Failure analysis question bank.

Fatigue failure:
1. Which of the following is failure of material due to cyclic stress?
a) Brittle fracture
b) Ductile fracture
c) Creep
d) Fatigue
Answer: d

2. Which of the following is the most common type of failure in industry?

a) Brittle fracture
b) Ductile fracture
c) Creep
d) Fatigue
Answer: d

3. Below which point does fatigue occur?

a) Ultimate strength
b) Fracture point
c) Elastic limit
d) Yield point
Answer: d

4. Which of the following is not a zone of fatigue fracture?

a) Zone of crack nucleation
b) Fatigue zone
c) Elastic zone
d) Final fracture
Answer: c

5. In fatigue failure, the cyclic loading is typically applied at:

a) Constant stress
b) Constant strain
c) Constant temperature
d) Variable frequency
 Answer: a

6. Which of the following factors does NOT influence fatigue life?

a) Stress amplitude
b) Mean stress
c) Temperature
d) Material density
Answer: d

7. Fatigue cracks usually initiate at:

a) Areas with highest tensile stress
b) Areas with highest compressive stress
c) Neutral stress zones
d) Stress concentrations or defects
Answer: d

8. S-N curve in fatigue testing represents the relationship between:

a) Stress and strain
b) Stress amplitude and number of cycles to failure
c) Strain rate and time
d) Temperature and fatigue life
Answer: b

9. What does the term "endurance limit" refer to in the context of fatigue
failure?
a) The maximum stress a material can withstand indefinitely
b) The stress at which plastic deformation occurs
c) The stress at which fatigue cracks initiate
d) The stress at which brittle failure occurs
Answer: A

10. Which factor is often used to account for the effect of mean stress in
fatigue analysis?
a) Stress concentration factor
b) Goodman diagram
c) Modulus of elasticity
 d) Poisson's ratio
Answer: b

11. What is the primary reason for the reduction in fatigue strength at
high temperatures?
a) Increased ductility
b) Decreased thermal conductivity
c) Creep deformation
d) Lower material density
Answer: c

12. The concept of "fatigue loading spectrum" is used to:

a) Represent the variation of stress over time in a cyclic loading
scenario
b) Calculate the elastic modulus of a material
c) Determine the yield strength of a material
d) Assess the impact strength of a material
Answer: a

13. Which type of fatigue failure is characterized by the initiation of cracks

at a point and subsequent propagation in a radial pattern?
a) Surface fatigue
b) Subsurface fatigue
c) Fretting fatigue
d) Axial fatigue
Answer: a

14. What is the term used to describe the phenomenon where the rate of
crack growth in fatigue increases as the crack size increases?
a) Crack initiation
b) Paris Law
c) Griffith's criterion
d) Crack propagation
Answer: d

15. In fatigue testing, the loading condition where the load varies
continuously and smoothly over time is known as:
 a) Random loading
b) Step loading
c) Variable loading
d) Spectrum loading
Answer: a

16. Which of the following is a common method for improving fatigue

resistance in materials?
a) Increasing notch sensitivity
b) Reducing surface hardness
c) Shot peening
d) Introducing microcracks
Answer: c

17. What is the primary reason behind the existence of an "infinite life"
region in the S-N curve?
a) Material fatigue limit
b) Creep deformation
c) Elastic deformation
d) Fatigue crack initiation
Answer: a

18. The term "cyclically stable material" refers to a material that:

a) Exhibits consistent fatigue behavior over time
b) Experiences fatigue only in extreme temperature conditions
c) Undergoes cyclic hardening
d) Has a high fatigue limit
Answer: c

19. Which type of loading is most likely to cause fretting fatigue?

a) Axial loading
b) Rotational loading
c) Oscillatory loading with small amplitudes
d) Static loading
Answer: c

20. In fatigue analysis, what is the purpose of the Miner's rule?

 a) To calculate the modulus of elasticity
b) To predict the time to failure due to creep
c) To estimate the total damage accumulation from different load
cycles
d) To determine the critical crack size for fatigue failure
Answer: c

