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MACHINE DESIGN

MANUFACTURING
PROCESSES AND METALS
PART 4
ES MECHANICAL ENGINEERING REVIEW

EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW


1
MEMBERS
1. A second type of primary bond is the
A. Metallic bond
B. Covalent bond
C. Ionic bond
D. Wooden bond

The answer is: B

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2
MEMBERS
2. Iron forms bcc structure (gamma iron) between
912 ̊C and _________.
A. 1194 ̊C
B. 1294 ̊C
C. 1394 ̊C
D. 1494 ̊C

The answer is: C


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3
MEMBERS
3. The effect of an increase in shear stress that
causes an increase in the overall strength of the
metal is known as
A. Grain boundaries
B. Edge and screw
C. Work hardening or strain hardening
D. Polycrystals
The answer is: C

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4
MEMBERS
4. If we continue to increase the temperature of the
metal, the grain begins to grow, and their size may
eventually exceed the original grain size. This
phenomenon is called:
A. Recrystallization
B. Grain growth
C. Diffusion
D. Orange peel
The answer is: B

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5
MEMBERS
5. Is also used to specify the point where the
stress and strain cease being proportional
A. Linear and elastic behavior
B. Engineering stress or nominal stress
C. Yield stress
D. Proportional limit

The answer is: D

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6
MEMBERS
6. Because of the lowered yield stress in the
direction opposite the original load application, this
phenomenon is called:
A. Strain softening
B. Disk test
C. Seamless tubing
D. Torsion test
The answer is: A

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7
MEMBERS
7. Caused by fluctuating mechanical loads, such as on
gear teeth, or by thermal stress, such as on cool die
coming into repeated contact with hot work piece.
A. Hot hardness
B. Cyclic stress
C. Fatigue failure
D. Stress amplitude

The answer is: B

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8
MEMBERS
8. Is the phenomenon in which carbon atoms in steels
segregate to dislocations, thereby pinning them and, in
this way, increasing the resistance to dislocation
movement.
A. Strain aging
B. Mechanical fibering
C. Strain aging
D. Blue brittleness
The answer is: C

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9
MEMBERS
9. Residual stresses can also be caused by within a
body, such as occur during the cooling of a casting or
forging.
A. Oxygen
B. Warping of parts
C. Temperature gradient
D. Stress- relief annealing

The answer is: C

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10
MEMBERS
10. Is the term generally used to describe development of
cracks after a single thermal cycle.
A. Shrink Fits
B. Thermal Fatigue
C. Thermal shock
D. Anisotropy of thermal expansion

The answer is: C

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11
MEMBERS
11. The interface of bolted or riveted joints as:
A. Inter-granular corrosion
B. Crevice corrosion
C. Galvanic corrosion
D. Stress- corrosion cracking

The answer is: B

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12
MEMBERS
12. Alpha ferrite is a solid solution of body-centered cubic
iron; it has a maximum solid solubility of 0.022% carbon
at temperature of 727 ̊C.
A. Alpha ferrite
B. Curie temperature
C. Hypoeutictoid
D. Delta ferrite

The answer is: A

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13
MEMBERS
13. Has essentially all of its carbon in the form of iron
carbide and receives its name from the white surface that
appears when the materials is fractured.
A. Nodular iron
B. White cast iron
C. Malleable iron
D. Ferritic malleable iron

The answer is: B

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14
MEMBERS
14. Is visible as white areas in the structure along with
the dark, needlelike martensite.
A. Retained austenite
B. Mechanical properties
C. Tempering
D. Hardenability

The answer is: A

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15
MEMBERS
15. Produces an increase in strength by means of plastic
deformation under cold-working conditions.
A. Aging
B. Age hardening
C. Precipitation hardening
D. Strain hardening

The answer is: D

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16
MEMBERS
16. Surface is heated with an oxyacetylene torch, then
quenched with water spray or other quenching method.
A. Flame hardening
B. Induction hardening
C. Decarburization
D. Annealing

The answer is: A

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17
MEMBERS
17. Are commonly used in various heat-treating
operations, particularly for nonferrous strip and wire.
A. Continuous furnaces
B. Salt-bath furnace
C. Fluidized beds
D. Induction heating

The answer is: B

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18
MEMBERS
18. The function of limestone is to:
A. Generate the high level of heat
B. Remove carbon monoxide
C. Add plastics and chemical compounds
D. Remove impurities from the molten iron.

