Q 1 .

Principle, procedure, advantage, limitation and application of Magnetic

particle test?
Magnetic Particle Test​: Magnetic Particle Testing (MPT), also referred to as
Magnetic Particle Inspection, is a nondestructive examination (NDE) technique used
to detect surface and slightly subsurface flaws in most ferromagnetic materials such
as iron, nickel, and cobalt, and some of their alloys.

Procedure​: the process begins by running a magnetic current through the

component. Any cracks or defects in the material will interrupt the flow of current and
will cause magnetism to spread out from them. This will create a “flux leakage field”
at the site of the damage.

The second step involves spreading metal particles over the component. If there are
any flaws on or near the surface, the flux leakage field will draw the particles to the
damage site. This provides a visible indication of the approximate size and shape of
the flaw.

Advantage​: It does not necessitate the degree of surface preparation required by

other nondestructive test methods, conducting MPT is relatively fast and easy.
It is highly portable, generally inexpensive, and does not need a stringent
pre-cleaning operation. MPT is also one of the best options for detecting fine,
shallow surface cracks. It is fast, easy, and will work through thin coatings

Limitation​: ​The material must be ferromagnetic. Likewise, the orientation and strength
of the magnetic field is critical.
Large currents are sometimes required to perform this method, thus “burning” of test
parts is sometimes possible. In addition, once MPT has been completed, the component
must be demagnetized, which can sometimes be difficult.

Q.2. Why cooling water system is needed in Diesel locos? What are the
problems arise in cooling water system & how is it solved?
Function: ​Heat of the components is taken away by cooling water in two ways:
By direct contact of cooling water with Diesel loco components.
Indirectly, by cooling lube oil which in turn cools Diesel loco components

Problems:
1. Scale formation
Scaling is deposition of mineral salt caused by precipitation of dissolved
impurities.
The most common type of scale is calcium carbonate.
Ca (HCO3)2+ heat= CaCO3+H2O + CO2
2. Fouling
The deposition of suspended particulate matter which was originally present
in insoluble form is called fouling.

A reliable practice is to use water having suspended solid less than 5ppm.

The most common foulant in engine cooling water system is corrosion product,
Fe2O3 (Rust), which is formed inside the system as a result of corrosion.

Foulant also reduce heat transfer similar to the scale.

3. Corrosion
a. Galvanic
This corrosion takes place when two metals are in electrical contact
with each other in presence of an electrolyte.

The intensity of attack will depend on the conductivity & polarization as

well as the distance from the contact point.

This type of corrosion can cause component failure by dip pitting at

anodic area.

This corrosion can be prevented ​by elimination of particular susceptible

metallic combination and use of corrosion inhibitor in cooling water.

b. Hydrogen
This may occur with iron, when H+ are developed & pH value is below
4 but for other metals, say Al, it occurs when the pH value is above 10.

It can be prevented​ by maintaining the pH of cooling water.

c. Oxygen Corrosion/Rusting
This type of corrosion takes place due to dissolved oxygen in cooling
water.

This causes sudden failure & plugging of radiator cooler.

It can be prevented​ by raising the alkalinity of water & absorbing the

oxygen from the system.

d. Cavitation
 Due to relative vibratory motion between the metal surface and cooling
water millions of bubbles are formed.

When these bubbles collapse it creates a tremendous pressure which

causes erosion on the metal surface.

4. Cavitation Erosion
Due to relative vibratory motion between the metal surface and cooling water
millions of bubbles are formed.

When these bubbles collapse it creates a tremendous pressure which causes

erosion on the metal surface.

5. Mechanical Erosion
This occurs due to vibration in different components which let in & let out
water molecules.

This progressively aids corrosion as well as erosion round the edge of

contact.

Q.3.a. AQL?
Q.3.b. What are different ‘levels of inspection’? At what context ‘Level III
inspection’ should be applied?

Q.4.a. Why short arc length is to be maintained for quality welding of SS?
The optimal arc length, or distance between electrode and puddle, is the same as
the diameter of the electrode (the actual metal part within the flux covering).

