METALLURGY Flashcards

1
Q
  1. In which physical state will the chemical reaction between metal atoms and foreign atoms be more rapid?

a. Solid state
b. Liquid state
c. Both “a” and “b” are equal
d. Migratory state

A
  1. In which physical state will the chemical reaction between metal atoms and foreign atoms be more rapid?
    b. Liquid state
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2
Q
  1. What is autogenous welding?

a. Oxyacetylene welding
b. Sheet metal welding with the short circuiting mode of GMAW
c. Welding with no added filler metal
d. Automatic welding

A
  1. What is autogenous welding?
    c. Welding with no added filler metal
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3
Q
  1. What is shielding of the weld pool?

a. Shielding is thermal protection from the welding process
b. Shielding is protection from radioactivity present during the welding process
c. Shielding is the technique of blanketing the welding area with gases or fluxes which exclude harmful atmospheric chemicals

A
  1. What is shielding of the weld pool?
    c. Shielding is the technique of blanketing the welding area with gases or fluxes which exclude harmful atmospheric chemicals
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4
Q
  1. Which of the following would be considered shielding?

a. A neutral gas flame
b. Flux
c. A protective slag
d. All of the above
e. Both b and c

A
  1. Which of the following would be considered shielding?

D. All of the above

a. A neutral gas flame
b. Flux
c. A protective slag

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5
Q
  1. What steels have the best weldability?

a. Steels with less than 0.20 percent carbon content
b. Steels with about 0.40 percent carbon content
c. Free machining steel with high lead content
d. Steels with over 1.0 percent nickel content

A
  1. What steels have the best weldability?
    a. Steels with less than 0.20 percent carbon content
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6
Q
  1. What is the carbon equivalent of a 1% Cr, 1% Mo weld containing 0.12% C, 0.8% Mn, and no Ni, Cu, or V, according to the following CE formula?

a. 0.44
b. 0.42

c. 0.40
d. 0.38

A
  1. What is the carbon equivalent of a 1% Cr, 1% Mo weld containing 0.12% C, 0.8% Mn, and no Ni, Cu, or V, according to the following CE formula?
    c. 0.40
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7
Q
  1. What CE indicates the highest probability of underbead cracking?

a. 0.20
b. 0.30

c. 0.40
d. CE does not indicate probability of underbead cracking

A
  1. What CE indicates the highest probability of underbead cracking?
    c. 0.40
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8
Q
  1. In what steels is it common to find grains of delta ferrite at room temperature?

a. Certain chromium-nickel stainless steels
b. Fully austenitic stainless steels
c. Ferritic straight chromium steels
d. Martensitic stainless

A
  1. In what steels is it common to find grains of delta ferrite at room temperature?
    b. Fully austenitic stainless steels
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9
Q
  1. A rectangular stainless steel tank is prepared using single pass welds to join a thin bottom sheet of unstabilized 18Cr/8Ni steel to four (4) side sheets made of Type 347 steel. The welding electrode is E-308l with 0.03 max. carbon. Where will chromium carbide precipitation occur?

a. At grain boundaries in the weld metal
b. In heat-affected zone of bottom sheet at grain boundaries
c. In heat-affected zone of the Type 34 7 side sheets
d. There should be no precipitation, because the electrode is stabilized

A
  1. A rectangular stainless steel tank is prepared using single pass welds to join a thin bottom sheet of unstabilized 18Cr/8Ni steel to four (4) side sheets made of Type 347 steel. The welding electrode is E-308l with 0.03 max. carbon. Where will chromium carbide precipitation occur?
    b. In heat-affected zone of bottom sheet at grain boundaries
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10
Q
  1. For welding purposes, how may protective oxide layers be removed from aluminum and magnesium?

a. Brush with brush previously used on carbon steel
b. Chemically remove the layer before welding
c. Use of straight polarity when welding assists in breaking down oxide layers
d. Both b and c above

A
  1. For welding purposes, how may protective oxide layers be removed from aluminum and magnesium?
    b. Chemically remove the layer before welding
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11
Q
  1. What technique is required for welding titanium or zirconium?

a. Use flux protection
b. Use complete shielding (vacuum or inert gas)
c. Weld under water
d. Forehand welding

A
  1. What technique is required for welding titanium or zirconium?
    b. Use complete shielding (vacuum or inert gas)
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12
Q
  1. Which substances contain hydrogen?

a. Moisture
b. Oil and grease
c. Rust
d. All of the above

A
  1. Which substances contain hydrogen?.

