Engineering, Materials And Components Quiz

Reviewed by Editorial Team
The ProProfs editorial team is comprised of experienced subject matter experts. They've collectively created over 10,000 quizzes and lessons, serving over 100 million users. Our team includes in-house content moderators and subject matter experts, as well as a global network of rigorously trained contributors. All adhere to our comprehensive editorial guidelines, ensuring the delivery of high-quality content.
Learn about Our Editorial Process
| By Suchanjv
S
Suchanjv
Community Contributor
Quizzes Created: 2 | Total Attempts: 39,361
| Attempts: 32,682 | Questions: 200
Please wait...
Question 1 / 200
0 %
0/100
Score 0/100
1. The factor which must be considered prior to selecting the best method to produce a closed die forging is:

Explanation

The best method to produce a closed die forging must consider the size of the forging, the production quantity, and the design of the forging. The size of the forging is important because it determines the equipment and resources needed for production. The production quantity will determine the most efficient method to meet the required quantity. The design of the forging is crucial as it affects the complexity and feasibility of different production methods. Considering all of these factors is necessary to select the most suitable method for closed die forging.

Submit
Please wait...
About This Quiz
Engineering, Materials And Components Quiz - Quiz

When you think of an engineer you may see people with the power to create that which most of us cannot and this is thanks to thousands of... see morehours of study and practice. Are you an engineering student? Below are some test questions for Materials and Processes exams. It is very helpful in your studying for CGSB exams. Give it a shot!
see less

2. The material used for making a pattern depends on:

Explanation

The material used for making a pattern depends on several factors. Firstly, it depends on the type of material that will be cast. Different materials have different properties and requirements, so the pattern material should be compatible with the casting material. Secondly, the grain structure desired in the finished casting is also a crucial factor. The pattern material should be able to create the desired grain structure in the casting. Lastly, the expected production quantity is important as it affects the durability and cost-effectiveness of the pattern material. Therefore, all of the above factors play a role in determining the material used for making a pattern.

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

Explanation

The factor that must be considered prior to selecting the hammer or press to produce a closed-die forging is all of the above. This means that the size of the forging, the production quantity, and the design of the forging are all important factors to consider when choosing between a hammer or press. The size of the forging will determine the capacity and capabilities of the equipment needed. The production quantity will influence the efficiency and speed of the process. And the design of the forging will determine the complexity and intricacy of the equipment required. Considering all these factors is crucial to ensure the successful production of a closed-die forging.

Submit
4. The material used for making a pattern depends on:

Explanation

The material used for making a pattern depends on multiple factors. Firstly, it depends on the type of material that will be cast, as different materials may require different patterns to achieve the desired shape and dimensions. Secondly, the grain structure desired in the finished casting also influences the choice of pattern material, as certain materials may be better suited for creating specific grain structures. Lastly, the expected production quantity plays a role, as patterns made from certain materials may be more cost-effective or durable for high-volume production. Therefore, all of the above factors affect the selection of pattern material.

Submit
5. Cracks may occur at any stage of manufacturing

Explanation

Cracks can occur at any stage of manufacturing due to various factors such as material defects, improper handling, excessive stress, or temperature changes. These cracks can compromise the structural integrity and quality of the product. Therefore, it is important to carefully monitor and control the manufacturing process to minimize the occurrence of cracks.

Submit
6. Like ingots, welds can contain porosity:

Explanation

Welds can contain porosity, which refers to the presence of small voids or gas pockets within the weld. This can occur due to a variety of factors such as improper shielding gas, inadequate cleaning of the base metal, or incorrect welding parameters. Porosity can weaken the weld and make it more susceptible to cracking or failure. Therefore, it is important to ensure proper welding techniques and parameters to minimize the occurrence of porosity in welds.

Submit
7. In the beginning all steel is perfect:

Explanation

The statement "In the beginning all steel is perfect" is false. This is because steel, like any other material, can have imperfections or defects from the start, such as impurities or inconsistencies in its composition. These imperfections can affect the strength, durability, and overall quality of the steel. Therefore, it is incorrect to assume that all steel is perfect from the beginning.

Submit
8. NDT is used for locating only those discontinuities open to the surface:

Explanation

The statement is false because NDT (Non-Destructive Testing) is used to detect and locate both surface and subsurface discontinuities in materials. It can identify defects such as cracks, voids, and inclusions that are not necessarily open to the surface. NDT techniques like ultrasonic testing, radiography, and magnetic particle inspection can penetrate the material and detect internal flaws, making it possible to identify discontinuities that are not visible on the surface.

Submit
9. NDT is a method of locating which of the following:

Explanation

NDT stands for Non-Destructive Testing, which is a method used to inspect and evaluate materials or components without causing any damage. The purpose of NDT is to detect any flaws or defects that may be present in the material. In this context, "discontinuities" refers to any interruptions or inconsistencies in the material's structure or composition. Therefore, NDT is used to locate and identify these discontinuities, such as cracks, voids, or inclusions, which could potentially compromise the integrity or functionality of the material or component being tested.

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

Explanation

All of the factors mentioned (grain size, grain orientation, and grain boundary composition) can have a negative influence on some non-destructive tests. This is because these factors can affect the propagation of waves or the interaction of radiation with the material being tested. For example, variations in grain size or orientation can cause scattering or diffraction of waves, making it difficult to accurately interpret the test results. Similarly, differences in grain boundary composition can affect the transmission or reflection of waves, leading to inaccuracies in the test measurements. Therefore, all of these factors can potentially impact the reliability and accuracy of non-destructive tests.

Submit
11. Elements may be added to the filler metal to:

Explanation

The correct answer is "Any of the above." This means that elements may be added to the filler metal for multiple reasons, including controlling grain growth, increasing ductility, and assuring adequate corrosion resistance. The addition of these elements can serve different purposes depending on the specific requirements of the metal being used.

Submit
12. Possible effect(s) of metal forming is (are) to:

Explanation

Metal forming processes such as rolling, forging, and extrusion can have multiple effects on the material. One effect is the refinement of the grain structure, where the metal grains become smaller and more uniform in size, leading to improved mechanical properties. Metal forming can also improve the mechanical properties of the material by increasing its strength, toughness, and hardness. Additionally, metal forming can close blow holes that may have formed during the ingot casting process, resulting in a more defect-free material. Therefore, all of the given options are possible effects of metal forming.

Submit
13. Elements may be added to the filler metal to:

Explanation

The correct answer is "Any of the above." This means that elements may be added to the filler metal for various reasons, including controlling grain growth, increasing ductility, or ensuring adequate corrosion resistance. In other words, the addition of elements to the filler metal can serve multiple purposes and can be done for any of these reasons.

Submit
14. Level II magnetic particle technicians should always be able to evaluate if an indiction is relevant, false or nonrelevant, and if it is rounded or linear.

Explanation

This statement is true because Level II magnetic particle technicians are expected to have a higher level of expertise and knowledge in their field. They should be able to accurately evaluate whether an indication is relevant or not, as well as determine if it is rounded or linear. This skill is important in determining the severity and potential impact of any detected indications, allowing for appropriate action to be taken.

Submit
15. Fatigue cracking is always caused by a single overloading.

Explanation

Fatigue cracking is not always caused by a single overloading. Fatigue cracking occurs due to repeated loading and unloading cycles, which gradually weaken the material and lead to cracks. It is a progressive process that can be caused by various factors such as fluctuating stress levels, vibrations, and material defects. Therefore, it is not accurate to say that fatigue cracking is always caused by a single overloading.

Submit
16. Spot welding is usually performed using:

Explanation

Spot welding is a process where two metal surfaces are joined together by applying heat and pressure. The high current passed for a very short time is the correct answer because it allows for a quick and intense burst of heat, melting the metal surfaces and creating a strong bond. Using a high current ensures that enough heat is generated to melt the metal, while the short duration prevents excessive heating and damage to the surrounding area. This combination of high current and short time is ideal for spot welding as it provides efficient and effective results.

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

Explanation

During the process of fusion welding, several phenomena may occur in the heat affected zone. Grain growth refers to the increase in the size of grains in the metal, which can affect its mechanical properties. Change of structure refers to the alteration of the crystal structure in the heat affected zone, which can also impact the material's properties. Recrystallization is the formation of new, strain-free grains in the metal, which can occur due to the high heat generated during welding. Therefore, all of these phenomena can happen in the heat affected zone during fusion welding.

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

Explanation

Cracks are considered the most serious type of flaw in metals because they can significantly weaken the structural integrity of the material. Unlike porosity, which refers to small voids or holes within the metal, cracks are visible separations or fractures that can propagate and lead to catastrophic failure. Inclusions, which are foreign particles or impurities trapped within the metal, can also cause weaknesses but are typically not as severe as cracks. Laminations, which are layers or sheets of material that are not properly bonded, can also compromise the strength of the metal but are generally less critical than cracks.

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

Explanation

Cracks are considered the most serious type of flaw in metals because they can significantly weaken the structural integrity of the material. Unlike porosity, which consists of small voids or air pockets, cracks are fractures that extend through the metal, making it prone to failure under stress. Inclusions and laminations, on the other hand, are typically non-uniformities or foreign particles within the metal, which may affect its properties but are generally not as severe as cracks in terms of structural integrity.

Submit
20. The purpose of metal forming is to:

Explanation

Metal forming is a process used to shape and manipulate metal into desired forms. It involves various techniques such as rolling, forging, and extrusion. The purpose of metal forming is to achieve multiple objectives, including refining the grain structure of the metal, which improves its mechanical properties. Additionally, metal forming can also be used to close blow holes that may have formed in an ingot, ensuring the integrity and quality of the final product. Therefore, the correct answer is "All of the above" as all of these objectives are achieved through metal forming.

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

Explanation

Inclusions are non-metallic impurities that are commonly found trapped within the molten metal of a casting. These impurities can include various substances such as oxides, slag, or other foreign materials. Inclusions can negatively affect the mechanical properties and overall quality of the casting, leading to potential defects or weaknesses. Therefore, it is important to minimize the presence of inclusions during the casting process to ensure a high-quality final product.

Submit
22. Better mechanical properties are obtained with:

Explanation

A fine grain structure is preferred because it leads to better mechanical properties. In a fine grain structure, the grains are smaller and more closely packed together, resulting in increased strength, hardness, and toughness of the material. This is because the smaller grains offer more grain boundaries, which act as barriers to dislocation movement and enhance the material's resistance to deformation. Additionally, fine grains also improve the material's fatigue resistance and reduce the likelihood of cracks or fractures. Therefore, a fine grain structure is desirable for achieving improved mechanical properties in materials.

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

Explanation

Galvanizing is a process that involves applying a protective layer to iron and steel products. This layer helps to prevent corrosion and extends the lifespan of the metal. The correct answer is zinc and zinc compounds because zinc is commonly used in the galvanizing process. Zinc coatings provide excellent protection against rust and corrosion, making it an ideal choice for preserving iron and steel.

Submit
24. A green sand mold is:

Explanation

A green sand mold is a sand mold mixture made up of sand, clay, and water. This mixture is called "green" because it is damp and has a greenish color due to the presence of clay. The sand mold is formed by packing this mixture into a mold cavity and then allowing it to dry and harden before casting. The clay helps to hold the sand particles together and provide the necessary strength and stability for the mold during casting.

