What can cause stress raisers?
Punch marks
Corrosion grooves
Corrosion pits
All of the above
When a metal (or alloy) cools from a liquid to a solid state, the lack of molten metal to feed the shrinkage will lead to:
Pipes, voids and cavities
Sponge like appearance and hot tears
None of the above
Both a and b
Which of the following is not a cause of undercutting?
Excessive amperage
Excessive travel speed
Excessive electrode diameter
Excessive restraint during welding
An extremely thin discontinuity that is the result of pipes or inclusions flattened and made directional by working is called:
A stringer
A lamination
A seam
A cold shut
In general, where can you find heat treatment cracks?
At the center of a weld
In areas of sudden change in thickness
On a cast plate
All of the above
Which of the following measurements indicates the smoothest surface finish?
250 micro inches
0.0002 inch
0.00015 inch
100 micro inches
After solidification of a casting, the internal granular structure consists of three layers: outer, intermediate and central. The central layer consists of:
A mixture of large and small grains with random shape and orientation
Large columnar grains
Large equi-axed grains
Small equi-axed grains with random shape and orientation
A cause of gas porosity is:
Welding at too low a temperature
Improper cleaning or preheating of the plates to be welded
The use of insufficient filler metal
Restriction of the movement of the material during heating or welding
A definite break in the material caused by excessive working of the metal during the forging, rolling or extruding operation is called a:
Cold shut
Seam
Burst
Hot tear
What must the direction of applied stress be to result in lamellar tearing?
Parallel to the rolling direction of the plate
Perpendicular to the rolling direction of the plate
45° to the rolling direction of the plate
All of the above
Since rolling results in the flattening and elongation of a sheet of metal, what happens to a pocket of gas in a metal sheet as a result of hot rolling?
It is still present and is the same size
It is still present and it has grown in size
It is still present but is smaller in size
None of the above
Aluminum sand castings are subject to:
Shrinkage cracks
Surface porosity and cold shuts
Micro shrinkage
All of the above
Hot tears generally originate:
Internally or at the surface
From internal chaplets
From a large pore
From flat areas
Under bead cracking occurs in the
Root pass of a weld
Heat affected zone of a weld
Second last layer of the weld
Crater at the end of a weld bead
In a shielded metal arc weld, entrapped gas pockets that are aligned and separated by a relatively small distance is called:
Piping porosity
Linear porosity
Pitting
Straight porosity
Which of the following is not a discontinuity common to forged products?
Laps
Shrinkage
Bursts
Flakes
Fine lines, likely to occur in groups caused by non-metallic impurities present in the original ingot and extruded lengthwise are called:
Stringers
Seams
Laminations
Laps
Can you say that there is a difference between a corrosion fatigue crack and intergranular corrosion in terms of the grain of the metal?
No, as these two defects are transgranular
No, as these two defects are intergranular
Yes, as a corrosion fatigue crack is transgranular and intergranular corrosion is intergranular
Yes, as a corrosion fatigue crack is intergranular and intergranular corrosion is transgranular
Grain boundaries are areas of a metal microstructure:
Where high melting point constituents are concentrated
Made up of rows of atoms arrayed in straight lines
That are not attacked by etchants and generally stand in relief during metallographic examination
Where low melting impurities tend to concentrate
A term used to describe the oxides and other solids which are shown radio graphically as elongated or rounded inclusions are:
Slag
Porosity
Suck-back
Worm holes
Most manufacturing discontinuities in a tube are:
Axial in direction
Circumferential in direction
On the outside of the tube
Subsurface
What are the 3 main types of corrosion?
General corrosion, pitting and intergranular corrosion
General corrosion, pitting and transgranular corrosion
General corrosion, intergranular and transgranular corrosion
Transgranular, intergranular and pitting
Where is the most logical place, on a casting, to look for discontinuities?
On the top surface
On the bottom surface
At internal surfaces
At junctions between light and heavy sections
What is the cause of cracks in the heat affected zone?