D. All of the above

a. Moisture
b. Oil and grease
c. Rust

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13
Q
  1. In which way does the presence of hydrogen adversely affect the welding process?

a. It causes porosity
b. It causes cracking
c. It causes laminations and striations
d. It will degrades the structure of the atomic cell

A
  1. In which way does the presence of hydrogen adversely affect the welding process?
    b. It causes cracking
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14
Q
  1. What is the major difference in the lattice structure between the solid and liquid states of metal?

a. The atoms are integral units (solid) or are broken into smaller components without electrons (liquid)
b. The shape of the atoms changes from square (solid) to round (liquid)
c. The atoms vibrate in a “fixed” structured position (solid) or move about freely (liquid)
d. None of the above

A
  1. What is the major difference in the lattice structure between the solid and liquid states of metal?
    c. The atoms vibrate in a “fixed” structured position (solid) or move about freely (liquid)
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15
Q
  1. What happens to the atoms as temperature is increased?

a. The movement of the atoms increases in both speed and distance
b. More electrons separate from the atoms
c. The shape of the atoms changes from square to round
d. Both a and b

A
  1. What happens to the atoms as temperature is increased?
    a. The movement of the atoms increases in both speed and distance
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16
Q
  1. What is diffusion of metal in the solid state?

a. Crumbling of edges due to oxidation
b. The migration of atoms from their “home” positions
c. Dissolving of the metal in other chemicals
d. Exchange of atoms in carbon steels

A
  1. What is diffusion of metal in the solid state?
    b. The migration of atoms from their “home” positions
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17
Q
  1. What is the major factor in determining the degree of diffusion?

a. The presence of chemicals which react with the metal
b. The temperature of the metal
c. The intensity of the magnetic field
d. The chemistry of each of the metals

A
  1. What is the major factor in determining the degree of diffusion?
    b. The temperature of the metal
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18
Q
  1. When filler metal and base metal in the liquid state are in contact with each other, what causes the two metals to mix together into a uniform composition?

a. Speed of the heated atoms
b. Convection caused by uneven heating
c. Stirring caused by external forces (pressure from torch and movement of electrode)
d. All of the above

A
  1. When filler metal and base metal in the liquid state are in contact with each other, what causes the two metals to mix together into a uniform composition?

D. All of the above

a. Speed of the heated atoms
b. Convection caused by uneven heating
c. Stirring caused by external forces (pressure from torch and movement of electrode)

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19
Q
  1. When metal freezes, what determines the initial configuration of the lattice structure of the metal changing from the liquid to the solid state?

a. The shape of the surrounding area
b. The lattice structure of the adjacent metal which is already in the solid state
c. The magnetic field
d. The original structure of the material

A
  1. When metal freezes, what determines the initial configuration of the lattice structure of the metal changing from the liquid to the solid state?
    b. The lattice structure of the adjacent metal which is already in the solid state
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20
Q
  1. What is thermal expansion?

a. The increase in temperature of metal adjacent to the weld
b. The change in shape of metal as it becomes malleable near the liquid state
c. The increase in volume of metal due to increased temperature
d. The ability of metal to deform without breaking

A
  1. What is thermal expansion?
    c. The increase in volume of metal due to increased temperature
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21
Q
  1. How is stress induced by the thermal effects of welding?

a. Molten metal is unable to support a load
b. The welding rod exerts force against the base metal
c. The lattice structure is distorted by non-uniform heating and cooling of the metal
d. Shrinkage of atoms when returning to BCC form

A
  1. How is stress induced by the thermal effects of welding?
    c. The lattice structure is distorted by non-uniform heating and cooling of the metal
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22
Q
  1. How is residual stress relieved in carbon steel?

a. By bending the metal back and forth
b. By drilling holes in nonstructural areas
c. By heating the metal to a designated temperature and then quenching it in water
d. By heating the metal to a designated temperature and then cooling it uniformly