Submit
25. Which of the following properties is controlled by the electrons in the atom?

Explanation

The electrical conductivity of a material is determined by the movement of electrons within its atoms. When electrons are free to move, such as in metals, they can carry an electric current, resulting in high electrical conductivity. Therefore, the electrons in an atom control the electrical conductivity of a material.

Submit
26. All metals solidify in a ___________ structure.

Explanation

Metals solidify in a crystalline structure because their atoms arrange themselves in a regular, repeating pattern called a crystal lattice. This arrangement allows for the efficient packing of atoms, resulting in the characteristic properties of metals such as high conductivity, malleability, and ductility. In contrast, amorphous structures lack long-range order, molecular structures consist of discrete molecules, and compounded structures involve the combination of different elements or compounds.

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

Explanation

Inclusions refer to non-metallic materials that are trapped within a solid metal. These materials can include impurities, oxides, or other foreign substances that are incorporated into the metal during the manufacturing process. Inclusions can have a negative impact on the mechanical properties of the metal, such as reducing its strength or causing brittleness. Therefore, it is important to minimize the presence of inclusions in order to ensure the quality and reliability of the metal product.

Submit
28. In its original shape, porosity would appear:

Explanation

Porosity refers to the presence of small openings or voids in a material. When a material is in its original shape, these openings are typically formed in a round or nearly round shape. This is because the material is naturally molded or shaped in a way that allows for the formation of rounded voids. Irregular or elongated shapes are less likely to occur in the original form of porosity. Square shapes are even less likely as they require specific external factors or interventions to be formed. Therefore, the most appropriate option for the appearance of porosity in its original shape is round or nearly round.

Submit
29. Grinding cracks can be caused by:

Explanation

Grinding cracks can be caused by a lack of or poor coolant, as insufficient cooling can lead to overheating and subsequent cracking. Dull or improper grinding wheels can also cause cracks, as they may not effectively remove material and instead generate excessive heat. Additionally, a too heavy cut can result in increased heat and stress, leading to cracks. Therefore, all of the mentioned factors can contribute to the occurrence of grinding cracks.

Submit
30. Heat treating might cause discontinuities which would probably start at:

Explanation

Heat treating can cause discontinuities, which are irregularities or imperfections in the material. These discontinuities are more likely to occur at heavy and light junctions and sharp areas. This is because these areas have a higher likelihood of experiencing stress concentrations during the heat treatment process, leading to the formation of cracks or other defects. Smooth surfaces and concave surfaces are less prone to stress concentrations, making them less likely to develop discontinuities. Similarly, within the heavy part of the casting, the material is more likely to experience higher levels of stress during heat treatment, increasing the chances of discontinuities forming.

Submit
31. A hot tear in a casting is a crack.  It could occur:

Explanation

A hot tear in a casting refers to a crack that occurs during the cooling process. These cracks are more likely to happen at junctions where there is a transition from a lighter section to a heavier section in the casting. This is because the differential cooling rates between the two sections create internal stresses, leading to the formation of cracks. Therefore, the answer "At junctions of light and heavy castings" is correct as it accurately identifies a common location for hot tears to occur in a casting.

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

Explanation

Argon is used intensively for shielding in the gas tungsten-arc welding process. This is because argon is an inert gas, meaning it does not readily react with other elements. In welding, argon is used to create a protective atmosphere around the weld area, preventing the molten metal from reacting with the surrounding air and forming unwanted oxides or other impurities. Argon also helps to stabilize the electric arc and improve the quality of the weld.

Submit
33. In spot resistance welding, pressure used may be:

Explanation

In spot resistance welding, the pressure used may be mechanical, pneumatic, or hydraulic. This means that any of these methods can be employed to apply pressure during the welding process. The choice of pressure method may depend on various factors such as the size and type of the workpiece, the desired welding strength, and the available equipment. Therefore, the pressure used in spot resistance welding can vary and is not limited to a specific method.

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

Explanation

A non-consumable electrode used for arc welding would be made of tungsten because it has a high melting point and excellent heat resistance. Tungsten is able to withstand the extreme temperatures generated during the welding process without melting or being consumed, making it an ideal choice for non-consumable electrodes.

Submit
35. 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:

Explanation

A forging lap is a defect that occurs during the forging process when the metal is folded over and forced into the surface but not properly welded to form a single piece. This results in a visible seam or overlap on the surface of the forged part. This defect weakens the integrity of the forged piece and can lead to failure under stress.

Submit
36. The grain size in a material may be controlled by:

Explanation

The grain size in a material can be controlled by various factors, including the cooling rate from the liquid to solid state, the amount of cold working, and heat treatment for allotropic materials. The cooling rate affects the formation of grains during solidification, with slower cooling rates resulting in larger grains. Cold working, such as rolling or forging, can refine the grain size by inducing plastic deformation. Heat treatment techniques, such as annealing or quenching, can also influence the grain size in allotropic materials. Therefore, any of the mentioned factors can be used to control the grain size in a material.

Submit
37. The top portion of a molding flask is called a:

Explanation

The top portion of a molding flask is called a "Cope".

Submit
38. In the Prayer of Hannah (1 Samuel 2:1-10), what is the primary theme of her prayer?

Explanation

The Prayer of Hannah is a song of thanksgiving in which she praises God's sovereignty, justice, and power. After God answers her prayer for a son, she acknowledges that God raises the humble and brings down the proud, recognizing His role in justice and deliverance. It reflects her gratitude and the recognition of God's divine will in her life.

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

Explanation

The reason an ingot used as forging stock is subjected to more than the minimum hot working required to develop contour is to remove evidence of cast structure, refine grain structure, and impose a more desirable grain direction. By subjecting the ingot to additional hot working, any remnants of the original cast structure can be eliminated, resulting in a more uniform and consistent material. This additional hot working also helps in refining the grain structure, making it finer and more homogeneous. Furthermore, by controlling the direction of the grain flow through hot working, a more desirable grain direction can be imposed, enhancing the mechanical properties of the forged part.

Submit
40. Non-metallic inclusions are:

Explanation

Non-metallic inclusions are irregular in shape because they are formed during the solidification process of metals and alloys. These inclusions can be various types of non-metallic substances, such as oxides, sulfides, or carbides, that are trapped within the metal matrix. Due to their random formation, these inclusions do not have a specific shape or pattern. Their irregular shape can affect the mechanical properties of the metal, leading to potential weaknesses or defects. Therefore, it is important to control and minimize the presence of non-metallic inclusions in order to improve the overall quality and performance of the metal.

Submit
41. In the shielded metal-arc process, the covering material:

Explanation

The correct answer is "All of the above". In the shielded metal-arc process, the covering material serves multiple purposes. It protects the metal from picking up nitrogen during melting and transfer across the arc, which can lead to brittleness in the weld. The covering material also acts as alloying elements, adding desirable properties to the weld. Additionally, it protects the metal from oxidation during melting, preventing the formation of oxides that could weaken the weld. Therefore, all of these statements are true.

Submit
42. An alloy is a substance composed of:

Explanation

An alloy is a substance that is made up of two or more elements, and it must contain at least one metal. This means that the correct answer is "Two or more elements, of which at least one is a metal."

Submit
43. A cause of gas porosity in welds is:

Explanation

Improper cleaning or preheating of the plates to be welded can cause gas porosity in welds. This is because contaminants such as oil, grease, rust, or moisture on the surface of the plates can release gases when exposed to high temperatures during welding. These gases can become trapped in the weld, resulting in gas porosity. Preheating the plates helps to remove moisture and reduce the risk of gas porosity. Proper cleaning of the plates ensures that any contaminants are removed, minimizing the chances of gas porosity.

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

Explanation

Pressure welding involves using pressure to join two materials together. While pressure alone can achieve a bond, the addition of heat is typically necessary to facilitate the welding process. Heat helps to soften the materials, allowing them to fuse together more easily and effectively. Therefore, heat is usually added in pressure welding to ensure a strong and durable bond between the materials.

Submit
45. Patterns used to prepare molds for casting are made of:

Explanation

Patterns used to prepare molds for casting can be made of wood, aluminum alloy, or epoxy resin. Wood is a common material used for pattern making due to its availability, ease of shaping, and cost-effectiveness. Aluminum alloy patterns are used when a higher level of precision and durability is required. Epoxy resin patterns offer excellent dimensional stability and can be used for complex shapes. Therefore, any of the above materials can be used depending on the specific requirements of the casting process.

Submit
46. A cause of gas porosity in welds is:

Explanation

Improper cleaning or preheating can cause gas porosity in welds. When the surface of the material is not properly cleaned before welding, contaminants such as dirt, oil, or rust can be trapped in the weld, leading to the formation of gas pockets. Additionally, if the material is not preheated to the correct temperature, moisture or other volatile substances may vaporize and create gas bubbles during the welding process. These gas bubbles can weaken the weld and result in porosity. Therefore, proper cleaning and preheating are crucial to prevent gas porosity in welds.

Submit
47. The fuel gas most commonly used in gas welding is:

Explanation

Acetylene is the most commonly used fuel gas in gas welding because of its high heat output and versatility. It has a high flame temperature, allowing for efficient welding and cutting. Acetylene is also easily controllable, making it suitable for various types of welding applications. Additionally, it can be used with different types of metals and alloys, making it a versatile choice for gas welding.

Submit
48. Cold shuts are most likely to be found in:

Explanation

Cold shuts are most likely to be found in castings. A cold shut occurs when two portions of molten metal do not properly fuse together during the solidification process. This can happen when there is insufficient heat or fluidity in the metal, causing a lack of fusion between the two sections. Castings involve pouring molten metal into a mold, and if the metal does not properly fuse during solidification, cold shuts can occur. Cold shuts are less common in extrusions, forgings, and sintered parts, making castings the most likely option.

Submit
49. Which term best describes what is sought by NDT?

Explanation

The term "Any breaks in the continuity of metal structure" best describes what is sought by NDT (Non-Destructive Testing). NDT is a method used to inspect and evaluate materials and components without causing damage. It is specifically used to identify any breaks or discontinuities in the metal structure, such as cracks, voids, or other defects that may affect the integrity or performance of the material. This term encompasses a broader range of potential defects than the other options provided, making it the most accurate description of what NDT aims to detect.

Submit
50. Cold shuts are most likely to be found in:

Explanation

Cold shuts are most likely to be found in castings. Cold shuts occur when the molten metal in a casting solidifies before completely filling the mold cavity, resulting in a discontinuity or gap in the final product. This defect is more common in castings because the liquid metal has to flow and fill complex shapes and cavities, making it more prone to solidify prematurely in certain areas. Extrusions, forgings, and sintered parts involve different manufacturing processes that do not typically involve the same risks of cold shuts as in castings.

Submit
51. When metals solidify:

Explanation

When metals solidify, the atoms lose their mobility and assume fixed positions in the space lattice of the unit cell. This means that the atoms become locked into a specific arrangement within the crystal structure. As the metal cools and solidifies, the atoms slow down and eventually come to a stop, settling into their designated positions. This fixed arrangement is what gives metals their characteristic crystalline structure.

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

Explanation

When a metal is folded in a thin plate on the surface of a forging, it can cause a lap. A lap is a defect that occurs when the metal folds over itself during the forging process, creating a thin layer of metal that is not properly bonded. This can weaken the structure of the metal and reduce its overall strength and integrity. Laps are undesirable because they can lead to failure or breakage of the forged part under stress or load.