A thermal cycle that increases hardness and reduces brittleness
A thermal cycle that reduces hardness and increases brittleness
A thermal cycle that reduces hardness and brittleness
A thermal cycle that increases hardness and brittleness
Elongates configurations of foreign substances aligned in the direction of working in wrought metals are called:
Slag
Inclusions
Stringers
Worms
A discontinuity which bears no relation to the direction of metal grains is:
Intergranular corrosion
Grinding crack
Quenching crack
Lamellar tearing
Which of the following techniques is often used to speed up the steel making process?
Adding large amounts of carbon to the molten metal
Reducing the amount of scrap steel that is often added to the molten metal
Adding oxygen to the molten metal
Converting the old open hearth furnaces into electric furnaces
Which of the following should not be in the list?
Ingot
Bloom
Billet
Slab
Wrought products invariably exhibit:
High susceptibility to corrosion
Lower strength than their cast counterparts
Directional properties
Poor weld ability
Which of the following is not a characteristic of plaster mold casting?
Only non-ferrous metals are cast in plaster molds
The mold materials can be reused
A uniform structure in the casting is obtained because of slow cooling
Plaster molds are well suited to the use of chills, which permit close control of thermal gradients in the molds
The welding process most widely used because of its versatility is:
Gas metal-arc welding
Shielded metal-arc welding
Gas tungsten-arc welding
Submerged-arc welding
In the process of diffusion welding, often called diffusion bonding, the base metal is joined by:
Melting the weld joint area with strip heaters
Using high temperature adhesives
Putting it under pressure, at temps below the melting point
The heat of frictional movement between the surfaces to be joined
Soldering, brazing and braze welding all:
Have the same strength characteristics
Utilize a process where only the filler metal is actually melted
Are fusion type weldments
Utilize liquid penetrant inspection to reveal porosity within the joint
Which of the following product forms is generally selected for high strength and controlled property directionality?
Castings
Extrusions
Hot rolled flat stock
Forgings
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?
Recrystallization
Pickling
Etching
Hardening heat treatment
Which of the following discontinuities could be classified as a primary processing discontinuity often found in wrought material?
Fatigue crack
Stress corrosion crack
Porosity
Machining tear
Discontinuities in plate, sheet, or strip causes by pipe, inclusions or blowholes in the original ingot which after rolling are usually flat and parallel to the outside are called:
Seams
Lamination
Cracks
Laps
Cracks in the weld metal are primarily of which 3 types?
Shallow, deep and intermittent
Longitudinal, transverse and crater
Laminar, through and oblique
Longitudinal, laminar and intermittent
The name of the discontinuity which is most likely to occur at the junction of light and heavy sections is:
Porosity
Hot tear
Blowhole
Both a and c
Oval or circular dark spots with smooth edges appearing on weld or casting radiographs would most probably be indicative of:
Burn through
Crater crack
Porosity
Incomplete fusion
Where on a forged piece can you find a burst?
Inside the piece
Always on the surface of the piece
On the surface of the piece
Both a and c
Which discontinuities result in damage to surfaces in contact, especially in a corrosive environment?
Stress corrosion crack
Embrittlement
Fretting corrosion
Intergranular corrosion
Shrinkage and micro shrinkage:
Are acceptable discontinuities
Are forms of porosity
Are always cause for rejection
Always give bold penetrant indications
In its original shape porosity would appear:
Elongated
Irregular
Round or nearly round
All of the above
Stringers are a type of discontinuity sometimes found in:
Weldments
Castings
Forgings
None of the above
Which is not a discontinuity that occurs during service of a part?
Forging crack
Fatigue crack
Stress corrosion crack
Intergranular corrosion
A non-magnetic stainless steel has:
A ferritic structure
An austenitic structure
A marensitic structure
A random grain structure
Increasing test sample temperature normally:
Increases electrical resistivity
Decreases electrical resistivity
Does not change electrical resistivity
Increases magnetic permeability
What is the origin of the ferromagnetic inclusions found in tubes of heat exchangers?