A
  1. How is residual stress relieved in carbon steel?
    d. By heating the metal to a designated temperature and then cooling it uniformly
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23
Q
  1. Why should a root weld bead not be peened?

a. For lack of strength, weld may yield and cause displacement of parts in the wrong direction
b. Heat treatment from later beads will over harden the peened metal
c. A root pass has unbalanced shrinkage stresses
d. Both a and b

A
  1. Why should a root weld bead not be peened?
    a. For lack of strength, weld may yield and cause displacement of parts in the wrong direction
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24
Q
  1. What happens to mar!ensite needles in 0.35 carbon steel heated 350°F above its transformation temperature?

a. Total change to austenite with dissolved carbon
b. Change to feathery needles of bainite
c. Change to cernentite bands in pearlite
d. No change takes place

A
  1. What happens to mar!ensite needles in 0.35 carbon steel heated 350°F above its transformation temperature?
    a. Total change to austenite with dissolved carbon
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25
Q
  1. What happens lo carbon in 0.35 carbon steel cooled in still air from an austenilic temperature?

a. Becomes trapped in BCC lattice, forming BCT martensite lattice structure
b. Migrates to grain boundaries
c. Forms bainite
d. Both a and c

A
  1. What happens lo carbon in 0.35 carbon steel cooled in still air from an austenilic temperature?
    c. Forms bainite
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26
Q
  1. Which area will generally exhibit the highest hardness after welding?

a. Weld
b. Base Metal
c. Heat affected zone
d. None of the above

A
  1. Which area will generally exhibit the highest hardness after welding?
    c. Heat affected zone
27
Q
  1. Which of the conditions below suggests a welding problem?

a. One welder seems to have difficulty making a sound weld on the grade of steel being used
b. Every Monday five (5) of the welders make poor welds, but the rest of the week, all goes well
c. Cracking is repetitive in certain joint configurations
d. One inspector has accepted every weld

A
  1. Which of the conditions below suggests a welding problem?
    c. Cracking is repetitive in certain joint configurations
28
Q
  1. How should your inspection of ASTM A514 steel differ from your standard technique?

a. Wait until two days after it was welded for final inspection
b. No change; give all welds 100 percent attention daily
c. Apply the LeHigh Weldability Test
d. UT prior to visual inspection

A
  1. How should your inspection of ASTM A514 steel differ from your standard technique?
    a. Wait until two days after it was welded for final inspection
29
Q
  1. As a metal is heated:

a. Energy is added to the structure
b. The atoms move farther apart
c. The atoms vibrate more vigorously
d. The metal expands
e. All of the above

A
  1. As a metal is heated:

E. All of the above

a. Energy is added to the structure
b. The atoms move farther apart
c. The atoms vibrate more vigorously
d. The metal expands

30
Q
  1. The state of matter which exhibits the least amount of energy is:

a. Solid
b. Liquid
c. Gas
d. Quasi-liquid
e. None of the above

A
  1. The state of matter which exhibits the least amount of energy is:
    a. Solid
31
Q
  1. A problem occurring in a weldment caused by the non-uniform heating produced by the welding operation is:

a. Porosity
b. Incomplete fusion
c. Distortion
d. Slag inclusions

A
  1. A problem occurring in a weldment caused by the non-uniform heating produced by the welding operation is:
    c. Distortion
32
Q
  1. All but which of the following will result in the elimination or reduction of residual stresses?

a. Vibratory stress relief
b. External restraint
c. Thermal stress relief
d. Peening
e. Postweld heat treatment

A
  1. All but which of the following will result in the elimination or reduction of residual stresses?
    b. External restraint
33
Q
  1. Steel exists in which of the following crystal arrangements?

a. HCP
b. FCC

c. BCC

d. “a” and “b” above
e. “b” and “c” above

A
  1. Steel exists in which of the following crystal arrangements?