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

Explanation

Lack of penetration refers to a welding defect where the weld does not fully penetrate the base metal, resulting in an incomplete bond. This defect occurs at the root of the weld and runs parallel to it. It can weaken the joint and compromise its structural integrity.

Submit
54. Cold shuts are most likely found in:

Explanation

Cold shuts are most likely found in castings. Cold shuts occur when two portions of molten metal fail to fully fuse together during the casting process, resulting in a visible line or seam in the final product. This defect is more commonly observed in castings because the molten metal has a higher likelihood of solidifying before complete fusion can occur. In contrast, extrusions, forgings, and sintered parts involve different manufacturing processes that are less prone to cold shut defects.

Submit
55. In gas welding, the acetylene is usually burned with:

Explanation

In gas welding, acetylene is typically burned with oxygen. This is because acetylene requires oxygen to support combustion and produce a high-temperature flame necessary for welding. Oxygen acts as the oxidizer, reacting with acetylene to generate heat and create a stable flame. Hydrogen, argon, and nitrogen are not commonly used as the primary gas for burning acetylene in gas welding processes.

Submit
56. Patterns made of wood:

Explanation

Wooden patterns used in casting can be made in one, two, or more pieces depending on the complexity of the casting. The number of pieces required for the pattern is determined by factors such as the shape, size, and intricacy of the final casting. For simpler castings, a single-piece pattern may be sufficient. However, for more complex castings, a pattern may need to be made in multiple pieces to ensure accurate and precise molding. Therefore, the number of pieces for wooden patterns can vary based on the complexity of the casting being produced.

Submit
57. Heat exchanger tubes are defect prone at regions:

Explanation

Heat exchanger tubes are prone to defects in regions adjacent to support plates, under support plates, and in between support plates. Support plates are used to hold the tubes in place, and due to the stress and pressure exerted on the tubes in these areas, they are more likely to develop defects. This can include cracks, leaks, or corrosion. Therefore, all of the mentioned regions are susceptible to defects in heat exchanger tubes.

Submit
58. Hot working an ingot may produce a product which has:

Explanation

Hot working an ingot involves subjecting it to high temperatures and mechanical deformation, such as rolling or forging, to shape it into a desired product. The process of hot working can lead to changes in the microstructure of the material, which may result in the formation of new defects or the elimination of existing defects. Therefore, depending on the specific circumstances, hot working can either reduce the number of defects in the original ingot, introduce more defects, or maintain the same number of defects in the final product.

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

Explanation

Gas tungsten-arc welding is the correct answer because in this process, the electrode is made of tungsten which is non-consumable. The tungsten electrode creates an arc with the workpiece, and the heat generated melts the base metal to form the weld. Since the electrode is not consumed during the welding process, it remains intact and does not need to be replaced, making it non-consumable.

Submit
60. The bottom portion of a molding flask is called a:

Explanation

The bottom portion of a molding flask is called a "drag". In foundry casting, a molding flask is a container used to hold the sand mold. The drag is the lower half of the flask, and it is filled with sand to create the bottom part of the mold. The cope, on the other hand, refers to the upper half of the flask, which is filled with sand to create the top part of the mold. The cheek and separator are not commonly used terms in the context of molding flasks.

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

Explanation

A chill is a metal insert that is placed in a sand mold to increase the cooling rate at a specific point. It helps to rapidly cool and solidify the metal in that area, preventing defects such as shrinkage or porosity. Chills are commonly used in foundry processes to control the solidification and cooling of the metal, ensuring a uniform and high-quality final product.

Submit
62. A metal support for holding cores in place within a sand mold is called:

Explanation

A chaplet is a metal support used to hold cores in place within a sand mold. It is designed to prevent the core from shifting or moving during the casting process. Chaplets are typically made of a material that can withstand the high temperatures of the molten metal. They are placed between the core and the mold cavity to provide support and stability.

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

Explanation

Pressure welding does not involve melting of the parts to be joined. In this process, the parts are joined together by applying pressure, without the need for melting. This can be achieved through various methods such as friction, ultrasonic vibrations, or explosives. Pressure welding is commonly used for joining materials that are difficult to melt or materials that have different melting points.

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

Explanation

Non-metallic inclusions are present before the billet is worked. During the manufacturing process of a billet, non-metallic inclusions such as oxides, sulfides, and silicates can form due to impurities in the raw materials or reactions with the surrounding environment. These inclusions can negatively impact the mechanical properties and quality of the final product. Therefore, it is important to control and minimize the presence of non-metallic inclusions through proper refining and processing techniques.

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

Explanation

Oxides in weldments can create discontinuities that are similar to non-metallic inclusions. These discontinuities are known as slag inclusions. Slag inclusions occur when molten slag becomes trapped in the weld metal during the welding process. Slag is a byproduct of the welding flux and can cause defects in the weld if not properly removed. These defects can weaken the weld and compromise its integrity. Therefore, it is important to ensure proper removal of slag to prevent slag inclusions in weldments.

Submit
66. A weld discontinuity that always occurs at the root of a weld is:

Explanation

Lack of penetration is a weld discontinuity that occurs when the weld metal does not fully penetrate the joint. This means that the weld does not reach the root of the joint, resulting in a weak and incomplete bond. Lack of penetration can lead to structural integrity issues and reduced strength in the welded joint. It is important to ensure proper penetration during welding to avoid this discontinuity.

Submit
67. The first step in the production of a casting is the making of:

Explanation

In the production of a casting, the first step is the making of a pattern. A pattern is a replica or model of the desired object, typically made from wood, plastic, or metal. It is used to create the mold into which the molten material will be poured to form the final casting. The pattern is designed to have the exact shape, dimensions, and surface finish of the desired casting, and it serves as a guide for creating the mold. Without a pattern, it would be impossible to create an accurate and consistent casting.

Submit
68. Grain direction in steel bar stock is always:

Explanation

The correct answer is "Through the length of the bar." Steel bar stock typically exhibits a grain direction that runs parallel to the length of the bar. This is due to the manufacturing process, where the steel is rolled or extruded into its final shape. The grain structure aligns along the length of the bar, which can affect the mechanical properties and performance of the steel in certain applications.

Submit
69. Which of the following is identified as a casting insert?

Explanation

A chaplet is a type of casting insert that is used to support or hold a core in place during the casting process. It is typically made of metal and is placed between the mold and the core to provide support and prevent distortion or movement. Chaplets are commonly used in sand casting and other casting processes to ensure the integrity and accuracy of the final casting.

Submit
70. The essential difference between permanent mold casting and die casting is:

Explanation

Permanent mold casting and die casting differ in terms of how the molten metal enters the mold. In permanent mold casting, the molten metal enters the mold by gravity, meaning it simply flows into the mold due to its own weight. On the other hand, in die casting, the molten metal enters the mold under pressure. This means that force is applied to inject the metal into the mold, resulting in a more controlled and precise filling of the mold cavity.

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

Explanation

When thick and thin casting sections are adjacent to each other, a potential discontinuity that may result is shrinkage. Shrinkage occurs when there is a difference in cooling rates between the thick and thin sections, causing the metal to contract at different rates. This can lead to internal voids or defects in the casting, compromising its structural integrity. Shrinkage is a common issue in casting processes and needs to be carefully managed to ensure high-quality castings.

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

Explanation

Premature blocking of a gate during the pouring of a casting can cause microshrinkage. Microshrinkage refers to the formation of small voids or shrinkage cavities in the casting due to the inadequate supply of molten metal. When the gate is blocked too early, it restricts the flow of molten metal into the mold cavity, leading to insufficient filling and solidification. This can result in the formation of tiny voids within the casting, causing microshrinkage defects.

Submit
73. Micro shrinkage might occur in a casting:

Explanation

Micro shrinkage is a defect that can occur during the casting process. It happens when there is insufficient molten metal to fill the entire mold, resulting in small voids or shrinkage cavities in the casting. These shrinkage defects are more likely to occur at junctions between light and heavy sections of the casting. This is because the heavier sections require more molten metal to fill them, leaving less material available for the lighter sections. Consequently, the junctions between these sections may not be completely filled, leading to micro shrinkage defects.

Submit
74. Usually, seamless tubing is produced by:

Explanation

Extrusion is the process used to produce seamless tubing. This process involves forcing a metal billet through a die, resulting in a tube with a consistent diameter and thickness. Unlike other methods mentioned, extrusion does not require welding or the use of filler metal, making it a preferred method for producing seamless tubing.

Submit
75. During on-line (Manufacturing) inspection of components, defective areas are often automatically marked to:

Explanation

During on-line manufacturing inspection of components, it is common to automatically mark defective areas for two main purposes. Firstly, marking the defects allows for their removal after the inspection if desired. This ensures that the final product is of high quality and free from any defects. Secondly, marking the defects also allows for destructive examination of those areas after the inspection if desired. This can help in identifying the root cause of the defects, improving the manufacturing process, and preventing similar issues in the future. Therefore, the correct answer is "Both a and b."

Submit
76. Heat treat cracks may be caused by:

Explanation

Unequal heating or cooling of the material can cause heat treat cracks. When there is a significant difference in temperature between different parts of the material during the heat treatment process, it can lead to thermal stress and differential expansion or contraction. This can result in the formation of cracks in the material. It is important to ensure proper and uniform heating and cooling to prevent these cracks from occurring.

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

Explanation

When a pouring gate in a casting blocks off prematurely, it can cause the metal to shrink before it completely fills the mold cavity. This shrinkage can result in the formation of many small, subsurface holes in the casting, which is known as microshrinkage.

Submit
78. In the submerged arc welding process:

Explanation

In the submerged arc welding process, flux is added separately and heaped along the joint to be welded. Flux is a material that is used to protect the weld from atmospheric contamination and to facilitate the welding process. By adding the flux separately and heaping it along the joint, it ensures that the weld is protected from any impurities in the atmosphere and that the welding process can occur smoothly. This method allows for better control and coverage of the weld, resulting in a stronger and more reliable joint.

Submit
79. Most manufacturing defects in a tube are:

Explanation

Most manufacturing defects in a tube are axial in direction. This means that the defects occur along the length of the tube, parallel to its axis. Axial defects can include cracks, splits, or deformations that run along the tube's length. These defects are typically caused by issues during the manufacturing process, such as improper heat treatment or insufficient material quality control. Axial defects can have a significant impact on the structural integrity and performance of the tube, making them a critical concern in manufacturing and quality control processes.

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

Explanation

When a metal is stressed below its elastic limit, it means that the applied stress does not exceed the maximum stress the metal can handle without permanent deformation. Therefore, once the stress is removed, the metal will be able to return to its original shape because it has not undergone any permanent changes in its structure. Heating the metal to its curie point or applying an equivalent stress in the opposite direction are not necessary for the metal to return to its original shape.

Submit
81. In the resistance welding process:

Explanation

In the resistance welding process, the correct answer states that the pieces to be joined are held firmly together under pressure, followed by the generation of heat at the interface. This is the accurate explanation of the resistance welding process. The pressure applied helps to ensure that the pieces are securely held together, and the generation of heat at the interface allows for the welding of the two parts. This process does not involve melting the parts or adding a filler metal, but rather relies on the application of pressure and heat to create a strong weld.