Local segregation in the tube
Incrustation, during manufacture, of chips of filings from austenitic steel
Incrustation, during manufacture, of chips of filings from martensitic steel
Incrustation, during manufacture, of chips of filings from copper
A discontinuity which is caused by the combined action of a constant stress and a corrosive environment is said to be a:
Fatigue crack
Stress corrosion crack
Corrosion fatigue crack
Intergranular corrosion
A casting process in which the working pattern is destroyed is:
Centrifugal casting
Green sand casting
Investment casting
None of the above
A common characteristic of sand casting and investment casting is:
Both may be used to produce small castings
Both produce castings of great dimensional accuracy
Both make use of wooden patterns
Both make use of reusable molds
The essential difference between permanent mold casting and die casting is:
In the first method, molten metal enters the mold by gravity, while in the second method, the molten metal enters the mold under pressure.
The mold in permanent mold casting is reusable while it is not in the case of die casting
The mold in permanent mold casting is made of ceramic while steel is used to make the mold for die casting.
There are no differences; both names are used to identify the same process.
The top portion of a molding flask is called a:
Cope
Drag
Cheek
Runner
In a mold, the runner connects:
The pouring basin to the sprue
The down gate to the riser
The sprue to the ingate
The pouring basin to the mold cavity
Which of the following methods produces a casting faster and at lower cost?
Green sand casting
Dry sand casting
Investment casting
Shell molding
Aircraft turbine blades are produces by:
Investment casting
Shell molding
Green sand casting
Dry sand casting
The “hot top” of an ingot is removed in order to:
Facilitate an even cooling rate in the ingot
Obtain a bloom or billet of the desired length
Remove many of the discontinuities from the ingot
All of the above
The grain structure at the center of castings of heavy sections would be expected to be:
Columnar and dendritic
Coarse equiaxed grains
Fine equiaxed grains
None of the above
A way to prevent segregation in an ingot is to:
Use a large ingot mold
Cool the ingot very slowly
Cool the ingot rapidly below the temperature of solidification
Stir the solidifying metal
Which of the following is not considered a forging process?
Open-die
Impression die
Swaging
Spinning
The process that plastically works a metal by means of localized compressive forces exerted by hammers and presses is known as:
Forging
Rolling
Casting
None of the above
Which of the following statements about forging is incorrect?
Forging is the working of metal into a useful shape
Hot forging closes many internal discontinuities
Forging may be done with either open of closed dies
Forging at too high a temperature may cause hot tears
Forming a taper or a reduction on metal products such as rod and tubing by forging is called:
Swaging
Upsetting
Punching
Drawing
Cold working of a metal has the following effect on its properties:
Hardness of the surface is increased
Strength of the metal is increased
Strength of the metal is decreased
Both a and b
Strain hardening occurs whenever a metal is:
Deformed at a temperature below the recrystallization temperature
Deformed at a temperature above the recrystallization temperature
Heat treated
Both a and c
As a metal’s hardness increases:
Its ability to deform is increased
Its strength in tension is increased
Its strength in compression is decreased
Its notch toughness is increased
A metal stressed below its elastic limit will return to its original shape:
Upon heating the metal to its Curie point
Only upon application of an equivalent stress in the opposite direction
Upon removal of the stress
All of the above
The mill working process performed principally on flat products and bars that improves hardness, strength, surface finish, and dimensional accuracy is:
Cold rolling
Hot rolling
Forging
Extrusion
Metals which cannot be work hardened are those which:
Recrystallize at room temperature
Recrystallize at very high temperatures
Recrystallize at the Curie temps
Recrystallize above the Curie temps
A possible effect(s) of metal forming is (are) to:
Refine the grains structure
Mprove the mechanical properties
Close blow holes which have formed in an ingot
All of the above
The work metal for forging with a forging hammer is:
A bloom
A billet
A bar
Any of the above
Which of the following statements is correct?
Blooms are intermediate rolling products with a square end section larger than 6”x6”
Blooms can be rolled into square or round billets
Intermediate shaped into which an ingot can be converted are a bloom and a billet
All of the above
Which of the following would have the least ductility?