E. “b” and “c” above

b. FCC
c. BCC

34
Q
  1. The type of alloying in which the alloy atoms are located in the spaces between the atoms of the parent metal is referred to as:

a. Atomic alloying
b. Substitutional alloying
c. Space alloying
d. Interstitial alloying
e. None of the above

A
  1. The type of alloying in which the alloy atoms are located in the spaces between the atoms of the parent metal is referred to as:
    d. Interstitial alloying
35
Q
  1. Rapid cooling of a steel from the austenitic range results in a hard, brittle structure known as:

a. Pearlite
b. Carbide
c. Cementite
d. Bainite
e. Martensite

A
  1. Rapid cooling of a steel from the austenitic range results in a hard, brittle structure known as:
    e. Martensite
36
Q
  1. Very slow cooling of steel may result in the production of a solid, ductile microstructure which has a lamellar appearance when viewed under high magnification. This structure is referred to as:

a. Martensite
b. Pearlite
c. Bainite
d. Ferrite
e. Cementite

A
  1. Very slow cooling of steel may result in the production of a solid, ductile microstructure which has a lamellar appearance when viewed under high magnification. This structure is referred to as:
    b. Pearlite
37
Q
  1. When rapid cooling produces a martensite structure, what non-austenitizing heat treatment may be applied to improve the ductility of the steel?

a. Quenching
b. Tempering
c. Annealing
d. Normalizing
e. None of the above

A
  1. When rapid cooling produces a martensite structure, what non-austenitizing heat treatment may be applied to improve the ductility of the steel?
    b. Tempering
38
Q
  1. When using a welding electrode having a strength which matches the base metal strength, what region of the weld zone generally exhibits the highest hardness?

a. Base metal
b. Heal affected zone next to the unaffected base metal
c. Heat affected zone next to the weld metal
d. Weld metal
e. Cannot be determined

A
  1. When using a welding electrode having a strength which matches the base metal strength, what region of the weld zone generally exhibits the highest hardness?
    c. Heat affected zone next to the weld metal
39
Q
  1. It is determined that a welding procedure is creating an excessive heat input Which of the changes listed below would result in a reduction of the heat input?

a. Decreased current
b. Decreased voltage
c. Increased travel speed
d. Change from weave to stringer bead technique
e. All of the above

A
  1. It is determined that a welding procedure is creating an excessive heat input Which of the changes listed below would result in a reduction of the heat input?

E. All of the above

a. Decreased current
b. Decreased voltage
c. Increased travel speed
d. Change from weave to stringer bead technique

40
Q
  1. The use of preheat will tend to:

a. Result in a wider heat affected zone
b. Produce a lower heat affected zone hardness
c. Slow down the cooling rate
d. Reduce the tendency of producing martensite in the heat affected zone
e. All of the above

A
  1. The use of preheat will tend to:

E. All of the above

a. Result in a wider heat affected zone
b. Produce a lower heat affected zone hardness
c. Slow down the cooling rate
d. Reduce the tendency of producing martensite in the heat affected zone

41
Q
  1. Which of the following changes will warrant the addition or increase in required preheat?

a. Decreased carbon equivalent
b. Increased carbon equivalent
c. Increased base metal thickness
d. “a” and “c” above
e. “b” and “c” above

A
  1. Which of the following changes will warrant the addition or increase in required preheat?

E. “b” and “c” above

b. Increased carbon equivalent
c. Increased base metal thickness

42
Q
  1. What heat treatment is characterized by holding the part at the austenitizing temperature for some time and then slow cooling in the furnace?

a. Normalizing
b. Quenching
c. Annealing
d. Tempering
e. Stress relief

A
  1. What heat treatment is characterized by holding the part at the austenitizing temperature for some time and then slow cooling in the furnace?
    c. Annealing
43
Q
  1. What heat treatment is characterized by holding the part at the austenitizing temperature for some time and then slow cooling in still air?

a. Normalizing
b. Quenching
c. Annealing
d. Tempering
e. Stress relief

A
  1. What heat treatment is characterized by holding the part at the austenitizing temperature for some time and then slow cooling in still air?
    a. Normalizing
44
Q
  1. Increasing the heat input:

a. Decreases the cooling rate and increases the likelihood of cracking problems
b. Decreases the cooling rate and decreases the likelihood of cracking problems
c. Increases the cooling rate and increases the likelihood of cracking problems
d. Increases the cooling rate and decreases the likelihood of cracking problems
e. None of the above