21. The term "gigacycle fatigue" is often used to describe fatigue failure
that occurs at:
a) Low stress amplitudes
b) High stress amplitudes
c) Moderate stress amplitudes
d) Elevated temperatures
Answer: a

22. Which factor is NOT typically considered in the design against fatigue
failure?
a) Material strength
b) Surface finish
c) Operating temperature
d) Electrical conductivity
Answer: d

23. In the given stress cycle, the range of stress is equal to ________

a) A
b) B
c) C
d) D
Answer: d
24. In the given stress cycle, the alternating stress is equal to ________

a) A
b) B
c) C
d) D
Answer: a

25. The mean stress is indicated by which point in this stress cycle?

a) A
b) B
c) C
d) D
Answer: c
26. In the following stress cycle, the stress amplitude is indicated by
which point in this curve?

a) A
b) B
c) C
d) D
Answer: c

Ductile and brittle failure

27. What is the primary characteristic of ductile failure?

a) Sudden fracture
b) Limited plastic deformation
c) Extensive plastic deformation
d) High brittleness
Answer: c

28. In ductile materials, failure is often preceded by:

a) Brittle cracking
b) Necking
c) Creep deformation
d) Hardening
Answer: b

29. Which of the following materials is typically associated with brittle

failure?
a) Rubber
b) Aluminum
c) Glass
d) Copper
 Answer: c

30. The ability of a material to deform plastically before fracture is known

as:
a) Toughness
b) Hardness
c) Brittleness
d) Resilience
Answer: a

31. In _____________ fracture, the crack grows at a slow pace and a lot
of plastic deformation occurs.
a) Ductile
b) Brittle
c) Fatigue
d) De-cohesive
Answer: a

32. ___________ amount of energy strain is required for ductile fracture.

a) Higher
b) Lower
c) Intermediate
d) Can’t say
Answer: a

33. What term is referred to the failure of highly ductile materials?

a) Ductile rupture
b) Orange peel
c) Patenting
d) Buckling
Answer: a

34. Brittle fracture is characterized by:

a) Ductile tearing
b) Microvoid coalescence
c) Rapid crack propagation
d) Necking
 Answer: c

35. The presence of which type of bond is often associated with brittle
materials?
a) Metallic
b) Ionic
c) Covalent
d) Van der Waals
Answer: c

36. Which type of loading is more likely to cause ductile failure?

a) Tensile loading
b) Compressive loading
c) Shear loading
d) Impact loading
Answer: a

37. At room temperature, which of the following materials is more prone

to brittle fracture?
a) Mild steel
b) High-strength aluminum alloy
c) Cast iron
d) Ductile iron
Answer: c

38. The fracture toughness of a material is a measure of its resistance to:

a) Creep deformation
b) Ductile fracture
c) Brittle fracture
d) Hardening
Answer: c

39. Which failure mode is often associated with the formation of dimples
on the fracture surface?
a) Ductile failure
b) Brittle failure
c) Creep failure
 d) Fatigue failure
Answer: a

40. What appearance does ductile fracture under microscope give?

a) Irregular and rough
b) Smooth
c) Plate like
d) Shiny
Answer: a

41. Ductile fracture generally occurs in ____________

a) Metals
b) Ceramics
c) Plastics
d) Composites
Answer: a

42. In what matter ductile fracture occurs?

a) Trans granular
b) Intra granular
c) Catastrophically
d) Shear fracture
Answer: a

43. Which material fails by brittle fracture?

a) White cast iron
b) Steel
c) Aluminum
d) Copper
Answer: a

44. Which of the following materials don’t give brittle fracture?

a) White cast iron
b) Grey cast iron
c) Aluminum
d) Ceramics
Answer: c
45. When does brittle fracture is noticed?
a) On overloading
b) On sudden loading
c) Uniaxial loading
d) Compressing
Answer: b