Holding the electrode too closely to the joint decreases welding voltage, which
creates an erratic arc that may extinguish itself or cause the electrode to freeze
faster and produces a weld bead with a high crown.

Excessively long arcs (too much voltage) produce spatter, low deposition rates,
undercuts and often leaves porosity.

Q.4.b. Different measures to restrict heat input during welding of SS?

Q.5.a.Composite materials? Give some examples related to Indian Railways.

A composite material is composed of at least two materials, which combine to give
properties superior to those of the individual constituents.
Most composites are made of just two materials. One is the matrix or binder. It
surrounds and
binds together fibres or fragments of the other material, which is called the
reinforcement.

Q.5.b. Important parameters on which properties of composite materials

depend?
Arrangement of fibres:
● Random
● Unidirectional
Selection of fibres:
● Continuous fibres
● Discontinuous fibres
● Particulate fibres

Q.6.a Different types of rubbers used in IR ? What are important tests related
to rubbers?
Q.6.b. List out the Green steps taken by IR to control Pollution?
1. Development of Emission test car.
2. Uses of alternative source of energy like BD & CNG
3. Process to develop electronic fuel injector.
4. Closure of foundry.
5. Implementation of ZDTS.
6. Out source the cleaning activity such as OBHS.etc

Q.7. a. Rockwell Hardness test

The Rockwell method measures the permanent depth of indentation produced by a
force/load on an indenter. First, a preliminary test force (commonly referred to as
preload or minor load) is applied to a sample using a diamond or ball indenter. This
preload breaks through the surface to reduce the effects of surface finish. After
holding the preliminary test force for a specified dwell time, the baseline depth of
indentation is measured.

After the preload, an additional load, call the major load, is added to reach the total
required test load. This force is held for a predetermined amount of time (dwell time)
to allow for elastic recovery. This major load is then released, returning to the
preliminary load. After holding the preliminary test force for a specified dwell time,
the final depth of indentation is measured. The Rockwell hardness value is derived
from the difference in the baseline and final depth measurements. This distance is
converted to a hardness number. The preliminary test force is removed and the
indenter is removed from the test specimen.

Test Method Illustration

A = Depth reached by indenter after application of preload (minor load)
B = Position of indenter during Total load, Minor plus Major loads
C = Final position reached by indenter after elastic recovery of sample material
D = Distance measurement taken representing difference between preload and
major load position. This distance is used to calculate the Rockwell Hardness
Number.

b.Cetane Number?
Hexadecane (100), alpha methyl naphthalene(0)
It is ignition quality of diesel fuel, is a measure of the delay that occurs in engine
between the fuel injection and combustion.

The ignition quality of diesel depends upon thermal stability and oxidizability of fuel.
This is expressed by Cetane Number as determined by a mixture of C16H34 which
has a high ignition quality and is given ​100 Cetane​ and Heptamethyl Nonane which
is given a Cetane Number 15. Cetane Number of the fuel is equal to: % of normal
Cetane + 0.15(% of Hepta
methyl Nonane ).

Method:
Cetane Number is determined with the help of CFR-F5 engine, in which Cetane
Number of diesel fuel is determined by comparing its ignition quality with those for
blends of reference fuel of known Cetane Number under standard operating
condition.
This is done by varying the compression ratio for the sample and each reference fuel
to obtain a fixed “delay period” that is the time interval between injection and ignition.
When the compression ratio for the sample is bracketed between those for two
reference fuel blend differing not more than 5 Cetane Number, the rating of the
sample is calculated by interpolation.

Significance:
If Cetane Number is increased the time of combustion is reduced. For high speed
engine high Cetane Number fuel is used and vice versa.

C. Storage of rubber?
D. Steels used in manufacturing of coaches and wagons of IR?
E. moisture in welding

Moisture in the flux, or electrode coating, is the principal source of hydrogen in weld
metal produced by flux-based arc welding processes.
● Increased arc voltage
● Spatter loss (liquid metal expelled from welding process. Spatter leaves
behind undesirable dots of metal.)
● Underbead cracking (which is not directly visible and which may result in
premature breaking of the joint)
● Poor slag removal
● Porosity in weld deposit