A
  1. Increasing the heat input:
    b. Decreases the cooling rate and decreases the likelihood of cracking problems
45
Q
  1. Increasing preheat:

a. Decreases the cooling rate and increases the likelihood of cracking problems
b. Decreases the cooling rate and decreases the likelihood of cracking problems
c. Increases the cooling rate and increases the likelihood of cracking problems
d. Increases the cooling rate and decreases the likelihood of cracking problems
e. None of the above

A
  1. Increasing preheat:
    b. Decreases the cooling rate and decreases the likelihood of cracking problems
46
Q
  1. Increasing the carbon content:

a. Decreases the likelihood of cracking problems
b. Increases the likelihood of cracking problems
c. Has nothing to do with the likelihood of cracking problems
d. All of the above
e. None of the above

A
  1. Increasing the carbon content:
    b. Increases the likelihood of cracking problems
47
Q
  1. Increasing the carbon equivalent:

a. Decreases the likelihood of cracking problems.
b. Increases the likelihood of cracking problems
c. Has nothing to do with the likelihood of cracking problems.
d. All of the above
e. None of the above

A
  1. Increasing the carbon equivalent:
    b. Increases the likelihood of cracking problems
48
Q
  1. With respect to the heat affected zone, thin materials and low restraint will result in:

a. Slower cooling rates, decreased distortion and increased residual stress
b. Slower cooling rates, increased distortion and decreased residual stress
c. Faster cooling rates, decreased distortion and increased residual stress
d. Faster cooling rates, increased distortion and decreased residual stress
e. None of the above

A
  1. With respect to the heat affected zone, thin materials and low restraint will result in:
    b. Slower cooling rates, increased distortion and decreased residual stress
49
Q
  1. With respect to the heat affected zone, thick materials and high restraint will result in:

a. Slower cooling rates, decreased distortion and increased residual stress
b. Slower cooling rates, increased distortion and decreased residual stress
c. Faster cooling rates, decreased distortion and increased residual stress
d. Faster cooling rates, increased distortion and decreased residual stress
e. None of the above

A
  1. With respect to the heat affected zone, thick materials and high restraint will result in:
    c. Faster cooling rates, decreased distortion and increased residual stress
50
Q
  1. Which of the following generally follows quenching?

a. Annealing
b. Normalizing
c. Quenching
d. Tempering
e. Stress relief

A
  1. Which of the following generally follows quenching?
    d. Tempering
51
Q
  1. Which of the following can be accomplished using either thermal or mechanical techniques?

a. Annealing
b. Normalizing
c. Quenching
d. Tempering
e. Stress relief

A
  1. Which of the following can be accomplished using either thermal or mechanical techniques?
    e. Stress relief
52
Q
  1. Which of the following results in the softest structure?

a. Annealing
b. Normalizing
c. Quenching
d. Tempering
e. Stress relief

A
  1. Which of the following results in the softest structure?
    a. Annealing
53
Q
  1. For a steel having the following composition: 0.11% carbon, 0.65% manganese, 0.13%chromium, 0.19% nickel, 0.005% copper, and 0.07% molybdenum, what is its carbon equivalent using the following formula?

CE=% C + % Mn/6 + % Ni/15 + % Cr/5 + ¾Cu/13 + % Mo/4

a. 0.16
b. 0.23
c. 0.28
d. 0.31
e. 0.42

A
  1. For a steel having the following composition: 0.11% carbon, 0.65% manganese, 0.13%chromium, 0.19% nickel, 0.005% copper, and 0.07% molybdenum, what is its carbon equivalent using the following formula?

CE=% C + % Mn/6 + % Ni/15 + % Cr/5 + ¾Cu/13 + % Mo/4

c. 0.28

54
Q
  1. For a steel having the following composition: 0.16% carbon, 0.85% manganese, 0.25% chromium, 0.09% nickel, 0.055% copper, and 0.41% molybdenum, what is its carbon equivalent using the following formula?

CE=% C + % Mn/6 + % Ni/15 + % Cr/5 + % Cu/13 + % Mo/4

a. 0.27
b. 0.30

c. 0.41
d. 0.46

A
  1. For a steel having the following composition: 0.16% carbon, 0.85% manganese, 0.25% chromium, 0.09% nickel, 0.055% copper, and 0.41% molybdenum, what is its carbon equivalent using the following formula?

