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UT1 EMC > UT1 EMC > Flashcards

UT1 EMC Flashcards

1
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

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2
Q

A common processing indication in rolled bar stock is:

A. Seam

B. Lap

C. Hot tear

D. Cold shut

A

A. Seam

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3
Q

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

A. Increases

B. Decreases

C. Remains constant

D. Any one of the above may be true, depending on material.

A

D. Any one of the above may be true, depending on material.

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4
Q

As COLD WORKING progresses, the energy required for further processing (assuming the temperature of the part is held constant)

A. Increases

B. Decreases

C. Remains constant

D. Any one of the above may be true depending on the material

A

A. Increases

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5
Q

An example of a processing discontinuity that is the result of an inherent discontinuity changing shape during rolling is a:

A. Cooling crack.

B. Burst

C. Lap

D. Lamination

A

D. Lamination

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6
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

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7
Q

A slag inclusion in a weld is normally found in a weld crater T/F

A

F

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8
Q

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

A. stringer

B. hot tear

C. cold shut

D. lap

A

C. cold shut

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9
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

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10
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

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11
Q

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

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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12
Q

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

A. bloom

B. billet

C. ingot

D. slab

A

A. bloom

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13
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

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14
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

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15
Q

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

A. cold shut

B. Unhealed porosity

C. lap

D. burst

A

C. lap

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16
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

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17
Q

Prior to forging, steel is usually heated to:

A. Slightly above the curie temperature

B. Slightly above the melting temperature

C. Slightly below the melting temperature

D. Slightly below the first transformation temperature

A

C. Slightly below the melting temperature

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18
Q

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

A. Undercutting

B. Heat affected zone cracking

C. crater crack

D. An incomplete sidewall fusion

A

C. crater crack

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19
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

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20
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

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21
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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22
Q

In gas welding, the acetylene is usually burned with:

A. Oxygen

B. Hydrogen

C. Argon

D. Nitrogen

A

A. Oxygen

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23
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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24
Q

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

A. Lamination

B. Burst

C. Lap

D. Stringer

A

D. Stringer

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25
Q

The grain size of 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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26
Q

As a metals hardness increases:

A. Its ability to deform is increased

B. Its strength in tension is increased

C. Its strength in compression increases

D. Its notch toughness is increased

A

B. Its strength in tension is increased

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27
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

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28
Q

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

A. A cold shut

B. A lap

C. A burst

D. A lamination

A

A. A cold shut

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29
Q

A flaw which can resemble a cold shut is:

A. An undercut in the 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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30
Q

Which of the following is true regarding solidification of molten metal in a casting mold?

A. The metal cools at a constant rate, thus providing fine equiaxed grains throughout.

B. Cooling takes place in phases having different rates that produce different types of grains.

C. Solidification occurs at a constant rate, beginning at the interior of the casting and progressing outward.

D. Thick sections tend to cool more rapidly than thin sections because thin sections consist of mostly fine equiaxed grains

A

B. Cooling takes place in phases having different rates that produce different types of grains.

31
Q

In a casting, shrinkage occurs:
A. only after the transformation from liquid to solid.
B. only after the transformation from solid to liquid.
C. before during and after the transformation from liquid to solid.
D. only when the metal is in the liquid state.

A

C. before during and after the transformation from liquid to solid.

32
Q

Large voids of porosity in a casting result from:
A. turbulent flow of the molten metal during pouring
B. alloy element segregation.
C. molten metal boiling because of superheat.
D. gas evolution before and during solidification.

A

D. gas evolution before and during solidification.

33
Q

During the solidification of a casting, the shrinkage that occurs:
A. may cause porosity and shrinkage cavities primarily in the outer surfaces where the metal cools first.
B. requires that the pattern used be slightly smaller than the desired dimension of the finished casting.
C. may cause cavities that are enlarged by the evolution of gases.
D. may result from all the above.

