression is increased
d. Its notch toughness is increased

A

b. Its strength in tension is increased

162
Q

A magnetic material may be demagnetized by:

a. Heating to above the curie temperature
b. Cold working
c. Passing the material through an AC coil
d. All of the above

A

d. All of the above

163
Q

The overall stress to give failure by fatigue is:

a. Greater than that required to produce tensile failure
b. Less than that required to produce tensile failure
c. Equal to that required to produce tensile failure
d. Greater or less than that required to produce tensile failure depending on the type of material

A

b. Less than that required to produce tensile failure

164
Q

Laminations are produced:

a. When forging with faulty dies
b. When excess metal is folded over during a rolling operation
c. When a pipe of blisters present in the original ingot are made directional by rolling
d. When blowholes introduced in earlier processing are elongated, by extruding, in the direction of working

A

c. When a pipe of blisters present in the original ingot are made directional by rolling

165
Q

The factor which must be considered prior to selecting the best method to produce a closed die forging is:

a. The size of the forging
b. The production of quantity
c. The design of the forging
d. All of the above

A

d. All of the above

166
Q

The most easily forgeable material, from the following, is:

a. High strength nickel base alloy
b. Stainless steel
c. Carbon steel
d. High strength aluminum alloy (7075)

A

d. High strength aluminum alloy (7075)

167
Q

A riser in the mold is there to:

a. Feed the casting as the metal shrinks before and during solidification
b. Let air escape from the mold
c. Ensure that impurities will segregate outside of the casting
d. All of the above

A

a. Feed the casting as the metal shrinks before and during solidification

168
Q

Grain boundaries are areas of metal microstructure:

a. Where high melting point constituents are concentrated
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 examination
d. Where low melting impurities tend to concentrate

A

a. Where high melting point constituents are concentrated

169
Q

What phenomenon(s) may happen in the heat affected zone during the process of fusion welding?

a. Grain growth
b. Change of structure
c. Recrystallization
d. Any of the above

A

d. Any of the above

170
Q

It is usually difficult to machine a smooth surface on a material when:

a. It as been cold worked
b. It has high strain hardening ability
c. It has low strain hardening ability
d. Both a and b

A

b. It has high strain hardening ability

171
Q

The folding of metal in thin plate on the surface or in a forging causes:

a. a cold shut
b. unhealed porosity
c. a lap
d. a burst

A

c. a lap

172
Q

Grinding cracks in metal are always:

a. Parallel to the grinding wheel rotation
b. Subsurface
c. Open to the surface
d. Inherent discontinuities

A

c. Open to the surface

173
Q

Microshrinkage might occur in a casting:

a. At the header
b. At junctions between light and heavy section
c. The casting’s surface
d. In the heavy part of the casting

A

b. At junctions between light and heavy section

174
Q

Severe grinding cracks appear as:

a. Wave like patterns
b. Widely spaced cracks
c. Lattice-work or checkerboard pattern
d. A single crack

A

c. Lattice-work or checkerboard pattern

175
Q

When a crack-like space is caused by molten metal covering solidified metal, the result is:

a. A cold shut
b. A lamp
c. A burst
d. A lamination

A

a. A cold shut

176
Q

If a weldment has a Crater crack, you might find it:

a. At the beginning of the weld
b. At the end of the weld
c. Somewhere in between the beginning and the end of the weld
d. At any one of the above places

A

d. At any one of the above places

177
Q

Metal has the property of:

a. Failing to unite if too hot
b. Retaining large grain structure when forged
c. Occupying more space when molten than when solid
d. Having a larger grain structure when molten than when solid

A

c. Occupying more space when molten than when solid

178
Q

Porosity is sometimes found in plate or sheet metal and is given the name:

a. Stingers
b. Seams
c. Bursts
d. Laminations

A

d. Laminations

179
Q

Grinding cracks occur crosswise to grinding wheel rotation

a. True
b. False

A

a. True

180
Q

A discontinuity that can be caused within a casting as it solidifies, would be called an/a:

a. shrinkage cavity
b. blowhole
c. inclusion
d. cold shut

A

a. shrinkage cavity

181
Q

Non-metallic inclusions are not present before the billet is worked:

a. True
b. False

A

b. False

182
Q

Which term best describes what is sought by Non-destructive examination?

a. Surface irregularities
b. Sub-surface holes and cracks
c. Any breaks in the continuity of metal structure
d. Any welding defect

A

c. Any breaks in the continuity of metal structure

183
Q

Seams are sub-surface discontinuities

a. True
b. False

A

b. False

184
Q

Which of the items listed below is a discontinuity found in ingots?

a. Laminations
b. Bursts
c. Non-metallic inclusions
d. Lack of fusion

A

c. Non-metallic inclusions

185
Q

Stringers are a type of discontinuity sometimes found in:

a. Sheet metal
b. Bar stock
c. Forgings
d. Submerged Arc welds

A

b. Bar stock

186
Q

Oxides in weldments can cause discontinuities which are similar to non-metallic inclusions. But these oxide-caused discontinuities are called:

a. Crater cracks
b. Seams
c. slag inclusions
d. Lack of root penetration

A

c. slag inclusions

187
Q

Heat treating might cause discontinuities which would probably start at:

a. Heavy and light junctions and sharp areas
b. Smooth surfaces
c. Concave surfaces
d. Within the heavy part of the casting

