Inspection Methods Flashcards
(193 cards)
1
Q
Methods of weld testing and analysis are used to assure what?
A
The quality and correctness of the weld after it is completed.
2
Q
Weld testing refers to testing and analysis focused on what?
A
Quality and strength of the weld.
3
Q
To ensure development of quality weld, what 2 data sources are collected?
A
Qualitative (NDT), Quantitative (Hardness, tensile strength, ductility, toughness, fracture toughness)
4
Q
What are the 3 stages of inspection?
A
Before, during and after welding.
5
Q
What are the 2 testing techniques (type)?
A
Destructive and non-destructive.
6
Q
What are 3 things that must happen before welding?
A
- Cleaning, 2. Edge Prep, 3. Baking of electrodes
7
Q
What must be monitored during welding?
A
Input parameters, current/voltage, welding speed, shielding gas, and head source temp
8
Q
What are 3 things that must happen after welding?
A
Removal of slag, peening (stress removal), and post welding treatment (heat)
9
Q
What is destructive testing?
A
Physical damage to w/p and welded joint. Quantitative data obtained.
10
Q
What is NDT?
A
Without physically damaging the work piece and joint. Qualitative data is obtained.
11
Q
What is the definition of a destructive test?
A
Damage takes place in the component which is being tested while being observed, until damage reaches an extent that it cannot be used for further targeted application.
12
Q
Destructive testing can be performed in what 2 places?
A
Workshop, laboratory
13
Q
What are the types of destructive weld testing?
A
Tensile, Bend, hardness, Toughness, fatigue.
14
Q
Tensile test is used to check how the weld joint will ______ and under different environments.
A
perform under tensile loading
15
Q
What is tensile testing?
A
Deformation at different stages and the total elongation of the weld joint till fracture. (Involves modulus of elasticity and yield strength)
16
Q
What are the two ways tensile properties are obtained?
A
- Taking specimen from transverse direction of weld joint consisting base metal - heat affected zone.
- All weld metal metal specimen: consists entirely of weld metal, oriented parallel to the weld axis.
17
Q
Tensile test results must be supported by ______ diagram.
A
stress/strain diagram
18
Q
What are the two reasons from performing an all weld metal test?
A
- qualify a filler metal
2. determine properties of the weld metal in a particular weldment
19
Q
What are the typical properties of an all weld metal tension test?
A
Tensile strength, yield strength, elongation.
20
Q
_____ determines ductility, soundness of welded joints in terms of porosity, inclusion, penetration, and other macro size weld discontinuities.
A
Bend Test
21
Q
The outside of the bend is extensively plastically deformed, why?
A
So that any defect in or embrittlement of the material will be revealed by the premature failure.
22
Q
Bend of the weld joint can be done from ________ or _____ side depending upong the purpose (whether ____ or ____ side is assessed)
A
face or root
23
Q
What are the 3 types of bend test?
A
Free bend, Guided bend, loading bend
24
Q
In _______ test between the two supports, the weld joint is placed and then the compressive load is applied for bending to take place.
A
Free bend
25
In ______ test, it is performed by placing the weld joint over a die. It offers better controlled conditions of the specimen and of the loading.
guided bend
26
_____ has a load that keeps on increasing until crack starts appearing on the face or root. Angle of bend is considered as measure of ductility.
load in Bend test
27
What am I? it is resistance to indentation or penetration. usually referred as a measure of resistance to abrasion or scratch.
Hardness test
28
Due to applications of heat in welding, materials like hard enable _____ or ______ are subjected to hardening. Materials like aluminum alloys ________.
Steel or cast Irons are subjected to hardening, aluminum alloys precipitation enabled become softer.
29
hardening and softening phenomenon usually occurs at _____.
HAZ
30
What does the hardness test reveal?
Micro structural transformation, any embrittlement.
31
_______ is the ability of a material to resist both fracture and deformation. Simulates service conditions often encountered by components of the system used in transportation, agricultural and construction equipment.
Toughness Test
32
What can be determined by calculating energy absorbed by material before fracture?