46. What is characteristic of brittle fracture?

a) Prior warning
b) High speed
c) Necking
d) Ductile rupture
Answer: b

47. Which of the following fracture modes is associated with a flat and
featureless fracture surface?
a) Ductile fracture
b) Brittle fracture
c) Fatigue fracture
d) Creep fracture
Answer: b

48. The transition from ductile to brittle behavior in a material is

influenced by:
a) Temperature
b) Material density
c) Hardness
d) Elastic modulus
Answer: a

In a stress-strain curve, the point at which necking begins is often

followed by:
a) Ultimate tensile strength
b) Yield point
c) Fracture point
d) Plastic deformation
 Answer: c

49. The fracture surface of a brittle material often exhibits:

a) Dimples
b) Microvoids
c) Cleavage planes
d) Necking patterns
Answer: c

50. Which type of loading is more likely to induce brittle fracture in a

previously ductile material?
a) Slow, controlled loading
b) Rapid impact loading
c) Cyclic loading
d) Creep loading
Answer: b

51. The presence of impurities or defects tends to promote:

a) Ductile behavior
b) Brittle behavior
c) Creep deformation
d) Plastic deformation
Answer: b

52. What is the critical flaw size concept related to in brittle fracture
analysis?
a) Creep resistance
b) Fatigue resistance
c) Stress concentration
d) Material toughness
Answer: c

53. Which type of fracture is typically characterized by a cup-and-cone

pattern on the fracture surface?
a) Brittle fracture
 b) Ductile fracture
c) Creep fracture
d) Fatigue fracture
Answer: b

54. The Charpy impact test is commonly used to assess the:

a) Ductility of a material
b) Brittleness of a material
c) Creep resistance of a material
d) Fatigue resistance of a material
Answer: b

55. What factor is critical in determining whether a material will fail in a

ductile or brittle manner under a given set of conditions?
a) Elastic modulus
b) Temperature
c) Density
d) Yield strength
Answer: b

Mechanical failure.

56. Which of the following is a primary factor contributing to mechanical

failure in materials?
a) Electrical conductivity
b) Thermal expansion
c) Stress concentration
d) Chemical stability
Answer: c

57. The term "yield strength" is associated with:

a) The maximum stress a material can withstand
b) The stress at which plastic deformation begins
c) The resistance of a material to fatigue
d) The ability of a material to absorb impact energy
Answer: b
58. What is the primary reason for introducing fillets and chamfers in
mechanical design?
a) Aesthetics
b) Stress concentration reduction
c) Surface finish improvement
d) Weight reduction
Answer: b

59. Which mechanical failure mode is characterized by permanent

deformation without fracture?
a) Brittle failure
b) Ductile failure
c) Fatigue failure
d) Creep failure
Answer: b

60. The fatigue limit of a material is defined as the stress level at which:
a) Plastic deformation begins
b) Fatigue cracks initiate
c) No fatigue failure occurs under cyclic loading
d) Creep deformation is observed
Answer: c

61. In a stress-strain curve, the point beyond which the material

undergoes rapid elongation with little increase in stress is called the:
a) Ultimate tensile strength
b) Yield point
c) Necking point
d) Fracture point
Answer: c

62. What type of loading is most likely to cause buckling as a mode of

mechanical failure?
a) Axial compression
b) Tensile loading
c) Shear loading
d) Torsional loading
 Answer: a

63. Which mechanical property is defined as the ability of a material to

absorb energy before fracture?
a) Hardness
b) Toughness
c) Brittleness
d) Ductility
Answer: b

64. The concept of stress concentration is particularly important in the

analysis of materials under:
a) Static loading
b) Dynamic loading
c) Torsional loading
d) Compressive loading
Answer: c

65. What is the primary purpose of adding reinforcements, such as fibers

or particles, in composite materials?
a) Improve thermal conductivity
b) Increase electrical resistance
c) Enhance mechanical strength
d) Reduce density
Answer: c

Distortion failure.