Submit
82. Inserts which may be found in sand molds are:

Explanation

The correct answer is "All of the above". Inserts such as chills, chaplets, and cores can be found in sand molds. Chills are used to control the solidification rate of the metal, chaplets are used to support cores in the mold, and cores are used to create internal cavities in the casting. Therefore, all of these inserts are commonly used in sand molds.

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

Explanation

Brazing is a joining process that occurs without fusion of the base metal. In brazing, a filler metal is heated above its melting point and distributed between two or more close-fitting parts. The filler metal then solidifies to form a strong bond between the parts. Unlike welding, where the base metal itself is melted, brazing only melts the filler metal, allowing for joining of dissimilar metals or delicate parts that cannot withstand the high temperatures of welding. Therefore, brazing is the correct answer as it involves joining without fusion of the base metal.

Submit
84. 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:

Explanation

Undercutting is a defect that occurs when the sidewalls of the welding groove melt away at the edge of a layer of weld metal and runs parallel to the weld bead. This defect is characterized by a groove or depression in the base metal adjacent to the weld. It is caused by excessive heat or improper welding technique, leading to the erosion of the base metal. Undercutting weakens the weld joint and can result in structural failure or leakage.

Submit
85. Grinding cracks are usually caused by:

Explanation

Grinding cracks are usually caused by grinding hard metal surfaces. When hard metals are being ground, the high pressure and friction generated can cause the metal to become overheated and brittle, leading to cracks. Soft metal surfaces are less likely to cause grinding cracks as they are more malleable and can withstand the grinding process better. Heat treatment may affect the hardness of the metal but is not directly responsible for grinding cracks. Similarly, too slow feeding rates may result in inefficient grinding but are not the primary cause of grinding cracks.

Submit
86. Forging laps can occur in which of the following places:

Explanation

Forging laps can occur where the dies come together. When the dies close during the forging process, there can be a misalignment or inadequate pressure at the point where they meet, leading to a lap. This can result in a defect in the forged part, causing a weak spot or a seam. Therefore, it is important to ensure proper alignment and pressure at the point where the dies come together to avoid forging laps.

Submit
87. An advantage of investment casting over green sand casting is:

Explanation

Investment casting allows for the production of more complex shapes compared to green sand casting. This is because investment casting uses a wax pattern that can be intricately designed and then coated in a ceramic shell, which allows for greater detail and precision in the final casting. Green sand casting, on the other hand, uses a mold made of sand, which may not be able to accurately reproduce complex shapes. Therefore, investment casting is advantageous when it comes to creating intricate and complex parts.

Submit
88. In gas welding, a reducing flame is produced when:

Explanation

A reducing flame is produced when there is excess acetylene in the flame. In gas welding, a reducing flame is used to protect the metal from oxidation by limiting the amount of oxygen available. This helps prevent the metal from becoming brittle and allows for a cleaner weld. Excess acetylene in the flame creates a fuel-rich environment, reducing the amount of oxygen and promoting a reducing flame.

Submit
89. The Curie point is:

Explanation

The Curie point refers to the temperature above which the steel is no longer magnetic. At this temperature, the steel undergoes a phase transition and loses its magnetic properties. This phenomenon is named after Pierre Curie, a French physicist who discovered it in the late 19th century.

Submit
90. A cold shut has:

Explanation

A cold shut refers to a type of defect that occurs during the casting process. It happens when two streams of molten metal do not properly fuse together, resulting in a seam or line in the final product. This seam appears smooth and curved, which distinguishes it from other types of defects such as a ragged shape, a straight thin line, or an undulating shape.

Submit
91. A forging lap may occur if:

Explanation

A forging lap may occur if faulty dies are used for forging, as they can cause irregularities in the shape of the metal. Additionally, if the metal is either too hot or too cold during the forging operation, it can lead to a forging lap. The temperature of the metal is crucial for proper forging. Lastly, if the metal is forced to flow too fast, it can cause excessive strain on the material and result in a forging lap. Therefore, all of the mentioned factors can contribute to the occurrence of a forging lap.

Submit
92. In a rolling mill, flattening and elongation of metal is accomplished by:

Explanation

In a rolling mill, flattening and elongation of metal is primarily accomplished by applying compressive stresses. This is because the metal is passed through a series of rollers that exert pressure on it, causing it to deform and elongate. The compressive stresses help to reduce the thickness of the metal and increase its length. Tensile stresses, bending stresses, and high frequency cyclical loads may also play a role in the process, but the primary mechanism for flattening and elongation is the application of compressive stresses.

Submit
93. In which of the following joining methods will flaws, when they do occur, be essentially two dimensional?

Explanation

Brazing is a joining method where flaws, when they occur, are essentially two-dimensional. In brazing, a filler metal is melted and flowed into the joint, creating a strong bond between the base metals. The filler metal has a lower melting point than the base metals, allowing it to flow and fill the joint. Flaws in brazing typically occur in the form of surface defects, such as cracks or voids, which are two-dimensional in nature. This is in contrast to the other joining methods mentioned, such as gas tungsten arc welding, gas metal arc welding, and submerged arc welding, where flaws can occur in three dimensions.

Submit
94. The middle portion of a molding flask is called a:

Explanation

The middle portion of a molding flask is called a cheek. The cheek is the section of the flask that separates the cope (top) and drag (bottom) portions. It provides support and stability to the mold during the casting process. The cheek is typically made of a sturdy material such as metal or wood to withstand the pressure and heat of the molten metal.

Submit
95. The work metal for working with a forging hammer is:

Explanation

The work metal for working with a forging hammer can be any of the above options mentioned, which are a bloom, a billet, or a bar. This means that all three forms of metal can be used as the workpiece when using a forging hammer. The choice of which form to use would depend on the specific requirements of the forging process and the desired outcome.

Submit
96. A material which is considered ferromagnetic is:

Explanation

The correct answer is "All of the above" because all three materials - Nickel, Cobalt, and Iron - are considered to be ferromagnetic. Ferromagnetic materials are those that can be magnetized and retain their magnetization even after the external magnetic field is removed. These materials have strong magnetic properties due to the alignment of their atomic magnetic moments. Nickel, Cobalt, and Iron are commonly used in various applications that require magnetic properties, such as in the production of magnets and magnetic storage devices.

Submit
97. Aircraft turbine blades are usually processed by:

Explanation

Investment casting is the most suitable method for processing aircraft turbine blades because it allows for the production of complex shapes with high dimensional accuracy and a smooth surface finish. This process involves creating a wax pattern of the desired blade shape, which is then coated with a ceramic material. The ceramic shell is heated to remove the wax, leaving behind a hollow mold. Molten metal is then poured into the mold, filling the cavity and solidifying to form the turbine blade. This method ensures the blades have the necessary strength, durability, and aerodynamic efficiency required for their function in an aircraft engine.

Submit
98. With a forging hammer the striking force is imposed on the work metal by:

Explanation

The correct answer is "The upper die only" because in the forging process, the upper die is responsible for delivering the striking force onto the work metal. The upper die is usually attached to a mechanical or hydraulic system that provides the necessary force to shape the metal. The lower die, on the other hand, acts as a support or guide for the metal and does not impose any striking force. Therefore, the correct answer is that the striking force is imposed on the work metal by the upper die only.

Submit
99. The hardest structure that can be produced by heat treating steel is:

Explanation

Martensite is the hardest structure that can be produced by heat treating steel. It is formed when austenite is rapidly cooled, causing a transformation from a face-centered cubic (FCC) structure to a body-centered tetragonal (BCT) structure. This rapid cooling prevents the carbon atoms from diffusing and forming other structures, resulting in a highly distorted and hard material. Martensite is known for its high strength and hardness, making it desirable for applications that require toughness and wear resistance.

Submit
100. The property of a material to exist under different lattice structures at different temperatures is:

Explanation

Allotropy is the property of a material to exist under different lattice structures at different temperatures. This means that the material can have different crystal structures depending on the temperature. This phenomenon is commonly observed in elements such as carbon (diamond and graphite) and oxygen (oxygen gas and ozone). Ductility refers to the ability of a material to be stretched without breaking, crystallinity refers to the regular arrangement of atoms in a material, and hardenability refers to the ability of a material to be hardened by heat treatment.

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

Explanation

In gas metal-arc welding, a stream of protective gas is passed through an inverted cup or a nozzle which surrounds the electrode. This is different from shielded metal-arc welding where the shielding gas is contained in the flux covering the electrode. The passing of protective gas through a cup or nozzle helps to protect the weld from atmospheric contamination and ensures a clean and strong weld.

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

Explanation

Excessive working of the metal during the forging or extruding operation can cause a burst. This means that when the metal is being shaped or formed, if too much force or pressure is applied, it can lead to the metal becoming weak and eventually bursting. This can happen due to the metal being overworked or stretched beyond its limits, resulting in a processing defect known as a burst.

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

Explanation

A hot tear, also known as a hot crack or solidification crack, is a type of defect that propagates along grain boundaries in metals and alloys during solidification or cooling. These cracks occur due to the inability of the material to compensate for the stresses induced by thermal contraction and shrinkage during the cooling process.

Submit
104. In gas welding, a reducing flame is produced when:

Explanation

A reducing flame is produced when there is excess acetylene in the flame. This means that there is more acetylene than the necessary amount to completely burn with the available oxygen. The excess acetylene creates a flame with a fuel-rich mixture, resulting in a reducing atmosphere where oxygen is limited. This type of flame is commonly used in gas welding as it helps prevent oxidation and promotes better control over the welding process.

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

Explanation

Fine lines that occur in groups and are caused by non-metallic impurities present in the original ingot and extruded lengthwise are known as stringers.

Submit
106. Metals which cannot be work hardened are those which:

Explanation

Metals that recrystallize at room temperature cannot be work hardened because work hardening is a process that involves deforming the metal's crystal structure. When a metal is work hardened, dislocations and defects are introduced into the crystal lattice, making it harder and stronger. However, if the metal has the ability to recrystallize at room temperature, it means that the crystal structure can recover and rearrange itself, eliminating the dislocations and defects caused by work hardening. Therefore, these metals cannot retain the increased hardness and strength obtained through work hardening.

Submit
107. Which discontinuity is not normally found in a casting?

Explanation

Slugging is not normally found in a casting. Misrun refers to a defect where the molten metal does not completely fill the mold cavity. Porosity refers to the presence of small voids or gas pockets in the casting. Shrinkage is a defect caused by the solidification and cooling of the metal, resulting in a reduction in size. However, slugging is not a common discontinuity in castings and is not typically associated with casting defects.

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

Explanation

Forging is the correct answer because it is a forming operation that involves shaping the material by applying compressive forces. The process of forging involves heating the material and then applying pressure to shape it into the desired form. This method allows for precise control over the dimensions and results in a high level of dimensional accuracy. Cold rolling of sheet, hot rolling of sheet, and cold rolling of bars may also result in dimensional accuracy, but forging is known to provide the greatest level of accuracy.

Submit
109. Materials of low ductility are best forged with:

Explanation

Materials of low ductility, which are less likely to deform under pressure, are best forged using hydraulic presses. Hydraulic presses provide a controlled and gradual application of force, allowing for precise shaping of the material without causing excessive deformation or cracking. The gradual application of pressure also helps to minimize the risk of material failure. On the other hand, gravity drop hammers, power drop hammers, and high energy rate forging hammers deliver a sudden and intense impact, which may not be suitable for materials with low ductility.