Cold-rolled steel plate
Cold-rolled steel sheet
Gray cast iron
Cold rolled aluminum plate
In which of the following weldments processes is filler metal never added?
Brazing
Soldering
Arc welding
Spot welding
The following gas is used intensively for shielding in the gas tungsten arc welding process:
Radon
Oxygen
Argon
Hydrogen
In which of the following welding processes is the electrode non-consumable?
Shielded metal arc welding
Gas tungsten arc welding
Gas metal arc welding
Submerged arc welding
In gas welding, a reducing flame is produced when:
There is no excess oxygen or acetylene in the flame
There is excess acetylene in the flame
There is excess oxygen in the flame
There is excess oxygen and acetylene in the flame
The electrodes used for spot welding are usually made of:
Carbon
Mild steel
Tungsten
Copper
Spot welding is usually performed using:
A very low current passed for a very short time
A very high current passed for a very short time
A very low current passed for a very long time
A very high current passed for a very long time
Arc welding is usually performed using:
Alternating current, low voltage and low amperage
Direct current, low voltage and high amperage
Direct current, high voltage and low amperage
Alternating current, high voltage and low amperage
In the resistance welding process:
Two parts to be joined are heated then pressure is applies
Two parts to be joined are held firmly together under pressure followed by the generation of heat at the interface
No heat is applied and the parts are welded by applying pressure only
The parts are heated but not melted and a filler weld is added
An advantage of the electro slag process over other methods of welding is that
A coarse grain structure is formed because of the slow cooling rate
It does not require special edge preparation on the base metal sections
Weld cracking is never a problem because of the absence of residual stress
Very thin sections can be welded easily
Which of the following statements is correct?
The heat affected zone of a weld is basically a homogeneous structure
In some areas of the weld heat affected zone, grain size can be smaller than in the unaffected base metal
The temp in the heat affected zone can sometimes exceed the temp in the fusion zone
Transverse cracks do not occur in the heat affected zone
The process in which a steel is heated above the upper critical temp and then cooled slowly through the transformation range in the furnace or a good heat insulated material is known as:
Tempering
Full annealing
Normalizing
Quenching
Crystalline materials include:
Copper
Steel
Aluminum
All of the above
Which of the following factors can have a negative influence on some NDT tests?
Grain size
Grain orientation
Grain boundary composition
All of the above
The overall stress to give failure by fatigue is:
Greater than that required to produce tensile failure
Less than that required to produce tensile failure
Equal to that required to produce tensile failure
Greater or less than that required to produce tensile failure depending on the type of material
The purpose of placing a plating on previously manufactured part is:
For corrosion protection
For greater wear resistance
For appearance
All of the above
Galvanizing is a process of applying, to iron and steel products a protective layer of:
Tin and tin compounds
Zinc and zinc compounds
Aluminum and aluminum compounds
Copper and copper compounds
A service discontinuity that appears as a series of small micro openings with no definite pattern and extend in any direction following the grain boundaries is:
A fatigue crack
A fillet crack
Hydrogen Embrittlement
Intergranular corrosion
A definite break in the material caused by excessive working of the metal during the forging, rolling or extruding operation is called a :
Cold shut
Seam
Burst
Hot tear
Fine lines, likely to occur in groups caused by nonmetallic impurities present in the original ingot and extruded length wise are called:
Stringers
Seams
Laminations
Laps
There is a groove in the surface of a plate along the edge of a weld. Which of the following could be used to describe the discontinuity?
Crater crack
Undercut
Incomplete penetration
Incomplete fusion
A forging discontinuity caused by the metal being folded over and forced into the surface but not welded to form a single piece is called:
A hot tear
A forging lap
A burst
A forging crack
A generally smooth indentation on a cast surface resulting from the meeting of two streams of metal coming from different directions and failing to fuse is called:
Stringer
Hot tear
Cold shut
Lap
Cyclical loading of the part above the yield strength of the material
Cyclical loading of the part below the yield strength of the material
Local overheating of the part
Corrosive atmosphere
Which of the following discontinuities might be found in a rolled plate?