A

a. Heavy and light junctions and sharp areas

188
Q

Blowholes occur beneath the surface of a casting

a. True
b. False

A

b. False

189
Q

Forging laps can occur in which of the places described below:

a. The top of the die
b. Where the dies come together
c. The bottom of the die
d. None of the above

A

b. Where the dies come together

190
Q

If a weld is manufactured and the parent metal is restrained, a crack might occur due to stress. It would usually occur:

a. In the direction of the weld
b. Transverse to the direction of the weld
c. Only in the parent metal
d. Only in the weld cap, and longitudinally with the weld

A

b. Transverse to the direction of the weld

191
Q

Which of the following is present in ingots?

a. Stringers
b. Porosity
c. Laminations
d. Seams

A

b. Porosity

192
Q

In its original shape, porosity would appear:

a. Elongated
b. Irregular
c. Round or nearly round
d. Square

A

c. Round or nearly round

193
Q

Nondestructive examination is a method of locating which of the following:

a. Discontinuations
b. Dislocations
c. Discontinuities
d. Disturbances

A

c. Discontinuities

194
Q

Like ingots, welds can contain porosity:

a. True
b. False

A

a. True

195
Q

Non-metallic materials trapped in solid metal are described as:

a. Porosity
b. Inclusions
c. Seams
d. Laminations

A

b. Inclusions

196
Q

A hot tear in a casting is a crack which could occur:

a. Within the heavy part of the casting
b. In the light section of the casting
c. At junctions of light and heavy castings
d. At the header

A

c. At junctions of light and heavy castings

197
Q

When a pouring gate in a casting blocks off prematurely, it can cause many small, subsurface holes. This condition is called:

a. Hot tears
b. Crater cracks
c. Microshrinkage
d. Seams

A

c. Microshrinkage

198
Q

A forging lap might occur:

a. Where grain direction makes an abrupt change
b. In the center of a forging
c. At the junction of light and heavy section
d. At the junction of the sprue and the ingate

A

a. Where grain direction makes an abrupt change

199
Q

A lamination is something which might be found in:

a. Bar stock
b. Pipe
c. Forgings
d. Sheet or plate material

A

d. Sheet or plate material

200
Q

In the beginning all steel is perfect:

a. True
b. False

A

b. False

201
Q

What is a non-metallic inclusion called in Bar stock?

a. Lamination
b. Burst
c. Lap
d. Stringer

A

d. Stringer

202
Q

Non-metallic inclusions are:

a. Round in shape
b. Rectangular in shape
c. Irregular in shape
d. Tall

A

c. Irregular in shape

203
Q

Grain direction in steel bar stock is always:

a. Through the length of the bar
b. Through the width of the bar
c. Spread out in all directions
d. A bar of steel has no grain direction

A

a. Through the length of the bar

204
Q

In forgings, grain:

a. Follows the shape of the dies
b. Becomes coarser
c. Retains its original shape
d. Is lateral to the shape of the dies

A

a. Follows the shape of the dies

205
Q

In which of the following might you expect to find a seam?

a. Forgings
b. Castings
c. Bar stock
d. Sheet or plate material

A

c. Bar stock

206
Q

A cold shut has:

a. A smooth, curved appearance
b. A ragged shape
c. A straight thin line
d. An undulating shape

A

a. A smooth, curved appearance

207
Q

Premature blocking of a gate during the pouring of a casting might cause:

a. A lap
b. Microshrinkage
c. Stringers
d. A lamination

A

b. Microshrinkage

208
Q

Nondestructive examination is used for locating only those discontinuities open to the surface:

a. True
b. False

A

b. False

209
Q

Usually, the most serious type of flaw in metals is/are:

a. Porosity
b. Cracks
c. Inclusions
d. Laminations

A

b. Cracks

210
Q

A definite break in the material caused by excessive working of the metal during the forging, rolling or extruding operation is called a:

a. Cold shut
b. Seam
c. Burst
d. Hot tear

A

c. Burst

211
Q

A service defect that appears as a series of small micro-openings with no definite pattern and extend in any direction following the grain boundaries is:

a. A fatigue crack
b. A fillet crack
c. Hydrogen embrittlement
d. Intergranular corrosion

A

d. Intergranular corrosion

212
Q

An extremely thin discontinuity that is the result of pipes, or inclusions flattened and made directional by working is called:

a. A stringer
b. A lamination
c. A seam
d. A cold shut

A

b. A lamination

213
Q

Fine lines, likely to occur in groups caused by non-metallic impurities present in the original ingot and extruded lengthwise are called:

a. Stringers
b. Seams
c. Laminations
d. Laps

A

a. Stringers

EMC (1 decks)

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