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Two lines are configured to produce 0.75 mm sheet; their historical standard deviations are unknown but are considered equal. The following data was collected to determine if the mean of the machines' output is equal with 95% confidence . . . |
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Your company manufactures high-quality steel plate for pressure vessels. You test the material for a variety of physical and chemical properties, and maintain records so that statistical data on the product can be maintained, trends noted and corrective action taken, if required. One of your company's most successful products is . . . |
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The control charts below are for two billet shears for which n=4. Which is (are) in control? |
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A first order, homogeneous liquid phase reaction has a rate constant of 0.2 min-1. A continuous reactor has been built to treat 10 L/min of the reactant (initial concentration of 1 mole/L). The reactor has a volume of 100 L. The reactor was supposed to be perfectly mixed . . . |
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A cross flow condensing heat exchanger is utilized to heat the pickling solution in a recirculating loop. How much heat exchanger area (m2) is needed given the following . . . |
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An electric arc furnace is used to melt steel scrap to liquid hot metal before refining and casting. The furnace has a nominal rating of 150 tons and is charged with scrap at 60°F. Electric power is delivered by three-phase current at 120 MVA (120 x 106 volt-amp) . . . |
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An electrolytic cell for producing aluminum metal from alumina generates molten aluminum metal at the cathode, and oxygen at the carbon anode. The oxygen then reacts with the anode material to produce an offgas consisting of CO and CO2. The overall cell reaction is . . . |
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Based upon the standard state electromotive series, immersion deposits would be expected in which of the following situations |
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An integrated steel maker produces carbon steel plate for industry. The plate is made in a mill at a rate of 450 tons/hr and sent to a laminar flow water cooling system to reduce the steel temperature from 1725°F to 400°F in a controlled manner. The plate can be considered to be infinite in length . . . |
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A zinc production furnace of the type above generates a vapor analyzing 47% metallic zinc, 53% carbon monoxide. The vapor is quenched to generate three metric tons of metallic zinc per hour. The volume of gas generated (cubic meters) by the furnace per hour at 950°C . . . |
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Define a safe internal pressure for 8-inch schedule 5S pipe made from 304L stainless steel. Use the approximate relationship between the internal pressure and stress in a thin-wall pipe. A safety factor of 4 relating to stresses remaining below the yield stress is required. Nominal dimensions of . . . |
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Significant residual stresses can develop in a metal during welding. The figure below shows the longitudinal stresses resulting from a single-pass groove weld. The distribution of this stress can be very closely approximated by . . . |
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The tempering operation of quench-hardened high carbon steel components requiring 58+/- 2 HRC (Rockwell hardness) changes the crystal structure from . . . |
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Stainless steel is "sensitized" when a precipitate is formed at grain boundaries, changing some of the properties of the material. Stainless steels will become sensitized in varying amounts; some not at all. Type 304 is an example of a stainless steel that . . . |
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Which of the following statement most accurately reflects the difference between a stress--relieving treatment and a full annealing treatment? |
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An aluminum alloy will be used to manufacture rivets (extruded rod) to hold the fuselage panels (sheet) together on the Concorde. If the rivets are manufactured from 6061, the processing steps that should be used to achieve a T6 temper are . . . |
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The major strengthening mechanisms in maraging steels are . . . |
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An Imperial Pb Smelter shown in Figure 1 reduces a feed of PbO and ZnO. The reduction is performed using coke composed of C and inert material. Molten hot metal tapped from the bottom of the furnace is a Pb-Zn alloy. Most of the Zn leaves the furnace in . . . |
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What is the primary reason for NOT using molybdenum electrical heating elements in an air furnace? |
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What conditions would best tend to enhance creep deformation and decrease the time to rupture of a specific alloy? |
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A dominant high-temperature creep mechanism is grain-boundary sliding. High temperature creep resistance (temperatures at or above 3/4 of the melting point) will be enhanced in a material with . . . |
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The stress intensity KI for a crack tip in a material containing a crack and subjected to tensile stress is given by . . . |
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What is the maximum draft (reduction in thickness per pass in mm) possible during hot rolling under the given conditions (see useful information)? |
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If the average flow stress at an intermediate stage of hot rolling to 12 mm is s = 50 MPa and the length of contact is 77 mm, then the approximate roll force (MN) would be most nearly . . . |
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A flat rectangular shim is to be cold open die-forged perpendicular to the long dimension of a bar 0.350 inch high x 0.350 inch wide x 3.000 inch long. The final height is to be 0.100 inch. The material is to be cartridge brass and it is desired to make the shim in one stroke. A 500-ton press is . . . |
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Choose the appropriate thermal and/or mechanical treatment for Alloy C-276 (UNS N60276, formerly known as Hastelloy C-276) for subsequent machining, then use in a corrosion resistant application. |
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Specialty steels such as tool steels and bearing steels have severe duty cycles. They require good fatigue life & wear resistance and often need complex heat treatments. Careful selection of materials and processing cycles is required to maximize properties and avoid . . . |