66. Distortion failure in materials is commonly caused by:

a) Tensile loading
b) Compressive loading
c) Residual stresses
d) Creep deformation
Answer: c

67. What is the primary role of heat treatment in minimizing distortion in

metal components?
 a) Increase hardness
b) Reduce residual stresses
c) Enhance electrical conductivity
d) Improve corrosion resistance
Answer: b

68. Distortion in a welded structure is often attributed to:

a) High welding temperature
b) Low welding speed
c) Weld metal composition
d) Welding electrode diameter
Answer: c

69. Which factor is crucial in preventing distortion during the machining of

precision components?
a) Cutting speed
b) Tool material
c) Feed rate
d) Lubrication
Answer: a

70. The term "springback" refers to the phenomenon where a material:

a) Experiences elastic deformation
b) Undergoes plastic deformation
c) Retains residual stresses
d) Exhibits shape recovery after deformation
Answer: d

71. Residual stresses in a material can lead to distortion during:

a) Casting
b) Quenching
c) Annealing
d) Hot rolling
 Answer: a

72. What is the primary reason for using fixtures and clamps in
manufacturing processes?
a) Improve surface finish
b) Reduce distortion
c) Increase material hardness
d) Enhance electrical conductivity
Answer: b

73. In sheet metal forming, the occurrence of wrinkles and warping is

associated with:
a) High forming temperature
b) Low forming pressure
c) Insufficient lubrication
d) Excessive material thickness
Answer: c

74. Which material property is critical in minimizing distortion during the

heat treatment of components?
a) Thermal conductivity
b) Ductility
c) Young's modulus
d) Coefficient of thermal expansion
Answer: a

75. The term "residual stress relief" is often associated with:

a) Quenching
b) Annealing
c) Tempering
d) Hardening
Answer: b
76. Distortion in polymers during processing can be minimized by
controlling:
a) Molecular weight
b) Glass transition temperature
c) Crystallinity
d) Impact strength
Answer: c

77. Which type of distortion is commonly associated with non-uniform

cooling rates in castings?
a) Warping
b) Springback
c) Creep distortion
d) Residual distortion
Answer: a

78. In metal forming processes, distortion due to uneven stress

distribution is often referred to as:
a) Wrinkling
b) Shearing
c) Bowing
d) Cupping
Answer: c

79. The distortion known as "camber" is typically observed in:

a) Forged components
b) Welded structures
c) Sheet metal parts
d) Machined surfaces
Answer: c

80. Distortion in machined components can be minimized by using:

a) High cutting speed
b) Coarse feed rate
c) Hardened cutting tools
d) Dry machining
 Answer: c

81. Which factor is crucial in preventing distortion during the heat

treatment of thin-walled components?
a) Quenching rate
b) Annealing temperature
c) Surface finish
d) Young's modulus
Answer: c

82. The phenomenon of "thermal buckling" is often observed in structures

subjected to:
a) Dynamic loading
b) Torsional loading
c) Elevated temperatures
d) Compressive loading
Answer: c

83. Distortion due to uneven cooling rates in welding is minimized by

employing:
a) Preheating
b) High welding speed
c) Narrow weld beads
d) Low heat input
Answer: a

84. The distortion known as "twist" is commonly associated with:

a) Forging
b) Casting
c) Rolling
d) Turning
Answer: d

85. Which property is most critical in minimizing distortion during the heat
treatment of composite materials?
a) Tensile strength
b) Elastic modulus
 c) Coefficient of thermal expansion
d) Hardness
Answer: c

Wear failure.