Laminations
Shrinkage
Incomplete fusion
Undercut
Grinding cracks can be caused by:
Lack of or poor coolant
Dull or improper grinding wheel
A too heavy cut
All of the above
Which of the following statements regarding seams is correct?
Seams are always open to the surface
Seams are in the direction of the grain flow and may spiral due to rolling conditions
Seams in an ingot are caused by improper heating conditions
None of the above
Elongated configurations of foreign substances aligned in the direction of working wrought metals are called:
Slag
Inclusions
Stringers
Pipe
A discontinuity which bears no relation to the direction of metal grains is:
Intergranular corrosion
Grinding crack
Quenching crack
Lamellar tearing
Which of the following provides the NDT inspector with a brief outline of the steps to perform a test on a specific item?
Code
Standard
Procedure (instruction)
Specification
In the inspection of a part, the following may justify rejection of some parts:
Inherent defects
Service defects
Processing defects
All of the above
In general, where can you find heat treatment cracks?
At the center of the weld
In areas of sudden change in thickness
On a cast plate
All of the above
A somewhat linear intermittent penetrant indication would be formed by a:
Crater crack
Hot tear
Forging lap
Cold shut
It may be said that specialists in NDT must:
Be aware of the capabilities of materials to sustain deformation without forming defects
Be knowledgeable about the materials they inspect and the defects which can form in them
Have an exhaustive knowledge of metallurgy
All of the above
When a metal (or alloy) cools from a liquid to a solid state, the lack of molten metal to feed the shrinkage will lead to:
Pipes, voids and cavities
Sponge like appearance and hot tears
None of the above
Both a and b
Dark or light bands in metal could be the result of:
Segregation
Shrinkage
Recrystallization
None of the above
A burst is associated with:
Castings
Forgings
Rolled plate
None of the above
Face centered cubic grain structures are normally found in:
Delta iron
Stress relieved steel
Gamma iron
Cold worked steel
The annealing process is normally carried out to
Decrease hardness caused by working
Customer request
Ncrease in electrical conductivity
Increase in surface hardness
Corrosion can be caused by:
Chemicals
Salty water
Electrolytic reactions between dissimilar metals
All of the above
Brazing is accomplished by the following:
Melting of the parent material
Adhesion and cohesion
Explosive compression
None of the above
Forging discontinuities could consist of the following:
Allotropic grain structures
Miss runs – cold shuts
Bursts – laps
Undercutting
Toughness of a material can be tested by:
Tensile testing
Charpy V notch testing
Telebrinneller testing
Microdur testing
Cathodic protection of a metal can be accomplished by:
Sacrificial anodes
Stress relieving
Ceramic coating
None of the above
Pickling is used on metals to:
Remove scale and impurities before coating
Preserve alloy steels
Remove epoxy coatings
Enhance stainless properties of 4140 steels
Which of the following is not a welding discontinuity?
Lamellar tearing
Distortion
Undercutting
Segregation
In the centrifugal casting process, which is not true?
Improved density of metal as gas is forced out
Can be hollow
Improved quality of metal as gas is forced out
Lack of segregation
Which is not part of a green sand casting mold?
Cope, drag, sprue
Vents, chills, chaplets
Backers, lentils, posts
Runners, gates, risers
Excess hydrogen may be trapped in a weld by the following:
Moisture
Carbon dioxide
Shielding gas
All of the above
Hydrogen cracking will normally take place in:
The cap
The root
Heat affected zone
Fillet welds
Which statement is true?
All defects are discontinuities
All discontinuities must be removed
All discontinuities are defects
All of the above
An investment casting:
Produces a fine surface finish
Uses a wooden pattern
Is used generally for large castings
Is used generally for small castings
Sphereodizing is a heat treatment process in which the metal is:
Heated to 100°F above the upper critical temp, then cooled in the still air to room temp
Heated and cooled alternatively between temps that are just above and just below the lower critical temp
Heated above the upper of lower critical lines and cooled slowly in the furnace
None of the above
Steels that contain more than 0.30% carbon if welded are prone to which type of discontinuity?