A

C. may cause cavities that are enlarged by the evolution of gases.

34
Q

The design of the casting is important because the quality of the finished product can be adversely affected by:

A. a lack of molten metal to compensate for contraction

B. location of the gate with reference to either progressive solidification or directional solidification

C. the location of “hot spots” in areas of the casting that are isolated by thin sections.

D. all of the above.

E. none of the above.

A

D. all of the above.

35
Q

A casting process used to produce hollow products like large pipes and hollow shafts is:
A. investment casting.
B. blow casting.
C. core casting.
D. centrifugal casting

A

D. centrifugal casting

36
Q
  1. Risers, feeders. or feed heads in castings serve lo provide sources of molten metal to compensate for:
    A. misruns.
    B. cold shuts.
    C. hot tears.
    D. dendritic grain growth,
    E. shrinkage.
A

E. shrinkage.

37
Q
  1. Green sand casting molds include:
    A. sand, clay, and water.
    B. sand, wax, and solvent.
    C. sand, refractory metals, and water.
    D. sand, carbon, and green clay.
A

A. sand, clay, and water.

38
Q
  1. Mold material in the form of inserts that exclude metal flow and thus form internal surfaces or passages in a casting are called:
    A. chills.
    B. chaplets.
    C. cores.
    D. patterns.
A

C. cores.

39
Q
  1. Which of the following may cause a discontinuity even though its intended purpose is to PREVENT SHRINKAGE CAVITIES BY ABSORBING HEAT from the molten metal in the center of the casting?
    A. Riser
    B. Core
    C. Internal chill
    D. Chaplet
A

C. Internal chill

40
Q

Casting molds made by covering a heated metal pattern with sand that is mixed with particles of thermosetting plastic are called:
A. green sand molds.
B. shell molds.
C. plaster molds.
D. die casting molds.
E. permanent molds.

A

B. shell molds.

41
Q

Permanent molds are most frequently made of:
A. ceramics.
B. fused sand and plastic,
C. metal.
D. plaster.

A

C. metal.

42
Q
  1. An assembly that has been created by joining two or more parts by one or more welds is called a:
    A. joint.
    B. bonded structure.
    C. weld.
    D. weldment.
A

D. weldment.

43
Q
  1. A general definition of welding describes the joining of two surfaces:
    A. with a filler metal that has a higher melting point than the base metal.
    B. with a filler material that is different from the base material.
    C. In a permanent union established by atom-to-atom bonds.
    D. where both heat and pressure are necessary for permanent bonding.
A

C. In a permanent union established by atom-to-atom bonds.

44
Q
  1. Metallurgical effects in a weld, such as grain size variation and shrinkage, are similar to those that occur in:
    A. forgings.
    B. castings.
    C. extrusions.
    D. hot-rolled plates.
A

B. castings.

45
Q
  1. Proper brazing depends upon numerous factors being controlled. Of the following, which is not appropriate?

A Proper joint fit-up and joint preparation
B Adequate heat to melt the braze filler metal
C. Selection of proper braze filler metal.
D. Complete melting of the step metal and diffusion of the braze filler metal into the base metal
E. All of the above are important

A

D. Complete melting of the step metal and diffusion of the braze filler metal into the base metal

46
Q
  1. Soldering, brazing, and braze welding all:

A. have the same strength characteristics.
B. utilize a process where only the filler metal is actually melted.
C. are fusion-type weldments
D. utilize liquid penetrant inspection to reveal porosity within the joint.

A

B. utilize a process where only the filler metal is actually melted.

47
Q

8 Due to high temperatures and rapid rate of cooling the filler material used to fusion welds.

A. is coated with an oxide to help reduce weld defects.
B. contains alloys that will help compensate for properties lost during the welding process.
C. is alloyed with nickel, copper, and carbon to eliminate cracking.
D. should be as close as possible to the same alloy content as the base material.

A

B. contains alloys that will help compensate for properties lost during the welding process.

48
Q

9 The uneven shrinkage and brittle structures that occur due to the rapid cooling of a weld can often be reduced by:
A. preheating the weldment prior to welding.
B. using a filler metal with a higher carbon content than the base metal.
C clamping the weldment in a rigid fixture.
D. over designing the size of the weldment to prevent shrinkage.