Toughness
33
What steel is the strongest?
high carbon steel (high stress/low strain)
34
What steel is the toughest?
medium carbon steel (medium stress/medium strain)
35
What is the most ductile?
low carbon steel (low stress/high strain)
36
What are 2 methods of toughness?
Charpy impact, izod impact
37
An izon sample is held _____ on an anvil as a cantilever.
vertically
38
An izon holding, cantilever type and ______ the pendulum.
notch faces
39
A charpy sample is held _____ on anvil as simply supported beam.
horizontally
40
A charpy holding simply supported type and notch is ____ side of pendulum impact (not facing to pendulum)
opposite
41
What is the most common fracture toughness test used by industry.?
Charpy
42
What am I? A notched specimen is broken by a swinging pendulum and the amount of energy required to break the specimen is recorded in foot-pounds or joules. this is determined by __________.
Charpy impact; how far the pendulum swings upwards after it fractures the specimen.
43
At ____ temp the material is more brittle and impact toughness is low.
low
44
At ___ temp the material is more ductile and impact toughness is higher.
high
45
What is an important consideration in the selection of material for toughness test?
The transition temperature of the boundary between brittle and ductile behavior.
46
_____ is generally carried out with the specimens at room temp since the time required to accurately place it in the machine allows its temp to increase. (This can introduce a significant error when conducting tests at various temperatures)
Izod Impact
47
______ standard for preparing specimen. Can be determined by endurance limit and number of load ccles that joint can withstand.
Fatigue Test
48
A fatigue test must include
______ - axial pulsating, reverse bending or tension compression.
______ - ratio of minimum stress to maximum stress.
_________ (ambient/vacuum/corrosive)
________
type of loading, stress ratio, temp/environment, type of sample
49
For plotting stress to number of cycles curve (s-n curve) fatigue test is conducted with _______________ to determine number of load cycle required for fracture.
maximum applied tensile load corresponding to 0.9 times of yield strength.
50
________ is a wide group of analysis techniques used in science and tech industry to evaluate the properties of a material, component or system without causing damage.
Non-Destructive testing
51
What are some uses of NDE methods?
- flaw detect and eval
- leak detect
- location determination
- dimensional measure
- structure and micro-structure characterization
- estima of mechanical/physical prop
- stress/strain and dynamic response measure
- material sort and chemical comp determination
52
Why nondestructive?
test piece too precious, needs to be reused, is in service, quality control purpose
53
What NDT methods used for surface flaw?
VT, MT, PT
54
What NDT methods used for internal flaw?
RT, UT, ET
55
What is the most basic and common inspection method?
VT
56
What is the most widely used NDE method?
PT... I don't agree with this
57
Why is PT popular?
Ease of use and its flexibility
58
You can't use PT on ______ surfaces.
rough or porous
59
Materials that are commonly inspected with PT include...
metals, glass, ceramic, rubber, plastic
60
PT is a method that is used to reveal surface breaking flaws by ____ of a colored or fluorescent dye from the flaw.
bleedout
61
The technique is based on the ability of a liquid to be drawn into a clean surface breaking flaw by ________.
capillary action
62
After a period of time for pt is called ______, where excess surface penetrant is removed and a developer is applied.
dwell
63
What acts as the blotter and draws the penetrant from the flaw to reveal its presence?
developer
64
_______ require good white light.
colored (contrast) penetrants
65
Fluorescent penetrants need to be used in darkened condition with an _______.
ultraviolet black light
66
____- can be used in non-ferromagnetic materials and even non-metals.
PT
67
Modern PT methods can reveal cracks ___ um wide
2
68
What are 2 ways that a penetrant inspection process makes flaws more easily seen?
1. flaw indication that is much larger and easier for the eye to detect than the flaw itself.
2. PT produces a flaw indication with a high level of contrast between the indication and the background
69
What is the basic steps for PT?
cleaner, penetrant+dwell, developer, dwell
70
One of the most critical steps of a liquid penetrant inspection is the ____ preparation
surface
71
the surface must be free of oil, grease, water, or other contaminants _______.
that may prevent penetrant from entering flaws.