Heat affected zone cracking
Porosity
Incomplete fusion
Slag formation
A discontinuity in welds caused by gas entrapment in the molten metal, moisture, improper cleaning, high winds, or lack of preheat is referred to as:
Dross
Incomplete penetration
Porosity
Slag inclusions
discontinuity consisting of one or several parallel fissures caused by the internal rupture or fracture of material while in the hot semi-plastic state is called:
Incomplete fusion
Tear
Unfused chaplet
Hot crack
Cracks or fractures formed in casting prior to completion of solidification because of restricted contraction is indicative of a:
Shrinkage cavity
Hot tear
Misrun
Cold shut
A discontinuity that may be the result of improper pouring temp or alloy composition is indicative of:
Gas porosity
Shrinkage porosity
Dispersed discontinuities
Unfused chaplet
A discontinuity caused by gas released during solidification or by the evaporation of moisture or volatile material from the mold surface is indicative of:
Micro shrinkage
Shrinkage porosity
Inclusion
Gas porosity
Failure of the metal to fill the mold cavity, thus creating a casting that is not complete, is known as:
Core shift
Misrun
Cold shut
Buckles
A definite discontinuity that exists because of imperfect fusion of two streams of metal that have converged is known as:
Misrun
Cold shut
Rat tails
Buckles
Voids in a casting caused by inadequate feeding to compensate for the volumetric shrinkage that occurs during solidification are:
Shrinkage cavities
Shift
Hot tears
Blowholes
Particles of foreign material such as sand or slag that are embedded in the cast metal are:
Gas holes
Buckles
Rat tails
Inclusions
An indication on a casting radiograph that appears as distinct dark lines or a band of variable length and width, with a definite smooth outline is indicative of:
Shrinkage
Segregation
Cold shuts
Tears
Voids that are readily recognizable as smooth, dark, round or oval shaped spots with radiographic contrast varying directly with their diameter are:
Gas porosity
Shrinkage porosity
Segregation
Core shift
An uneven wall thickness in an internal passage of a casting as viewed in a radiograph is indicative of:
Misruns
Segregation
Unfused chaplets
Core shift
If an elongated dark area of varying length and width, which is either continuous or intermittent appears in the center of a radiograph of a weldment, it is indicative of:
Cracks
Incomplete penetration
Inclusions
Shrinkage
An indication(s) on a radiograph that appear as dark, ragged lines of variable widths and numerous branches with no definite line of continuity are indicative of:
Cold cracks
Cold shuts
Hot tears
Core shift
A dark line of varying width on a radiograph which follows the edge of the fusion zone of a weld is indicative of:
Undercutting
Incomplete fusion
Porosity
Shrinkage
An indication appearing on a radiograph as a dark, elongated area of varying length of width located at the center of a weld would probably be classified as:
Aligned porosity
Slag line
Wagon tracks
Incomplete penetration
An oval or circular dark spot with smooth edges appearing on the radiograph would most probably be indicative of:
Burn through
Crater crack
Porosity
Incomplete fusion
An intermittent or continuous dark line found at the edge of the weld groove or bevel would probably be classified as:
Aligned porosity
Slag line
Root concavity
Crater cracking
A narrow, dark line traveling in irregular directions would generally indicate the presence of:
A crack
A slag line
Aligned porosity
Incomplete fusion
A very thin, straight, dark line, either continuous or intermittent, located parallel to and normally on one side of a weld would be indicative of:
A slag inclusion
Suck back
Aligned porosity
Incomplete fusion
Indications appearing singly or as clusters of small, light spots in the GTA weld would probably be classified as (on radiograph):
Weld spatter
Nonmetallic inclusions
Tungsten inclusions
Gas holes
The term used to describe the reduction in the bas metal thickness where the last weld bead is fused to the surface is called:
Convexity
Undercut
Incomplete fusion
Concavity
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