A

A. preheating the weldment prior to welding.

49
Q
  1. After welding, many steel weldments are heat treated to obtain more uniform properties between the weld and base metal and to relieve stress. Which heat treatment method .s often used following welding?
    A. Tempering
    B. Martensitic aging
    C. Normalizing
    D. Spheroidizing.
A

C. Normalizing

50
Q
  1. Weldments subject to restraint during welding can develop high residual stresses. Unrestrained weldments can develop:
    A. geometric distortion.
    B. high residual stresses. - r
    C. cracking after the weld has cooled.
    D. all of the above.
A

D. all of the above.

51
Q

12 Welds and weldments have been known to develop cracks long after cooling but prior to being used in service. What is the principal cause for such cracks?

A. Accelerated corrosion at high temperature
B. Scattered porosity in the weld
C. Improper selection of base material
D. Excessive residual stresses

A

D. Excessive residual stresses

52
Q

22 Thermal conductivity of a metal is an important factor to consider in making quality weldments because:

A. some metals, such as aluminum, have a low conductivity which results in weld defects due to localized heat build up.
B. some metals, such as stainless steel, have a high conductivity which results in lack of fusion defects as the heat is quickly removed from the weld zone.
C. in some metals, such as aluminum, very high temperature gradients are produced, causing stresses during cooling.
D. all of the above,
E. none of the above.

A

E. none of the above.

53
Q
  1. Cracks in the weld metal are primarily of which three types?
    A. Shallow, deep, and intermittent
    B. Longitudinal, transverse, and crater
    C. Laminar, through, and oblique
    D. Longitudinal, laminar, and intermittent
A

B. Longitudinal, transverse, and crater

54
Q
  1. Crater cracks may take the form of a single crack or star-shaped cracks and will usually be found:

A. by magnetic particle techniques since crater cracks are always subsurface.
B. anywhere along a weld where the welding was stopped and restarted,
C. in the natural crater formed between the two plates in a typical fillet weld.
D. In the root area of a multiple pass weld where the weld metal failed to flow completely into the root opening.

A

B. anywhere along a weld where the welding was stopped and restarted,

55
Q
  1. A slag inclusion can result in the following?

A. Small pieces of tungsten being dislodged from the electrode in the gas tungsten arc process.
B insufficient cleaning of successive passes in a multi-pass weldment
C. Excessive undercut on intermediate passes in a multi-pass weldment
D. All of the above
E. Only B and C above

A

E. Only B and C above

56
Q
  1. Undercut on a weld pass is usually caused by:

A. too slow a rate of travel, causing the base metal to become too hot
B. using an Electrode that is too large for the current capacity of the welding machine.
C. all of the above.
D. only B and C above.

A

A. too slow a rate of travel, causing the base metal to become too hot

57
Q

4 During the steel-making process, a large number of faults such as slag, porosity, and shrinkage cavities exist In the top of the Ingot. These discontinuities are:

A. mostly eliminated in subsequent hot working due to the pressure which “welds” the void shut.
B. located with nondestructive testing techniques at later stages of production.
C. almost non-existent with modern steel-making processes.
D. removed by cropping up to 1/3 off the top of the ingot.

A

D. removed by cropping up to 1/3 off the top of the ingot.

58
Q

5 Discontinuities with their origin in the original ingot can be reduced in severity by the closing and welding of voids and the breaking up and elongation of inclusions by which of the following processes?
A. Cold working
B. Hot working
C. Heat treatment
D. Welding

A

B. Hot working

59
Q

8 Which of the following statements is true concerning deformation processes?

A. Hot working usually follows cold working.
B. Hot working must be followed by heat treatment.
C. Hot worked materials must be cold worked before they can be used.
D. Cold working usually follows hot working.
E. Cold working renders brittle material more ductile.

A

D. Cold working usually follows hot working.

60
Q

9 Machinability and fatigue resistance are improved in most metals that have been:
A. hot worked.
B. cold worked.
C. heat treated.
D. cast.