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A new product is being made as a ductile iron-casting project. The casting has a minimum section size 5 mm. Several attempts to produce this casting in a production facility have been made using various alloy modifications to the base 60-40-10 iron. These attempts have resulted in . . . |
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First stage turbine blades operate at very high temperature often reaching 90% of the melting point of the alloy. These blades are typically cast as single crystal castings in nickel base superalloys to minimize creep. Which of the following conditions is more conducive to . . . |
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With the advent of vacuum melting, increased number of steels and superalloys are cast in vacuum because of the benefit of improved cleanliness. The composition of vacuum-melt alloys, however, differs slightly from that of their air-melt version because of the differences in . . . |
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A new product is being made as a ductile Iron casting project. The casting has a minimum section size 5 mm. Several attempts to produce this casting in a production facility have been made using various alloy modifications to the base 60-40-10 iron. These attempts have resulted in . . . |
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The designer decides to possibly eliminate all porosity. Which of the following fabrication changes will reduce porosity in this part? |
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Why would carburizing be chosen over through-hardening to improve fatigue resistance in a part? |
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Which one of the following alloys could you harden most by heat treatment? |
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You specified 304H stainless steel for a load-bearing application at 1,000o F (540oC) in an industrial atmosphere. The stress level is approximately 8,000 psi (55 MPa). Cost is a factor and the correct choice will be the one that satisfies the requirements at the lowest cost. You have been requested to . . . |
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A material for a discharge line to a waste tank in a chemical processing plant is required. The conditions are severe; the aqueous solution pH ranges form 3 to 7, the flow is at high velocity with considerable turbulence and entrained air. The pipe is 12" (300 mm) diameter, and . . . |
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Stainless steel is "sensitized" when a precipitate is formed at grain boundaries, changing some of the properties of the material. Stainless steels will become sensitized in varying amounts; some not at all. Type 304 is an example of a stainless steel that will become sensitized. Assume that . . . |
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Your partners are trying to understand why 316 stainless steel is more expensive than 304. You explain that it is because of the higher nickel content and the presence of molybdenum. They ask what is the purpose of the higher nickel content. What should you tell them? |
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One manufacturer, concerned about quench-related distortion, decided to change to an alloy with a higher chromium content. Why would that help? |
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The chief element added to stainless steels to promote machinability is . . . |
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The most important properties desired in master gages are dimensional stability and wear resistance since they are used in checking other gages and expected to hold their accuracy over a long period of time. Based on these property requirements, which of the following . . . |
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The CS series of bridges feature low-maintenance grated decks, and are intended for use throughout the United States. Of the following alloys, which is best suited for this application (consider exposure to road deicing salts) . . . |
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Copper and steel panels are mistakenly joined together for an application exposed on one side to alternative seawater immersion and marine atmosphere. The area of the copper panel is 240 cm2 while the steel panel area is 1350 cm2. The average current density on the . . . |
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A continuously operated 2,500 psig boiler suffers from a superheater tube failure after 3 years. The tube is composed of ASME SA 209 T1 (0.15C-0.50Mn- 0.30Si-0.50Mo) steel. The tube was inspected and shown to have a normal microstructure prior to its installation into . . . |
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Piping at a chemical processing plant was typically exposed to temperatures above 75°F. Low ambient temperatures due to an unusually cold winter, in combination with operating problems, caused the temperature of the piping to drop to almost -100°F. This low temperature strongly contributed to . . . |
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Your facility's metallography laboratory has Rockwell, Brinell, and Vickers hardness testers. There is often confusion among investigators regarding the proper kind of hardness test to choose. You have been asked to present a seminar on hardness testing and the capabilities of . . . |
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A ship yard has a crane capable of lifting 90 ton (short) pieces of equipment. The lifting frame, see diagram below, has 2 cables that attach to the lifting bolts and does not impart any bending stresses into the lifting bolts. The lifting bolts are 50 mm . . . |
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What is the best way to measure wall thickness in a carbon steel pressure vessel, from outside the vessel? |
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A carbon steel tank was "hydrotested" (pressure tested using water as the pressurizing medium) to 50 psig (345 kPa gage pressure). The tank had work performed on some of the inside baffles prior to testing, and the hydrotest was conducted immediately after the . . . |
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A finished high-quality steel plate is subjected to ultrasonic inspection that makes five simultaneous measurements on a plate. What data can be obtained from this inspection? |
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Carbon steel piping was welded using Gas Tungsten Arc Welding (GTAW). The piping was installed and hydrostatically tested. During the hydrostatic test, one of the weld joints started to leak. Visual examination of the weld cap revealed what appeared to be . . . |
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Which of the following phenomena can usually be detected by visual examination using only a hand magnifier with up to 10X magnification? |
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