Submit
110. A fatigue crack is a service defect that is caused by a:

Explanation

A fatigue crack is caused by cyclic loading of the part below the yield strength of the material. When a material is subjected to repeated loading and unloading, stresses are generated within the material. If these stresses are below the yield strength of the material, they can cause the formation and propagation of cracks over time. This is known as fatigue failure. Cyclic loading above the yield strength can cause plastic deformation and yield, but it is not the main cause of fatigue cracks. Local overheating and corrosive atmosphere can lead to other types of damage, but they are not specifically related to fatigue cracks.

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

Explanation

Fine lines that occur in groups and are caused by non-metallic impurities present in the original ingot and extruded lengthwise are called stringers. These stringers can weaken the material and affect its overall integrity.

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

Explanation

As cold working progresses, the energy required for further processing increases. This is because cold working involves deforming the material at room temperature, which causes strain hardening. Strain hardening increases the strength and hardness of the material but also makes it more difficult to further process or deform. Therefore, more energy is needed to continue working or processing the material as cold working progresses.

Submit
113. Amorphous materials include:

Explanation

Copper, steel, and aluminum are all examples of crystalline materials, not amorphous materials. Amorphous materials lack a regular, ordered atomic structure and instead have a disordered arrangement of atoms. Examples of amorphous materials include glass, rubber, and some plastics.

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

Explanation

Cropping is a method commonly used to remove a number of flaws in an ingot prior to forming. This process involves cutting off the defective or unwanted parts of the ingot, such as cracks, impurities, or uneven surfaces. By removing these flaws, cropping helps to improve the overall quality and integrity of the ingot, making it more suitable for further processing and forming into desired shapes or products. Heat treating, welding, and sand blasting are not typically used for removing flaws in ingots.

Submit
115. The millworking process used most to form metals into 3D shapes is:

Explanation

Forging is the millworking process used most to form metals into 3D shapes. It involves the application of compressive forces to shape the metal by heating it to a high temperature and then hammering or pressing it into the desired shape. This process allows for the creation of complex and strong metal components, making it a commonly used method in industries such as automotive, aerospace, and manufacturing. Casting involves pouring molten metal into a mold, cold rolling is a process for shaping metal sheets, and welding involves joining metal pieces together, but they are not as commonly used for forming 3D shapes as forging.

Submit
116. Seams are sub-surface discontinuities

Explanation

Seams are not sub-surface discontinuities. Seams are actually visible lines or ridges that occur when two pieces of material are stitched or joined together. They are typically found in fabrics or other materials that have been sewn or fused together. Unlike sub-surface discontinuities, seams can be seen and felt on the surface of the material. Therefore, the correct answer is False.

Submit
117. Resistance welding differs from fusion welding in that:

Explanation

Resistance welding differs from fusion welding because it requires the use of pressure. In resistance welding, the two metal pieces to be joined are pressed together under pressure while an electric current is passed through them. This pressure is essential to create a strong bond between the metals. In fusion welding, on the other hand, the metals are melted and fused together without the need for pressure.

Submit
118. The process in which a steel is heated above the upper critical temperature into the austenite and then cooled slowly through the transformation range in the furnace or a good heat insulated material is known as:

Explanation

Full annealing is the correct answer because it involves heating the steel above its upper critical temperature to transform it into austenite, and then slowly cooling it through the transformation range. This process helps to refine the grain structure of the steel, relieve internal stresses, and improve its mechanical properties. Tempering involves heating the steel to a lower temperature to reduce its hardness, while normalizing involves cooling the steel in still air after heating it above its upper critical temperature. Quenching involves rapidly cooling the steel to increase its hardness.

Submit
119. The principal purpose of risers in molds is to:

Explanation





Risers, also known as feeders, are used in casting processes to provide additional molten metal to compensate for shrinkage during solidification. This helps ensure that the casting fills completely and avoids defects such as shrinkage voids.
Submit
120. A casting process in which the pattern is not re-usable is called:

Explanation

Investment casting is a casting process in which a pattern is created from wax or a similar material, and then coated with a ceramic material. The ceramic shell is then heated to remove the wax, leaving behind a hollow cavity in the shape of the desired part. Molten metal is then poured into the cavity, creating the final casting. Unlike other casting processes, investment casting does not involve the use of a reusable pattern. Instead, each pattern is destroyed in the process, making it a non-reusable casting method.

Submit
121. 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:

Explanation

A heat treat crack is a rupture or crack that occurs in a material due to localized stresses that exceed the material's tensile strength, often as a result of the heat treatment process. This process involves heating and cooling metal to alter its physical properties, which can sometimes introduce residual stresses or uneven cooling. If these stresses exceed the tensile strength, cracks may form, potentially in any direction. Heat treat cracks can compromise the integrity and durability of a part, and their formation might require adjustments to heat treatment methods or improved stress-relief processes to prevent reoccurrence. User

Submit
122. 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:

Explanation

Intergranular corrosion is the correct answer because it is a service defect that manifests as small micro-openings that do not follow a specific pattern and extend in any direction along the grain boundaries. This type of corrosion occurs due to the preferential attack of the grain boundaries by corrosive agents, leading to the formation of cracks and pits. It is different from fatigue cracks, fillet cracks, and hydrogen embrittlement, which have distinct characteristics and causes.

Submit
123. Lack of penetration may be the result of:

Explanation

Using a welding rod that is too large can result in a lack of penetration. When the welding rod is too large, it requires more heat to melt and fuse the metal together. This can cause the welding current to be spread out over a larger area, resulting in insufficient heat concentration at the joint. As a result, the metal may not fully melt and penetrate, leading to a weak and incomplete weld. To ensure proper penetration, it is important to use a welding rod that is appropriate for the thickness and type of metal being welded.

Submit
124. In forgings, grain:

Explanation

In forgings, the grain follows the shape of the dies. This means that during the forging process, the metal is deformed and shaped according to the shape of the dies. As a result, the grains within the metal also align and follow the same shape. This is important because it helps to improve the mechanical properties of the forgings, such as strength and durability. By aligning the grains, the metal becomes more uniform and less prone to defects or weaknesses. Therefore, it is crucial for the grain to follow the shape of the dies in order to produce high-quality forgings.

Submit
125. Grinding cracks occur crosswise to grinding wheel rotation

Explanation

Grinding cracks occur crosswise to grinding wheel rotation because the grinding process generates high heat and stress on the workpiece. As the grinding wheel rotates, it applies pressure and friction on the workpiece, causing it to heat up and expand. This expansion, combined with the stress from the grinding process, can result in cracks forming in a crosswise direction to the rotation of the grinding wheel. Therefore, the statement is true.

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

Explanation

Non-metallic inclusions are a type of discontinuity found in ingots. These inclusions are foreign substances that are trapped within the metal during the solidification process. They can be in the form of oxides, sulfides, or other impurities that are not part of the desired composition of the ingot. Non-metallic inclusions can have detrimental effects on the mechanical properties of the metal, such as reducing its strength and ductility. Therefore, they are considered a type of defect or discontinuity that needs to be minimized or eliminated during the ingot production process.

Submit
127. A burst is _____________ discontinuity.

Explanation

A burst is a processing discontinuity.

Submit
128. 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:

Explanation

A cold shut is a generally smooth indication on a cast surface that occurs when two streams of metal, coming from different directions, fail to fuse together. This can happen due to improper pouring or inadequate fluidity of the metal. As a result, a visible line or seam forms on the cast surface, indicating the incomplete fusion.

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

Explanation

Continuous casting is a metal production process that eliminates the need for ingot cropping. In this process, molten metal is poured into a water-cooled mold, which solidifies the metal into a continuous form. The solidified metal is then continuously pulled out of the mold, creating a long strand or slab. This eliminates the need for traditional ingot cropping, where the ends of the ingot are cut off to remove any impurities or unevenness. Continuous casting allows for a more efficient and cost-effective production process, as it reduces waste and provides a continuous supply of metal.

Submit
130. Bursts are caused by:

Explanation

Bursts in metal can be caused by working at extreme temperatures, either too low or too high. When the temperature is too low, the metal becomes brittle and prone to cracking under stress. On the other hand, when the temperature is too high, the metal can become overheated and lose its structural integrity, leading to bursting. Therefore, it is important to work within the appropriate temperature range to avoid bursts in metal.

Submit
131. One of the main causes of cold shuts is:

Explanation

The presence of several sprues or gates in the mold can cause cold shuts. When there are multiple sprues or gates, the flow of molten metal can be disrupted, leading to incomplete filling of the mold cavity. This can result in a lack of fusion between the metal streams, causing a cold shut. A cold shut is a defect where two metal streams do not fully merge, resulting in a visible line or seam in the final casting. Therefore, the presence of multiple sprues or gates increases the likelihood of cold shuts occurring.

Submit
132. Laminations are produced:

Explanation

Laminations are produced when a pipe or blisters present in the original ingot are made directional by rolling. This means that during the rolling process, the pipe or blisters in the ingot are elongated in a specific direction, resulting in the formation of laminations.

Submit
133. One of the main causes of cold shuts is:

Explanation

The presence of several sprues or gates in the mold can be one of the main causes of cold shuts. When there are multiple sprues or gates in the mold, it can lead to uneven filling of the molten metal, causing the metal to solidify before it completely fills the mold cavity. This results in incomplete fusion of the metal, leading to cold shuts. Cold shuts are defects where two streams of molten metal fail to fuse together properly, resulting in a visible line or seam in the final product.

Submit
134. Discontinuities are:

Explanation



Discontinuities are either relevant or nonrelevant in the context of inspection or testing. They may or may not cause the test object to fail, and their acceptability depends on predefined criteria. They are not always defects and may be acceptable depending on the standards and specifications of the particular application.
Submit
135. A metal forming operation which allows three dimensional control over the shape of the product is:

Explanation

Forging is a metal forming operation that allows three-dimensional control over the shape of the product. It involves heating the metal and then applying compressive forces to shape it into the desired form. This process allows for precise control over the dimensions and contours of the final product, making it an ideal choice when three-dimensional control is required. Rolling and extruding are also metal forming operations, but they do not offer the same level of control over the shape as forging does.

Submit
136. As cold working progresses, the energy required for further processing (assuming the temperature of the part is held constant)

Explanation

As cold working progresses, the energy required for further processing increases. This is because cold working involves deforming the material at room temperature, which causes strain hardening. Strain hardening increases the strength and hardness of the material, but it also makes it more difficult to further deform the material. Therefore, as cold working progresses, more energy is needed to continue processing the material.

Submit
137. Submerged arc welding may be performed:

Explanation

Submerged arc welding (SAW) is a limited-position welding process. The welding positions are limited because the large pool of molten metal and the slag are very fluid and will tend to run out of the joint. Welding can be done in the flat position and in the horizontal fillet position with ease. SAW is ideally suited for longitudinal and circumferential butt and fillet welds. However, because of the high fluidity of the weld pool, molten slag, and loose flux layer, welding is generally carried out on butt joints in the flat position and fillet joints in both the flat and horizontal-vertical positions.