86. What is the primary mechanism responsible for wear failure in

materials?
a) Creep deformation
b) Fatigue cracking
c) Surface interactions
d) Residual stresses
Answer: c

87. Abrasive wear is characterized by the presence of:

a) Smooth wear scars
b) Grooves and scratches
c) Plastic deformation
d) Surface oxidation
Answer: b

88. Which type of wear is associated with the gradual removal of material
due to adhesive forces between surfaces?
a) Abrasive wear
b) Adhesive wear
c) Erosive wear
d) Fretting wear
Answer: b

89. The lubrication method that involves placing a solid between two
moving surfaces to reduce wear is called:
a) Boundary lubrication
b) Hydrodynamic lubrication
c) Solid lubrication
d) Anti-friction lubrication
Answer: c
90. Which property of a material is most critical in determining its
resistance to abrasive wear?
a) Hardness
b) Ductility
c) Toughness
d) Elastic modulus
Answer: a

91. The phenomenon of wear that occurs due to repeated small-scale

sliding or oscillatory motion is known as:
a) Adhesive wear
b) Fretting wear
c) Abrasive wear
d) Erosive wear
Answer: B

92. Which wear mechanism is commonly observed in rolling contact

bearings?
a) Sliding wear
b) Rolling wear
c) Erosive wear
d) Fretting wear
Answer: B

93. The wear mode characterized by the formation of tiny cracks and
particles that are detached from the surface is called:
a) Abrasive wear
b) Fatigue wear
c) Adhesive wear
d) Erosive wear
Answer: B

94. The term "tribology" encompasses the study of:

a) Material hardness
b) Wear, friction, and lubrication
c) Creep deformation
d) Fatigue cracking
 Answer: B

95. Which factor is often used to assess the wear resistance of a material
under specific conditions?
a) Coefficient of friction
b) Wear rate
c) Ultimate tensile strength
d) Young's modulus
Answer: B

96. Flank wear depends upon the

a) hardness of the work and tool material at the operating temperature
b) amount and distribution of hard constituents in the work material
c) degree of strain hardening in the chip
d) none of the mentioned
Answer: b

97. Crater wear is predominant in

a) carbon steels
b) tungsten carbide tools
c) high speed steel tools
d) ceramic tools
Answer: b

98. Crater wear is mainly due to the phenomenon is known as

a) adhesion of metals
b) oxidation of metals
c) diffusion of metals
d) none of the mentioned
Answer: c

99. Crater wear leads to

a) increase in cutting temperature
b) weakening of tool
c) friction and cutting forces
d) all of the mentioned
Answer: d
100. Which type of wear occurs due to the repeated impact of solid
particles on a material's surface?
a) Adhesive wear
b) Abrasive wear
c) Erosive wear
d) Fretting wear
Answer: c

101. The wear mode in which material is removed by the relative

motion of contacting surfaces is known as:
a) Abrasive wear
b) Fatigue wear
c) Adhesive wear
d) Erosive wear
Answer: a

102. In which scenario is boundary lubrication most effective in

preventing wear?
a) High-speed applications
b) Low-speed, heavy-load applications
c) No relative motion between surfaces
d) Harsh environmental conditions
Answer: b

103. Which factor is NOT typically considered a parameter affecting

wear in sliding contacts?
a) Load
b) Velocity
c) Temperature
d) Density
Answer: d

104. The wear mechanism characterized by the formation of wear

debris due to localized welding and tearing is called:
a) Adhesive wear
b) Abrasive wear
 c) Fretting wear
d) Erosive wear
Answer: c

105. The wear mode that is often caused by the repetitive impact of
particles at a material's surface is known as:
a) Abrasive wear
b) Fretting wear
c) Fatigue wear
d) Erosive wear
Answer: c

106. Which type of lubrication involves the use of a fluid film to

separate moving surfaces and reduce wear?
a) Solid lubrication
b) Boundary lubrication
c) Hydrodynamic lubrication
d) Anti-friction lubrication
Answer: c

107. The term "wear rate" is defined as:

a) The rate of material removal due to wear
b) The rate of surface oxidation
c) The rate of fatigue cracking
d) The rate of creep deformation
Answer: a

108. Which wear mode is commonly observed in situations where

two surfaces undergo repeated microscopic relative motion?
a) Adhesive wear
b) Abrasive wear
c) Erosive wear
d) Fretting wear
Answer: d

109. The coefficient of friction is a crucial parameter in wear analysis

because it indicates the resistance to:
 a) Material strength
b) Creep deformation
c) Surface oxidation
d) Relative motion between surfaces
Answer: d

Creep failure.