72
Sanding or grit blasting may cause ______, thus closing the defects.
metal smear
73
penetrant material is applied by ___, ___, or ___
spraying, brushing, immersing the parts in a penetrant bath
74
dye must provide ______ against the developer
good contrast
75
What is red liquid against white developer?
Dye penetrant
76
What is liquid contain additives to give fluorescence under uv
fluorescent penetrants
77
Method A-
water washable
78
method B
Post Emulsifiable, Lipophilic (gets composed with solvent)
79
Method C
Solvent Removable
80
Method D
Post Emulsifiable, Hydrophilic (dissolve in water)
81
Based on the ______ of the indication that is produced for a number of very small and tight fatigue cracks, penetrants can be classified into 5 sensitivity levels.
strength or detectability
82
level 1/2 -
ultra low sensitivity
83
level 1
low sensitivity
84
level 2
medium sensitivity
85
level 3
high sensitivity
86
level 4
ultra high sensitivity
87
What is the role of developer?
To pull the trapped penetrant material out of defects and to spread the developer out on the surface of the part so it can be seen by an inspector
88
What does fine developer particles?
Both reflects and refracts the incident ultraviolet light, allowing more of it to interact with the penetrant, causing more efficient fluorescence.
89
Developer allows more light to be emitted through the same mechanism, that is why ______ are brighter than the penetrant itself under UV.
indications
90
Developers that create a white background have a greater degree of ____ between the indication and the surrounding background.
contrast
91
______ is the least sensitive but inexpensive developer type
dry powder developer
92
____ consist of a group of chemicals that are dissolved in water and form a developer layer when the water is evaporated away.
water soluble
93
______ consist of insoluble developer particles suspended in water.
Water suspendible
94
_______ suspend the developer in a volatile solvent and are typically applied with a spray gun.
nonaqueous
95
Using dye and developer from different manufacturers should be ______.
avoided
96
Which method has a high sensitivity to small surface discontinuities.
PT
97
What NDT method is most widely utilized.
MT
98
The only requirement for MT, is tha.t____
components being inspected must be made of a ferromagnetic material like iron, nickel, cobalt, or some of their allows.
99
________ materials are materials that can be magnetized to a level that will allow the inspection to be effective.
ferromagnetic
100
Examples of MT use are
structural steel, automotive, petrochemical, power generation, and aerospace
101
Mt is a mix of
magnetic flux leakage and visual testing
102
The pole where a magnetic line of force exits the magnet is called the _____ pole.
north
103
A pole where a line of force enters the magnet is called the _____ pole.
south
104
What is a diamagnetic metal?
very weak and negative susceptibility to magnetic fields. (slightly repelled by a magnetic field and the material does not retain the magnetic prop when the external field is removed)
105
What is a paramagnetic metal?
Small and positive susceptibility to a magnetic field. These materials are slightly attracted by a magnetic field and the material does not retain the magnetic prop when the external field is removed.
106
What is a ferromagnetic material?
large and positive susceptibility to an external magnetic field. They exhibit a strong attraction to magnetic fields and are able to retain their magnetic prop after the external field has been removed.
107
Ferromagnetic materials become magnetized when the magnetic domains within the material are _____.
aligned
108
The more domains that are aligned the ______ the magnetic field is in the material.
stronger
109
When all the domains are aligned, the material is said to be magnetically _____.
saturated
110
When a material is magnetically saturated, ______ amount of external magnetization force will cause an increase in its internal level of magnetization.
no additional
111
It is common to classify the magnetizing methods as either ____ or ______.
direct or indirect
112
Direct magnetization is ______.
current
113
Indirect magnetization uses a _________ to establish a magnetic field within the component.
a strong external magnetic field
114
Magnetic lines of force ____ cross one another.
never
115
Magnetic lines of force will follow the path of ______ resistance between opposite magnetic poles.
least
116
The ______ decreases when lines of force move from an area of higher permeability to an area of lower permeability.
density
117
Their density ______ with increasing distance from the poles.
decreases
118
Flow goes from the south pole to the north pole within the ______ and north pole to south pole in _____.
material, air
119
When a bar magnet is broken in the center of its length, what happens?
Two complete bar magnets with magnetic poles on each end of each piece will result.