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

Explanation

Grinding involves the use of abrasives to remove material from a workpiece, resulting in a very fine surface finish. This process can achieve tight tolerances and smooth surface finishes, making it ideal for precision components where surface finish is critical.

Submit
139. A dark narrow line running down the center of the weld is:

Explanation

Incomplete penetration refers to a welding defect where the weld does not fully penetrate the joint, resulting in a dark narrow line down the center of the weld. This occurs when the weld pool does not fully fuse with the base metal, leaving a gap. Incomplete penetration weakens the weld and reduces its integrity, making it more susceptible to failure under stress. It is important to ensure proper penetration during welding to maintain the strength and quality of the joint.

Submit
140. A steel casting suitable for working or remelting is called:

Explanation

An ingot is a correct term for a steel casting suitable for working or remelting. It refers to a solid block of metal that is typically rectangular in shape and is produced by pouring molten metal into a mold to solidify. Ingots are commonly used in the steel industry for further processing and shaping into various products. They can be easily reheated and manipulated to meet specific requirements, making them suitable for working or remelting.

Submit
141. Which of the following is present in ingots?

Explanation

Porosity refers to the presence of small holes or voids in a material. In the context of ingots, porosity can occur during the solidification process when gases or impurities become trapped in the metal. This can result in weakened areas within the ingot, reducing its structural integrity. Therefore, porosity is a common defect that can be found in ingots.

Submit
142. The most easily forgeable material, from the following, is:

Explanation

High strength aluminum alloy (7075) is the most easily forgeable material among the given options. This is because aluminum alloys have a lower melting point and are more malleable compared to other metals like stainless steel, carbon steel, and nickel-based alloys. The 7075 alloy specifically is known for its high strength-to-weight ratio, making it desirable for applications requiring strength and lightness. However, this same characteristic also makes it easier to forge and shape compared to the other materials listed.

Submit
143. A common processing indication in rolled bar stock is:

Explanation

A common processing indication in rolled bar stock is a seam. A seam refers to a line or crack that is formed during the rolling process of the bar stock. It occurs when the edges of the metal sheet do not properly join together during the rolling process, resulting in a visible line or crack on the surface of the bar stock. This can affect the structural integrity and quality of the bar stock, making it an important consideration in the manufacturing and inspection processes.

Submit
144. Bursts usually have the following characteristics:

Explanation

Bursts are described as three-dimensional discontinuities with smooth internal surfaces that are typically situated near the surface of the wrought material. They appear as smooth indentations on metal surfaces and are cavities of varying sizes, usually parallel to the grain. Bursts are extremely thin and flat, aligning parallel to the work surface of the material.

Submit
145. 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:

Explanation

Intergranular corrosion is the correct answer because it is a service defect that appears as small micro-openings following the grain boundaries. These openings do not have a definite pattern and can extend in any direction. This type of corrosion occurs at the grain boundaries due to chemical reactions, causing the material to weaken and deteriorate. Fatigue crack, fillet crack, and hydrogen embrittlement do not exhibit the same characteristics as described in the question.

Submit
146. In which of the following welding processes is filler metal never added?

Explanation

Spot welding is a process in which two metal surfaces are joined together by applying pressure and heat. In this process, no filler metal is added because the heat generated by the electric current passing through the metal surfaces causes them to melt and fuse together. Therefore, spot welding does not require the use of filler metal.

Submit
147. The acronym EDM refers to:

Explanation

EDM stands for Electric Discharge Machining. This process involves the use of electrical discharges between an electrode and a workpiece to remove material. It is commonly used for precision machining of complex shapes and hard materials that are difficult to machine using traditional methods. EDM is widely used in industries such as aerospace, automotive, and medical for applications such as mold making, tool and die production, and prototype development.

Submit
148. A dark linear indication appearing at the edge of a weld is probably:

Explanation

Undercut is a type of weld defect characterized by a groove or depression at the edge of the weld joint. It occurs when the base metal is melted or eroded away, leaving a recessed area. This dark linear indication suggests that the edge of the weld has not been properly fused with the base metal, resulting in a weakened joint. Undercut can be caused by factors such as improper welding technique, excessive heat, or incorrect electrode angle.

Submit
149. A riser in the mold is there to:

Explanation

A riser in the mold is used to feed the casting as the metal shrinks before and during solidification. This is necessary because as the metal cools and solidifies, it contracts and can create voids or shrinkage defects in the casting. The riser provides additional molten metal that can flow into the casting to compensate for this shrinkage and ensure a complete and sound casting.

Submit
150. A riser in the mold is there to:

Explanation

The correct answer is "Feed the castings as the metal shrinks before and during solidification." A riser in the mold is designed to provide additional molten metal to compensate for the shrinkage that occurs during solidification. As the metal cools and solidifies, it contracts, which can lead to defects like shrinkage cavities. By having a riser, the extra molten metal can feed into the casting as it shrinks, ensuring that it fills any voids and prevents defects. The other options, letting air escape from the mold and ensuring impurities segregate outside the casting, are not the primary purpose of a riser.

Submit
151. Severe grinding cracks appear as:

Explanation

Severe grinding cracks appear as lattice-work or checkerboard patterns. This type of pattern is characterized by a series of interconnected cracks that form a grid-like structure. These cracks are often caused by excessive heat and pressure during the grinding process, leading to the formation of multiple cracks in a systematic pattern. The lattice-work or checkerboard pattern is easily distinguishable and indicates a significant issue with the grinding process, requiring immediate attention to prevent further damage.

Submit
152. A magnetic material may be demagnetized by:

Explanation

All of the mentioned methods can demagnetize a magnetic material. Heating the material above its Curie temperature causes the alignment of magnetic domains to break down, resulting in demagnetization. Cold working, which involves deforming the material at low temperatures, can also disrupt the alignment of magnetic domains and lead to demagnetization. Passing the material through an AC coil creates alternating magnetic fields that can cause the magnetic domains to realign randomly, resulting in demagnetization. Therefore, all of the mentioned methods can effectively demagnetize a magnetic material.

Submit
153. The electrodes used for spot welding are usually made of:

Explanation

Copper is the preferred material for electrodes used in spot welding due to its high electrical conductivity and thermal conductivity. These properties allow for efficient transfer of electrical energy and effective dissipation of heat during the welding process. Copper electrodes also have good resistance to wear and deformation, ensuring longer electrode life and consistent weld quality. Additionally, copper does not contaminate the weld, making it suitable for welding a wide range of materials.

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

Explanation

A lamination is an example of a processing discontinuity that can occur during rolling when an inherent discontinuity, such as a void or inclusion, changes shape due to the forces applied during the process. This can result in the formation of a laminar structure within the material, which can weaken its mechanical properties and lead to failure under stress.

Submit
155. A burst may be found in a:

Explanation

A burst may be found in a forging. A burst refers to a defect or flaw that occurs during the forging process. It is characterized by the sudden rupture or tearing of the material, resulting in a visible crack or break. This defect can be caused by various factors such as improper heating, excessive pressure, or inadequate design. In a forging, the metal is shaped and formed by applying compressive forces, and if these forces are not properly controlled, it can lead to the formation of bursts.

Submit
156. Laminations are produced:

Explanation

Laminations are produced when a pipe or blisters present in the original ingot are made directional by rolling. This means that during the rolling process, any existing defects in the ingot, such as pipes or blisters, are elongated and aligned in a specific direction. This can result in the formation of laminations, which are layers or sheets of metal that are separated by these elongated defects.

Submit
157. Arc welding is usually performed using:

Explanation

Arc welding is usually performed using direct current, low voltage and high amperage because this combination provides the best conditions for a stable and efficient welding process. Direct current allows for better control of the arc, resulting in a more stable and concentrated heat source. Low voltage ensures that the arc remains stable and prevents excessive heat buildup. High amperage provides the necessary power to melt the metal and create a strong weld. This combination of direct current, low voltage, and high amperage allows for precise and effective welding.

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

Explanation

Die casting is the correct answer because it refers to a casting process that involves pouring molten metal into a reusable mold, usually made of steel. The molten metal is forced into the mold under high pressure, allowing for the production of complex shapes with high precision and surface finish. This process is commonly used for manufacturing parts with thin walls, such as automotive components and consumer electronics.

Submit
159. Metal has the property of:

Explanation

When metal is in its molten state, the atoms have more energy and are able to move more freely, causing the metal to expand and occupy more space. As the metal cools and solidifies, the atoms lose energy and become more tightly packed, resulting in a smaller grain structure and occupying less space. This property of metal is known as thermal expansion and contraction.

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

Explanation

Submerged arc welding is a process in which multiple electrodes are used to deposit metal more rapidly. In this method, the welding arc is completely submerged under a layer of granular flux. The flux protects the weld pool from atmospheric contamination and also provides a shielding gas to prevent oxidation. The multiple electrodes allow for a higher deposition rate, making this method efficient for welding thick materials.

Submit
161. Inherent discontinuities are:

Explanation

Inherent discontinuities are formed when molten metal solidifies. This is because during the solidification process, the metal undergoes a phase change from liquid to solid, resulting in the formation of internal defects or irregularities within the material. These discontinuities can include shrinkage cavities, porosity, and inclusions, which can affect the mechanical properties and integrity of the metal. Therefore, inherent discontinuities are a natural consequence of the solidification process in metal manufacturing.

Submit
162. A crater crack may occur when:

Explanation

A crater crack may occur when the welder fails to fill the crater before breaking the arc. When welding, a small depression called a crater is formed at the end of the weld. If the welder does not properly fill this crater by continuing to deposit weld metal, it can create a weak point in the weld. As the weld cools and contracts, the stress concentration at the unfilled crater can cause it to crack. Therefore, it is important for the welder to ensure that the crater is properly filled to prevent this type of crack from occurring.

Submit
163. Grinding cracks in metal are always:

Explanation

Grinding cracks in metal are open to the surface because the grinding process involves the removal of material from the surface using a grinding wheel. As the wheel rotates and grinds against the metal, it creates small cracks or fissures that are visible on the surface. These cracks are not subsurface or parallel to the grinding wheel rotation, but rather they are open and can be seen on the surface of the metal. This is a common occurrence and is considered an inherent discontinuity in the metal due to the grinding process.

Submit
164. An advantage of electroslag welding over other methods of welding is that:

Explanation

Electroslag welding does not require special edge preparation on the base metal sections. This means that the edges of the metal pieces being welded do not need to be specially shaped or prepared before the welding process. This can save time and effort in the welding process, as there is no need for additional steps to prepare the edges.

Submit
165. Which of the following measurements indicates the smoothest surface finish?

Explanation

The measurement of 100 microinches indicates the smoothest surface finish because it is the smallest measurement among the given options. A smaller measurement indicates a smoother surface as it means there are fewer imperfections or irregularities on the surface. Therefore, a measurement of 100 microinches suggests a smoother and more refined surface finish compared to the other options.

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

Explanation

A cold shut is a defect that occurs in casting when two streams of molten metal do not merge properly, leaving a seam or incomplete fusion in the final casting. This usually happens because the metal temperature is too low, causing it to solidify prematurely before it fills the mold entirely. When the metal cools too quickly or isn't hot enough to fuse seamlessly, it can lead to this defect. Other factors, such as improper mold design or the flow rate of the metal, can also contribute to the formation of cold shuts, but the most common cause is low metal temperature.