A

B. cold worked.

61
Q

1 Nondestructive testing is often utilized just following hot and cold working operations to:

A. assure that further operations are not performed on material that contains defects that could reject the manufactured part.
B. determine that defects do not exist in the material that could damage the rolling mills and other equipment.
C. determine the ductility of the material after the rolling operation is complete.
D. accurately determine the compressive strength of the material after it passes through the rolling mill.

A

A. assure that further operations are not performed on material that contains defects that could reject the manufactured part.

62
Q

2 Slabs, blooms, and billets are:

A. the three consecutive stages that the metal goes through during the production of products such as angle iron and channel iron.
B. the shapes that the ingot is rolled into prior to a variety of secondary operations.
C. types of defects that occur during the hot rolling of steel.
D. the three different shapes produced during typical cold rolling operations.

A

B. the shapes that the ingot is rolled into prior to a variety of secondary operations.

63
Q
  1. In drawing and deep drawing, the final shape often can be completed in a series of draws, each successively deeper. What process performed between draws might effectively reduce the number of draws required?
    A. Recrystallization
    B. Pickling
    C. Etching
    D. Hardening heat treatment
    E. Hot rolling
A

A. Recrystallization

64
Q

3 Spinning can be used to form:

A. spherical tank halves.
B. cemented carbide cutting tools.
C. crane hooks.
D. rectangular sheet metal tanks.
E. solid spheres.

A

A. spherical tank halves.

65
Q

12 A cutting operation that has the ability to cut through thicknesses of over 3 feet of steel and is commonly used to remove surface defects on castings and forgings by “scarfing” is called:
A. friction cutting.
B. oxyacetylene cutting.
C. ultrasonic cutting.
D. gas metal arc cutting.
E. plasma arc cutting.

A

B. oxyacetylene cutting.

66
Q

11 A process which is the reverse of electrochemical machining and which is the basis for electroplating is called:
A. chemical milling
B. electrical discharge machining
C. electroforming
D. magnetoforming

A

C. electroforming

67
Q

15-4 Which of the following statements is true concerning composite materials?

A. Composite materials include combinations of non-metallic materials only.
B. When composite materials are cured, the constituents lose their original identity and form chemical compounds with one another.
C. A unique feature of composite materials is that their tensile strength frequently exceeds the
D Composites are usually formed into complex three-dimensional shapes with each dimension approximately equal to the other two.
E. None of the above statements are true.

A

E. None of the above statements are true.

68
Q

6 The major difference between materials classified as composites and those classified as mixtures is that:

A. mixtures are a type of composite with random orientation and shape of the constituents.
B. composites contain metallic constituents and mixtures are non-metallic.
C. mixtures start as liquids blended together and composites start as solids.
D. mixtures are elastomeric, while composites are characterized as having at least one plastic component.

A

A. mixtures are a type of composite with random orientation and shape of the constituents.

69
Q

10 A process that converts the base metal surface to an OXIDIZED BARRIER layer of very small porous cells is called:
A. galvanizing.
B. plating.
C. anodizing.
D. metalizing.

A

C. anodizing.

70
Q

5 The best and most economical cleaners used for removal of oils and greases are:
A. pickling baths.
B. de-ionized water sprays.
C. wire brushes and cloth buffers.
D. petroleum solvents.

A

D. petroleum solvents.

71
Q

6 Some materials, such as aluminum, are corrosion resistant:

A. by virtue of the Immediate oxidation of newly exposed surfaces.
B. only if anodized.
C. because the material itself will not readily combine with oxygen.
D. against all types of corrosive atmospheres.

A

A. by virtue of the Immediate oxidation of newly exposed surfaces.

72
Q

8 A corrosion protection material commonly applied to steel by hot dipping and galvanizing is:
A. porcelain.
B. copper.
C. paint.
D. zinc
E. chromic acid.

A

D. zinc

73
Q

9 Metals commonly applied to other metals by electroplating are:

A Nickel, chromium, and cadmium.
B. tin, zinc, and tungsten.
C. sliver, gold, and carbon.
D. copper, aluminum, and magnesium.
E. both A and D above.

A

A Nickel, chromium, and cadmium.

UT1 EMC (1 decks)

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