CE=% C + % Mn/6 + % Ni/15 + % Cr/5 + % Cu/13 + % Mo/4

d. 0.46

55
Q
  1. The FCAW process is being utilized to weld a 1” thick structural steel member to a building column. The welding is being done with a 3/32” diameter self-shielded electrode with a 150°F minimum preheat and interpass temperature. The welding parameters are adjusted to 30 volts, 250 amperes and 12 in/min. What is the heat input?

a. 375 J/in
b. 37,500 kJ/in
c. 37 .5 kJ/in
d. 3. 75 MJ/in
e. 37.5 MJ/in

A
  1. The FCAW process is being utilized to weld a 1” thick structural steel member to a building column. The welding is being done with a 3/32” diameter self-shielded electrode with a 150°F minimum preheat and interpass temperature. The welding parameters are adjusted to 30 volts, 250 amperes and 12 in/min. What is the heat input?
    c. 37 .5 kJ/in
56
Q
  1. GMAW (short circuiting) welds are produced at 18 volts, 100 amperes and 22 in/min. What is the heat input?

a. 238 J/in
b. 7333 J/in

c. 4315 J/in

d. 30 J/in
e. None of the above

A
  1. GMAW (short circuiting) welds are produced at 18 volts, 100 amperes and 22 in/min. What is the heat input?
    e. None of the above
57
Q
  1. The GMAW process is mechanized for welding 1/8” thick stainless steel sheets against a copper backing bar. The process is operated at 300 amperes, 28 volts and 15 in/min. What is the resulting heat input?

a. 3.36 kJ/in
b. 33.6 kJ/in
c. 336 kJ/in

D. 3360 kJ/in

A
  1. The GMAW process is mechanized for welding 1/8” thick stainless steel sheets against a copper backing bar. The process is operated at 300 amperes, 28 volts and 15 in/min. What is the resulting heat input?
    b. 33.6 kJ/in
58
Q
  1. The GTAW process is being utilized for welding 1/16” thick titanium using DCEN at 110 amperes, 15 volts and 6 in/min. What is the heat input?

a. 1650 J/in
b. 6501 J/in

c. 16,500 J/in

d. “a” and “b” above
e. “b” and “d’ above

A
  1. The GTAW process is being utilized for welding 1/16” thick titanium using DCEN at 110 amperes, 15 volts and 6 in/min. What is the heat input?
    c. 16,500 J/in
59
Q
  1. Which of the following is/are sometimes used to control distortion in a weldment?

a. Backstep welding
b. Fixtures and stress relief
c. Preheating

d. Peening
e. All of the above

A
  1. Which of the following is/are sometimes used to control distortion in a weldment?

E. All of the above

a. Backstep welding
b. Fixtures and stress relief
c. Preheating

d. Peening

60
Q
  1. The upper limits of preheat and interpass temperatures for quenched and tempered steels are specified for what reason(s)?

a. To avoid cracking in the weldment
b. To keep the weld metal from becoming too strong
c. To maintain the strength in the base metal heat-affected-zone

d. To keep deposition rate to a minimum
e. “a” and “c” above

A
  1. The upper limits of preheat and interpass temperatures for quenched and tempered steels are specified for what reason(s)?
    c. To maintain the strength in the base metal heat-affected-zone
61
Q
  1. Backstep welding is most often used:

a. For ease of operation
b. To reduce distortion
c. For tacking the welded material

d. To prevent crater cracks
e. To speed up welding

A
  1. Backstep welding is most often used:
    b. To reduce distortion
62
Q
  1. Which of the following affects the changes in a metal during welding?

a. Rate of heating
b. Maximum temperature attained
c. Length of time at temperature

d. Rate of cooling
e. All of the above

A
  1. Which of the following affects the changes in a metal during welding?

E. All of the above

a. Rate of heating
b. Maximum temperature attained
c. Length of time at temperature

d. Rate of cooling

63
Q
  1. Steel has better weldability if the carbon content is:

a. .2 percent or less
b. .2 - .35 points
c. 35 to 50 points

d. 50 to 120 points

A
  1. Steel has better weldability if the carbon content is:
    a. .2 percent or less
64
Q

METALLURGY ANSWER SHEET

A