Submit
167. If a weldment has a crater crack, you might find it:

Explanation

A crater crack in a weld is typically found at the end of the weld. It is a small crack that can occur when the welding arc is terminated abruptly, and it often appears as a depression or small crack near the end of the weld bead.

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

Explanation

A non-metallic inclusion in bar stock is referred to as a stringer. Inclusions are foreign substances or particles that are present in the metal, and non-metallic inclusions are those that are not made of metal. Stringers are long, thin inclusions that can be found in the bar stock. They can negatively impact the quality and strength of the metal, making it important to identify and minimize their presence during manufacturing processes.

Submit
169. A discontinuity can be caused within a casting as it solidifies.  It would be called:

Explanation

A shrinkage cavity can occur during the solidification of a casting when the metal contracts and leaves a void or cavity in the material. This can happen due to uneven cooling or insufficient feeding of molten metal into the solidifying region. Shrinkage cavities are typically found near thick sections of the casting where the cooling rate is slower, and they can affect the structural integrity of the final product if not properly addressed.

Submit
170. Machinability and fatigue resistance are improved in metals that have been _________________.

Explanation

Heat treatment involves heating and cooling a metal in a controlled manner to alter its properties. This process can improve the machinability of a metal by making it softer and easier to cut or shape. Additionally, heat treatment can enhance the fatigue resistance of a metal by increasing its strength and hardness, making it more resistant to failure under cyclic loading conditions. Therefore, heat treated metals generally exhibit improved machinability and fatigue resistance compared to metals that have not undergone this process.

Submit
171. Stringers are a type of discontinuity sometimes found in:

Explanation

Stringers are a type of discontinuity that can be found in bar stock. Stringers refer to elongated or linear defects that run parallel to the direction of the bar stock. These defects can occur during the manufacturing process or due to improper handling or storage of the bar stock. Stringers can weaken the structural integrity of the bar stock and may lead to failure under stress. Therefore, it is important to inspect bar stock for the presence of stringers to ensure its quality and reliability.

Submit
172. A slag inclusion in a weld is normally found in a weld crater.

Explanation

A slag inclusion in a weld is not normally found in a weld crater. Slag inclusions occur when molten slag, a byproduct of the welding process, gets trapped in the weld metal. It can be found on the surface or within the weld, but it is not specific to the weld crater.

Submit
173. Which of the following discontinuities is not normally associated with a casting?

Explanation

Bursts are not normally associated with castings. Bursts refer to the rupturing or cracking of the mold during the casting process due to excessive internal pressure. This can result from factors such as improper gating or excessive pouring temperature. However, other discontinuities like segregation, core shift, and misrun are commonly associated with castings. Segregation refers to the non-uniform distribution of alloying elements, core shift occurs when the core is not properly aligned with the mold, and misrun happens when the molten metal does not completely fill the mold cavity.

Submit
174. A lamination is something which might be found in:

Explanation

Laminations are a form of discontinuity or separation that can occur within the material's structure, typically parallel to the surface. They are often a result of imperfections in the manufacturing process, such as poor rolling or forming practices. Sheet and plate materials are particularly susceptible to laminations due to their production methods involving rolling or flattening processes. Laminations can negatively affect the mechanical properties, strength, and surface quality of a material, making it crucial to identify and address them during the manufacturing and quality control stages.

Submit
175. Electoplating complex parts results in:

Explanation

Electroplating complex parts results in uniform plate thickness because the process involves the deposition of a uniform layer of metal onto the surface of the part. This is achieved by immersing the part in an electrolyte solution and applying an electric current, causing metal ions to be attracted to and deposit onto the surface of the part evenly. As a result, the plated layer will have a consistent thickness across the entire part, regardless of its shape or complexity.

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

Explanation

Swaging is the correct answer because it refers to the process of forming a taper or reducing the diameter of metal products such as rod and tubing through forging. This process involves applying pressure to the metal to shape it into the desired taper or reduction. Upsetting refers to the process of increasing the diameter of a metal workpiece, punching refers to creating holes in metal, and drawing refers to pulling metal through a die to reduce its diameter.

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

Explanation

A burst is a definite break in the material that occurs due to excessive working of the metal during forging, rolling, or extruding operations. This breakage is usually caused by high internal stresses within the metal, which exceed its strength and result in a rupture. Unlike other options, such as cold shut, seam, or hot tear, a burst is specifically associated with the excessive working of the metal, leading to a visible break in the material.

Submit
178. Cold working steel or aluminum results in a decrease in:

Explanation

Cold working steel or aluminum involves subjecting the material to mechanical stress at low temperatures. This process causes the material to become harder and stronger due to the formation of dislocations and grain boundaries. However, it also leads to a decrease in ductility, which refers to the ability of a material to deform under tensile stress without breaking. Therefore, the correct answer is ductility.

Submit
179. A disadvantage of dry sand molds when compared to green sand molds is:

Explanation

Dry sand molds are made from a mixture of sand and binders, which do not contain moisture. This lack of moisture makes the mold more prone to erosion when compared to green sand molds, which have a higher moisture content. Erosion can occur due to the high temperatures and pressures involved in the casting process, causing the mold to break down and deteriorate more easily. This can lead to a shorter lifespan for the mold and potentially affect the quality and integrity of the casting.

Submit
180. Blowholes occur beneath the surface of a casting:

Explanation

Blowholes, also known as gas porosity, are defects that can occur beneath the surface of a casting. They are caused by trapped gases in the molten metal that do not escape before solidification, resulting in voids or cavities within the casting.

Submit
181. Polishing is a surface finishing operation which results in:

Explanation

Polishing typically entails the use of abrasive materials to refine the surface of metal. Its objective is to eliminate scratches and imperfections from machined parts, enhancing their gloss and sheen. The application of buffing to a polished surface results in a reflective, mirror-bright finish.

Submit
182. In fusion welding, preheating will result in:

Explanation

Preheating in fusion welding refers to the process of heating the base metal before welding. This helps to reduce the cooling rate during the welding process. When the base metal is preheated, it retains heat for a longer duration, which slows down the cooling rate after welding. This slower cooling rate allows for a more controlled solidification process, resulting in a reduced cooling rate. This can lead to various benefits such as reduced residual stresses, improved weld quality, and reduced risk of cracking.

Submit
183. Wrought products invariably exhibit:

Explanation

Wrought products exhibit directional properties, meaning that their mechanical properties can vary depending on the direction in which they are tested or used. This is due to the processing method used to produce wrought products, which involves shaping and deforming the material through rolling, forging, or extrusion. These processes align the grains and result in anisotropic behavior, where the material's properties differ along different axes. In contrast, cast products have isotropic properties, meaning they exhibit the same mechanical behavior in all directions.

Submit
184. Which of the following statements is correct?

Explanation

The hardness of dies for open-die forging is generally lower than the hardness of impression dies for closed-die forging. This is because open-die forging involves the shaping of metal between two flat dies, which do not fully enclose the workpiece. As a result, the forces and pressures applied during open-die forging are distributed over a larger surface area, leading to lower hardness requirements for the dies. Additionally, the life of dies for open-die forging is generally less than that of impression dies for closed-die forging due to the higher forces and wear experienced during the closed-die forging process.

Submit
185. Prior to forging, steel is usually heated to:

Explanation

Steel is heated to slightly below the melting temperature prior to forging because this temperature allows the steel to become more malleable without actually melting. At this temperature, the steel can be easily shaped and formed through the forging process, while still maintaining its solid state. Heating the steel slightly below the melting temperature also helps to reduce the risk of overheating and potential damage to the steel during the forging process.

Submit
186. Increasing test sample temperature normally:

Explanation

Increasing the test sample temperature normally increases the electrical resistivity. This is because as the temperature increases, the atoms in the material gain more thermal energy and vibrate more vigorously, disrupting the flow of electrons. This increased atomic movement hinders the movement of charge carriers, causing an increase in resistivity.

Submit
187. The overall stress to give failure by fatigue is:

Explanation

The overall stress to give failure by fatigue is less than that required to produce tensile failure. Fatigue failure occurs due to repeated loading and unloading of a material, causing it to weaken over time. This type of failure typically occurs at stress levels below the ultimate tensile strength of the material. Therefore, the stress required to cause fatigue failure is lower than the stress required to cause tensile failure, which is the point at which the material breaks under a single, static load.

Submit
188. A flaw which can resemble a cold shut is:

Explanation

A forging lap is a flaw that can resemble a cold shut. A forging lap occurs when a portion of the metal folds over itself during the forging process, creating a defect in the material. This defect can resemble a cold shut, which is a type of discontinuity in a weld where the molten metal does not properly fuse together. Both a forging lap and a cold shut can result in weak points in the material, compromising its structural integrity.

Submit
189. A common discontinuity in a weld or casting that is difficult to detect by magnetic particle testing is:

Explanation

Lamination is a type of discontinuity in a weld or casting that occurs as layers within the material, often due to improper rolling during production. It is difficult to detect by magnetic particle testing because this method is more effective for surface or near-surface defects like cracks. Laminations are often subsurface or internal, making them less responsive to magnetic particle inspection, which relies on detecting surface-breaking discontinuities.

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

Explanation

After solidification, the outside surface of a casting usually consists of fine equiaxed grains that have a random orientation and shape. This means that the grains are small and have a similar size in all directions, and they are distributed randomly without any specific alignment or pattern. This structure is typically observed in the outermost layer of a casting, and it is a result of the cooling and solidification process. The fine equiaxed grains provide good mechanical properties and improved surface finish for the casting.

Submit
191. 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:

Explanation

Shell molding is the correct answer because it involves the formation of a mold using a mixture of sand and a thermosetting resin binder. This mixture is placed against a heated metal pattern to create the mold. Shell molding is a type of casting process that allows for the production of complex and detailed parts with high dimensional accuracy.

Submit
192. A common characteristic of sand casting and investment casting is:

Explanation

The common characteristic of sand casting and investment casting is that both may be used to produce small castings.
While both processes are versatile enough to produce castings of various sizes, they are particularly suitable for small-scale productions and intricate designs. Other characteristics of these processes include:
  • Sand Casting: Sand casting uses a reusable sand-based mold, often created from a wooden pattern. The accuracy of sand casting is generally lower than investment casting due to the nature of the mold, and it is suitable for producing larger castings.
  • Investment Casting: Investment casting offers greater dimensional accuracy and a smoother surface finish than sand casting due to its use of wax patterns and ceramic molds. However, this process is typically more expensive and complex compared to sand casting, and it often involves the use of a disposable mold.
Submit
193. An extremely thin discontinuity that is the result of pipes, or inclusions flattened and made directional by working is called:

Explanation

A lamination is an extremely thin discontinuity that occurs as a result of pipes or inclusions being flattened and made directional through working. This means that during the manufacturing or processing of a material, such as metal, pipes or inclusions are compressed and elongated, resulting in a thin layer or strip-like discontinuity called a lamination. Laminations can weaken the material and may cause structural integrity issues if not properly addressed.

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

Explanation

When a weld is manufactured and the parent metal is restrained, it creates stress in the material. This stress can cause a crack to occur. The crack would typically occur transverse to the direction of the weld, meaning it would be perpendicular to the weld line. This is because the stress is being applied in a direction that is perpendicular to the weld, causing the crack to form in that direction.