120
If the magnet is just cracked but not broken completely in two, what happens?
A north and south pole will from at each edge of the crack.
121
The magnetic field exits the ____ pole and reenters at the _____ pole.
north, south
122
The magnetic field spreads out when it encounters the small _____ created by the crack because the ____ cannot support as much magnetic field per unit volume as the magnet can.
air gap, air
123
When the field ______ it appears to leak out of the material and thus it is called a ______.
spreads out, flux leakage field
124
If iron particles are sprinkled on a cracked magnet, the particles will be ___________ not only at the poles at the ends of the magnet but also at the poles at the edges of the crack.
attracted to and cluster
125
The magnetic flux line close to the surface of a ferromagnetic material tends to __________________.
follow the surface profile of the material.
126
_______ (cracks or voids) of the material perpendicular to the flux lines cause fringing of the magnetic flux lines.
discontinuities
127
The leakage field can attract other ________ particles
ferromagnetic
128
The magnetic particles form a ridge may times _____ than the crack itself.
wider
129
Cracks just below the surface __________ for MT
can also be revealed
130
MT is not ______ to shallow and smooth surface defects.
sensitive
131
The effectiveness of MT depends strongly on the orientation of the crack related to the flux lines.
True or false
true
132
what is the testing procedure of MT?
1. pretreatment
2. magnetization
3. apply magnetic particles
4. observation
5. detect crack/flaw
6. post-treatment
133
_______ involves the use of penetrating gamma or x-radiation to examine materials and products defect and internal features.
radiography
134
________ shows the internal features and soundness of a part in RT.
shadowgraph
135
________ and ____ changes are indicated as lighter or darker areas on the film.
material thickness and density changes
136
The ______ areas in the radiograph below represent internal voids in the component
the darker areas
137
x-rays are part of the ________ spectrum, with wavelengths shorter than visible light.
electromagnetic
138
______ are produced whenever high-speed electrodes collide with a metal target.
x-rays
139
a source of electrons is hot W filament, a ____________ (30-50kv) between the cathode (w) and the anode and a metal target.
high accelerating voltage
140
The anodes is a ______.
water-cooled block of Cu containing desired target metal.
141
X-rays are electrode magnetic radiation with very _____ wavelengths
short
142
the x-ray photon with wavelength 1 A has energy of
12.5keV
143
Emitted gamma radiation is one of the 3 types of ______ radioactivity. It is also the most energetic form of electromagnetic radiation, with a very short wavelength of less than one-tenth of a nano-meter.
natural
144
______ are essentially very energetic x-rays emitted by excited nuclei.
gamma rays
145
Man made sources are produced by introducing an extra ____ to atoms of the source material. As the material rids itself of the _____, energy is released in the form of gamma rays.
neutron
146
What are the 2 more common industrial gamma-ray sources?
Iridium 192 and cobalt 60.
147
The part tested is place between what?
the radiation source and the piece of film.
148
_______ area will stop more of the radiation.
thicker and more
149
the film _______ density will vary with the amount of radiation reaching the film through the test object.
darkness
150
The first subjective criteria for determining radiographic quality is radiographic _____.
contrast
151
What is radiographic contrast?
the degree of density difference between adjacent areas on a radiograph.
152
It is essential that sufficient contrast exist between the defect of interest and the____.
surrounding area
153
The radiographic definition of quality is the ______________.
abruptness of change in going from one density to another.
154
y-ray from Co-60 can penetrate up to ____ mm of steel
150
155
In Rt the operator must have access to both sides of an object. true or false?
true
156
Cracking can be detected in a radiograph on the crack is propagating in a direction that produced a change in thickness that is _____ to the x-ray beam.
parallel
157
In Rt ____ will appear as jagged and often very faint irregular lines. They can also so appear as tails on inclusions or porosity.
cracking
158
______ (icicles) results when too much heat causes excessive weld metal to penetrate the weld zone. lumps of metal sag through the weld creating a thick globular condition on the back of the weld.
burn through
159
_____ burn through appears as dark spots surrounded by light globular areas.
burn through
160
_____ or ____ are cause by accumulated gas or air which is trapped by the metal. These discontinuities are usually smooth-walled rounded cavities of a spherical, elongated or flattened shape.