110. What is creep failure?

a. Sudden material fracture
b. Gradual deformation over time under constant load
c. Elastic deformation only
d. Plastic deformation only
Answer: b

111. Which of the following materials is most susceptible to creep

failure?
a. Steel
b. Rubber
c. Concrete
d. Glass
Answer: c

112. Creep is influenced by:

a. Temperature and stress
b. Material density
c. Color and texture
d. Hardness and ductility
Answer: a

113. The primary driving force behind creep is:

a. Gravity
b. Temperature
c. Pressure
d. Magnetic forces
Answer: b
114. At higher temperatures, the rate of creep:
a. Decreases
b. Increases
c. Remains constant
d. Becomes unpredictable
Answer: b

115. Which of the following is a common method to mitigate creep

failure?
a. Cooling the material
b. Increasing the load
c. Reducing material thickness
d. Adding impurities to the material
Answer: a

116. Creep is a time-dependent phenomenon primarily associated

with:
a. Dynamic loads
b. Static loads
c. Impact loads
d. Fatigue loads
Answer: b

117. In which industry is creep failure a significant concern?

a. Information technology
b. Fashion
c. Aerospace
d. Entertainment
Answer: c

118. What role does stress play in creep failure?

a. Higher stress accelerates creep
b. Lower stress accelerates creep
c. Stress has no effect on creep
d. Stress reverses creep
Answer: a
119. Creep testing is commonly conducted at:
a. Room temperature
b. Elevated temperatures
c. Low temperatures
d. Atmospheric pressure
Answer: b

120. Which of the following is a primary concern in the design of

structures operating at high temperatures?
a. Elastic deformation
b. Creep deformation
c. Plastic deformation
d. Brittle fracture
Answer: b

121. What is the typical unit for measuring creep rate?

a. Newtons per square meter (N/m²)
b. Meters per second (m/s)
c. Degrees Celsius (°C)
d. Percent per hour (%/hr)
Answer: d

122. What role does grain size play in the susceptibility to creep
failure?
a. Larger grain size increases susceptibility
b. Smaller grain size increases susceptibility
c. Grain size has no effect on creep
d. Grain size is inversely proportional to creep
Answer: b

123. In the power generation industry, which material property is

crucial to resist creep in high-temperature environments?
a. Conductivity
b. Elastic modulus
c. Creep strength
d. Color
 Answer: c

124. What is the phenomenon where creep deformation accelerates

with time under constant stress?
a. Primary creep
b. Secondary creep
c. Tertiary creep
d. Quaternary creep
Answer: c

125. Which temperature range is generally associated with high-

temperature creep?
a. 0-100°C
b. 100-300°C
c. 300-600°C
d. 600-1000°C
Answer: c

126. Which type of load is particularly detrimental to materials prone

to creep failure?
a. Constant load
b. Cyclical load
c. Variable load
d. Impact load
Answer: a

127. What is the term for the gradual deformation that occurs at
stresses below the yield point but over an extended period?
a. Plastic deformation
b. Elastic deformation
c. Creep deformation
d. Tensile deformation
Answer: c
128. Which factor is NOT considered a primary factor influencing
creep?
a. Stress
b. Temperature
c. Pressure
d. Material color
Answer: d

129. Creep curves typically exhibit three distinct regions. What are
these regions called?
a. Primary, secondary, and tertiary
b. Elastic, plastic, and brittle
c. Slow, moderate, and fast
d. Initial, intermediate, and final
Answer: a

130. In the dislocation creep mechanism of the creep, the rate-

controlling step is ____________
a) rate of recovery
b) rate strain hardening
c) atomic diffusion
d) dislocation glide
Answer: c

131. The power-law relation is used to describe the ____________

a) creep elongation
b) creep mechanism
c) creep rate
d) fracture behavior
Answer: b