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

Explanation



Cores are never used in Permanent Mold Casting. In permanent mold casting, the mold consists of two parts, and it is not necessary to use sand cores to create internal features. Instead, the mold is typically made of metal, and the molten material is poured into the mold cavity directly without the need for additional cores.
Submit
196. 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:

Explanation

A bloom is a large semi-finished hot rolled product that is approximately square in cross section and typically has a cross-sectional area of at least 36 sq. inches. It is commonly used in the production of various metal products, such as bars, rods, and wire. Blooms are usually further processed through rolling or forging to achieve the desired shape and dimensions.

Submit
197. Which of the following statements is correct?

Explanation

This statement is correct because the heat-affected zone (HAZ) is a region of the base metal that has been affected by the heat from welding. In some cases, the HAZ can have variations in microstructure, including changes in grain size, due to the rapid heating and cooling during the welding process. So, it's possible for the grain size to be smaller in some areas of the HAZ compared to the unaffected base metal.

Submit
198. Which of the following metals is least suitable to be cold worked?

Explanation

Zinc is the least suitable metal to be cold worked because it is a brittle metal with low ductility. Cold working involves deforming the metal at room temperature, and zinc is prone to cracking and fracturing under such conditions. In contrast, iron, low carbon steel, and nickel have higher ductility and can withstand cold working processes more effectively.

Submit
199. Which of the following methods produces a casting faster and at a lower cost?

Explanation

Green sand casting is a method that uses a mixture of sand, clay, and water as the mold material. It is a cost-effective and efficient casting method because the sand mixture is easily available and can be reused multiple times. The process is also relatively fast as the mold can be quickly prepared and the casting can be produced in a shorter time compared to other methods. Additionally, green sand casting allows for flexibility in design and can accommodate various shapes and sizes, making it a preferred choice for casting faster and at a lower cost.

Submit
200. Which of the following can be classified as processing defects:

Explanation



Grinding cracks are considered processing defects because they specifically arise from errors in the grinding process. This can include issues such as excessive heat generation and improper handling or techniques, which create stress and fractures in the material surface.
Submit
View My Results

Quiz Review Timeline (Updated): Jul 2, 2025 +

Our quizzes are rigorously reviewed, monitored and continuously updated by our expert board to maintain accuracy, relevance, and timeliness.

  • Current Version
  • Jul 02, 2025
    Quiz Edited by
    ProProfs Editorial Team
  • Apr 25, 2014
    Quiz Created by
    Suchanjv
Cancel
  • All
    All (200)
  • Unanswered
    Unanswered ()
  • Answered
    Answered ()
The factor which must be considered prior to selecting the best method...
The material used for making a pattern depends on:
The factor which must be considered prior to selecting the hammer or...
The material used for making a pattern depends on:
Cracks may occur at any stage of manufacturing
Like ingots, welds can contain porosity:
In the beginning all steel is perfect:
NDT is used for locating only those discontinuities open to the...
NDT is a method of locating which of the following:
Which of the following factors can have a negative influence on some...
Elements may be added to the filler metal to:
Possible effect(s) of metal forming is (are) to:
Elements may be added to the filler metal to:
Level II magnetic particle technicians should always be able to...
Fatigue cracking is always caused by a single overloading.
Spot welding is usually performed using:
What phenomenon(s) may happen in the heat affected zone during the...
Usually, the most serious type of flaw in metals is/are:
Usually, the most serious type of flaw in metals is/are:
The purpose of metal forming is to:
Non-metallic impurities trapped within the molten metal of a casting...
Better mechanical properties are obtained with:
Galvanizing is a process of applying to iron and steel products a...
A green sand mold is:
Which of the following properties is controlled by the electrons in...
All metals solidify in a ___________ structure.
Non-metallic materials trapped in solid metal are described as:
In its original shape, porosity would appear:
Grinding cracks can be caused by:
Heat treating might cause discontinuities which would probably start...
A hot tear in a casting is a crack.  It could occur:
The following gas is used intensively for shielding in the gas...
In spot resistance welding, pressure used may be:
A non-consumable electrode used for arc welding would be made of:
A forging defect caused by the metal being folded over and forced into...
The grain size in a material may be controlled by:
The top portion of a molding flask is called a:
In the Prayer of Hannah (1 Samuel 2:1-10), what is the primary theme...
The reason an ingot used as forging stock is subjected to more than...
Non-metallic inclusions are:
In the shielded metal-arc process, the covering material:
An alloy is a substance composed of:
A cause of gas porosity in welds is:
Pressure welding can be accomplished with pressure alone, but what...
Patterns used to prepare molds for casting are made of:
A cause of gas porosity in welds is:
The fuel gas most commonly used in gas welding is:
Cold shuts are most likely to be found in:
Which term best describes what is sought by NDT?
Cold shuts are most likely to be found in:
When metals solidify:
The folding of a metal in a thin plate on the surface of a forging...
A welding defect that occurs at the root and runs parallel with the...
Cold shuts are most likely found in:
In gas welding, the acetylene is usually burned with:
Patterns made of wood:
Heat exchanger tubes are defect prone at regions:
Hot working an ingot may produce a product which has:
In which of the following arc welding processes is the electrode...
The bottom portion of a molding flask is called a:
A metal insert imbedded in the surface of a sand mold to increase the...
A metal support for holding cores in place within a sand mold is...
Which of the following welding processes does not involve melting of...
Non-metallic inclusions are not present before the billet is worked:
Oxides in weldments can cause discontinuities which are similar to...
A weld discontinuity that always occurs at the root of a weld is:
The first step in the production of a casting is the making of:
Grain direction in steel bar stock is always:
Which of the following is identified as a casting insert?
The essential difference between permanent mold casting and die...
When thick and thin casting sections are adjacent to each other, what...
Premature blocking of a gate during the pouring of a casting might...
Micro shrinkage might occur in a casting:
Usually, seamless tubing is produced by:
During on-line (Manufacturing) inspection of components, defective...
Heat treat cracks may be caused by:
When a pouring gate in a casting blocks off prematurely, it can cause...
In the submerged arc welding process:
Most manufacturing defects in a tube are:
A metal stressed below its elastic limit will return to its original...
In the resistance welding process:
Inserts which may be found in sand molds are:
A joining process which occurs without fusion of the base metal is:
The following defect is caused by the melting away of the sidewalls of...
Grinding cracks are usually caused by:
Forging laps can occur in which of the following places:
An advantage of investment casting over green sand casting is:
In gas welding, a reducing flame is produced when:
The Curie point is:
A cold shut has:
A forging lap may occur if:
In a rolling mill, flattening and elongation of metal is accomplished...
In which of the following joining methods will flaws, when they do...
The middle portion of a molding flask is called a:
The work metal for working with a forging hammer is:
A material which is considered ferromagnetic is:
Aircraft turbine blades are usually processed by:
With a forging hammer the striking force is imposed on the work metal...
The hardest structure that can be produced by heat treating steel is:
The property of a material to exist under different lattice structures...
A difference between shielded metal-arc welding and gas metal-arc...
A burst is a processing defect that may be caused by:
A type of defect which propagates along grain boundaries is called:
In gas welding, a reducing flame is produced when:
Fine lines, likely to occur in groups caused by non-metallic...
Metals which cannot be work hardened are those which:
Which discontinuity is not normally found in a casting?
A forming operation which results in the greatest dimensional accuracy...
Materials of low ductility are best forged with:
A fatigue crack is a service defect that is caused by a:
Fine lines, likely to occur in groups caused by non-metallic...
As cold working progresses, the energy required for further processing...
Amorphous materials include:
A method commonly used to remove a number of flaws in an ingot prior...
The millworking process used most to form metals into 3D shapes is:
Seams are sub-surface discontinuities
Resistance welding differs from fusion welding in that:
The process in which a steel is heated above the upper critical...
The principal purpose of risers in molds is to:
A casting process in which the pattern is not re-usable is called:
A rupture in the material that can be in any direction on the part and...
A service defect that appears as a series of small micro-openings with...
Lack of penetration may be the result of:
In forgings, grain:
Grinding cracks occur crosswise to grinding wheel rotation
Which of the items listed below is a discontinuity found in ingots?
A burst is _____________ discontinuity.
A generally smooth indication on a cast surface resulting from the...
A metal production process which eliminates the need for ingot...
Bursts are caused by:
One of the main causes of cold shuts is:
Laminations are produced:
One of the main causes of cold shuts is:
Discontinuities are:
A metal forming operation which allows three dimensional control over...
As cold working progresses, the energy required for further processing...
Submerged arc welding may be performed:
The machining process which can produce the best surface finish is:
A dark narrow line running down the center of the weld is:
A steel casting suitable for working or remelting is called:
Which of the following is present in ingots?
The most easily forgeable material, from the following, is:
A common processing indication in rolled bar stock is:
Bursts usually have the following characteristics:
A service defect that appears as a series of small micro-openings with...
In which of the following welding processes is filler metal never...
The acronym EDM refers to:
A dark linear indication appearing at the edge of a weld is probably:
A riser in the mold is there to:
A riser in the mold is there to:
Severe grinding cracks appear as:
A magnetic material may be demagnetized by:
The electrodes used for spot welding are usually made of:
An example of a processing discontinuity that is the result of an...
A burst may be found in a:
Laminations are produced:
Arc welding is usually performed using:
A casting process involving a re-usable mold is called:
Metal has the property of:
A process in which multiple electrodes are most commonly used in...
Inherent discontinuities are:
A crater crack may occur when:
Grinding cracks in metal are always:
An advantage of electroslag welding over other methods of welding is...
Which of the following measurements indicates the smoothest surface...
A cold shut is an inherent defect that may be caused by:
If a weldment has a crater crack, you might find it:
What is a non-metallic inclusion called in bar stock?
A discontinuity can be caused within a casting as it solidifies. ...
Machinability and fatigue resistance are improved in metals that have...
Stringers are a type of discontinuity sometimes found in:
A slag inclusion in a weld is normally found in a weld crater.
Which of the following discontinuities is not normally associated with...
A lamination is something which might be found in:
Electoplating complex parts results in:
Forming a taper, or a reduction of metal products such as rod and...
A definite break in the material caused by excessive working of the...
Cold working steel or aluminum results in a decrease in:
A disadvantage of dry sand molds when compared to green sand molds is:
Blowholes occur beneath the surface of a casting:
Polishing is a surface finishing operation which results in:
In fusion welding, preheating will result in:
Wrought products invariably exhibit:
Which of the following statements is correct?
Prior to forging, steel is usually heated to:
Increasing test sample temperature normally:
The overall stress to give failure by fatigue is:
A flaw which can resemble a cold shut is:
A common discontinuity in a weld or casting that is difficult to...
After solidification, the structure of the outside surface of a...
The process in which a mold is formed from a mixture of sand and a...
A common characteristic of sand casting and investment casting is:
An extremely thin discontinuity that is the result of pipes, or...
If a weld is manufactured and the parent metal is restrained, a crack...
In which of the following casting processes are cores never used?
A large semi-finished hot rolled product, approximately square in...
Which of the following statements is correct?
Which of the following metals is least suitable to be cold worked?
Which of the following methods produces a casting faster and at a...
Which of the following can be classified as processing defects:
Alert!

Advertisement