gas porosity or blow holes
161
_____________ and ____ are nonmetallic oxides, appearing on the radiograph as irregular, dark blotches.
sand inclusions and dross
162
______ is high-frequency sound waves are transmitted into a material to detect imperfections or to locate changes in material properties.
ultrasonic testing
163
The most commonly used ultrasonic testing technique is _______, whereby sound is introduced into a test object and reflections (echoes) from internal imperfections or the parts geometrical surface are returned to a receive.
pulse echo
164
the _______ between the transmission and reception of pulse give clues to the internal structure of the material.
time interval
165
____ has high frequency sound wave introduced into a material and thy are reflected back from surfaces or flaws.
pulse echo
166
reflected sound energy is displayed versus time and inspector can visualize a cross section of the specimen showing the ____ of features that reflect sound.
depth
167
______ transducers are used for converting electrical pulses to mechanical vibrations and vice versa.
piezoelectric
168
commonly used piezoelectric materials are _____, and ______.
quartz, polarized ceramics
169
Usually transducers generate ultrasonic waves with frequencies in range ___ or ___ mhz
2.25 to 5.0
170
The active element of the most accoustic transducer is ______ ceramic.
piezoelectric
171
A thin wafer vibrates with a wavelength that is twice its thickness, therefore, piezoelectric _____ are cut to a thickness that is 1/2 the desired radiated wavelength.
crystals
172
_______ matching is achieved by a matching layer with thickness 1/4 wavelength
optimal impedance
173
______ waves: similar to audible sound waves. The only type of wave which can travel through liquid.
longitudinal waves
174
_____ waves: generated by passing the ultrasonic beam through the material at an angle. Usually a plastic wedge is used to couple the transducer to the materials.
shear
175
__________ does not contact the component. These transducers are designed to operate in a liquid environment and all connects are watertight. Wheel and squirter transducers are examples of such immersion applications.
immersion
176
_______ contains two independently operating elements in a single housing. One of the elements transmits and the other receives. _____ element transducers are very useful when making thickness measurements of thing materials and when inspecting for near surface defects.
dual element
177
____ and wedges are typically used to introduce a refracted shear wave into the test material. they are used to generate surface waves for use in detecting defects on the surface of a component.
angle beam
178
______ or a _____ is needed for effective transmission of ut from the transducer to the material
fluid couplant or a fluid bath
179
Straight beam contact search unit projects a beam of ultrasonic vibrations _____ to the surface.
perpendicular
180
_____ contact units send ultrasonic beam into the test materials at the predetermined angle to the surface.
angle beam
181
When the geometry of the part is relatively uncomplicated and the orientation of a flow is well known, the length of a crack can be determined by a technique known as _______.
tip diffraction
182
One common application of the diffraction technique is to determine the length of a crack originating form on the backside of a _____.
flat plate
183
______ is a function of the ultrasound velocity in the material, the _______ and the difference in arrival times between the two signal
crack height, incident angle
184
What are the 3 most common formats for data presentation in UT?
A-scan, b-scan and c-scan
185
_____ displays the amount of received ultrasonic energy as a function of time.
a-scan
186
______ presentations is a profile cross-sectional view of the a test specimen. TOF of the sound energy is displayed along the vertical and linear position of the transducer is along the horizontal axis.
b-scan
187
_____ provides a plan-type view of the location and size of test specimen features. the plane of the image is parallel to the scan pattern of the transducer.
c-scan
188
electrical currents are generated in conductive material by an induced alternating magnetic field. the electrical currents are called ____ because the flow in circles at and just below the surface of the material.
eddy current
189
the strength of the secondary field depends on the electrical and magnetic properties, structural integrity of the test object. true or false
true
190
The changes in the secondary field will be a _____ to the primary coil and affect the primary current
feedback
191
the depth as which eddy current density has decreased to 1/e or about 37% of the surface density, called the standard depth of _____.
penetration
192
What are the 3 types of ET probes?
surface, internal bobbin, encircling probe
193
What is on the y and x axis of the eddy current impedance plane response?
inductive reactance, resistance