The answer is: D

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19
MEMBERS
19. Electric furnace capacities ranges:
A. From 60 to 80 tons of steel per day
B. From 60 to 90 tons of steel per day
C. From 60 to 100 tons of steel per day
D. From 60 to 110 tons of steel per day

The answer is: B

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20
MEMBERS
20. Improves hardenability, without the loss of
machinability and formability
A. Boron
B. Calcium
C. Carbon
D. Cerium

The answer is: C

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21
MEMBERS
21. Severely embrittles steels; however, heating during
processing drives out most of the hydrogen.
A. Hydrogen
B. Nitrogen
C. Oxygen
D. Tin

The answer is: A

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22
MEMBERS
22. Are characterized primarily by their corrosion
resistance, high strength and ductility, and high chromuim
content.
A. Dual-phase steels
B. Stainless steels
C. Weathering steels
D. Structural-grade alloy steels

The answer is: B

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23
MEMBERS
23. These steels have a mixture of austenite and ferrite.
They have good strength, and they have higher
resistance to both corrosion and stress-corrosion
cracking than to the 300 series of austenitic steels.
A. Austenitic stainless steels
B. Ferritic stainless steels
C. Martensitic stainless steels
D. Duplex structure stainless steel
The answer is: D

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24
MEMBERS
24. A turbofan jet engine for the Boeing 757 aircraft
typically contains the following nonferrous metals 38%
titanium, 37% nickel, 12% chromium, 6% cobalt, 5%
aluminum, 1% niobium and __________.
A. 0.01%
B. 0.02%
C. 0.03%
D. 0.04%
The answer is: B

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25
MEMBERS
25. Is the third most abundant metallic element(2%0 in
the earth’s crust coming after iron and aluminum.
A. Porous Aluminum
B. Magnesium
C. Copper
D. Brass

The answer is: B

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26
MEMBERS
26. The dry cooper concentrate, as much as one-third of
which is copper, is traditionally smelted and refined. This
process is known as:
A. pyrometallurgy
B. Hydrometallurgy
C. Technometallurgy
D. Evaporametallurgy

The answer is: A

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27
MEMBERS
27. Is used for low sensitivity to temperature.

A. Monel K-500
B. Hastelloy C-4
C. Hastelloy
D. Invar

The answer is: D

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28
MEMBERS
28. A silver –white metal, was discovered in the 18th
century.

A. Molybdenum
B. Titanium and Zirconium
C. Mineral molybdenite
D. Niobium
The answer is: A

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29
MEMBERS
29. An alloy of copper and nickel.

A. Niobium
B. Tungsten
C. Tantalum
D. berylium

The answer is: D

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30
MEMBERS
30. Are common soldering materials with wide’range of
compositions and melting points.
A. Babbit
B. Tin alloys
C. Tin
D. Tin-lead

The answer is: D

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31
MEMBERS
31. most common example of polymer
A. Plastics
B. Polymer
C. Cellulose
D. Bakellite

The answer is: C

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32
MEMBERS
32. The increase in density with increase crystallinity is
called:
A. Amorphous
B. Crystallites
C. Crystallization shrinkage
D. elastomer

The answer is: C

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33
MEMBERS
33. Have excellent resistance to heat, water, and steam;
they have dielectric properties that are virtually affected
by humidity, and they are highly resistant to chemicals.
A. Polypropylenes
B. Polystyrenes
C. Polysulfones
D. Polyvinyl chloride

The answer is: C

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34
MEMBERS
34. The most common example of clay is:
A. Ceramics
B. Ceramics
C. Clay
D. Kaolin

The answer is: D

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35
MEMBERS
35. Have a high crystalline component to their structure;
good thermal-shock resistance and strong
A. Silica
B. Glasses
C. Glass ceramics
D. graphite

The answer is: C

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36
MEMBERS
36. Is an amorphous solid with the structure of a liquid.
A. Glass
B. Silica
C. Lampback
D. Bukyballs

The answer is: A

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37
MEMBERS
37. Sprue, runners, and gates are known as:
A. Pyrolysis
B. Kelvar
C. Gating system
D. Sprue

The answer is: C

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38
MEMBERS
38. The temperatures for carbonizing range up to about:
A. 1300 ̊C
B. 1400 ̊C
C. 1500 ̊C
D. 1600 ̊C

The answer is: C

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39
MEMBERS
39. Were first as matrix material in the 1930’s.
A. Formica
B. Epoxies
C. Reinforced plastics
D. Ceramic matrix

The answer is: B

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40
MEMBERS
40. Is that portion of the runner through which the molten
metal enters the mold cavity.
A. Sprue
B. runners
C. gates
D. risers

The answer is: C

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41
MEMBERS
41. The traditional method for casting metals.
A. Expendable molds
B. Permanent molds
C. Composite molds
D. Sand casting

The answer is: D

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42
MEMBERS
42. Are used to mold the sand mixture into the
shape of the casting.
A. Two-piece mold
B. Cores
C. Vents
D. Pattern

The answer is: D

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43
MEMBERS
43. Uses a polystyrene pattern, which evaporates
upon contact with mollen metal to form a cavity for
A. Shell-mold casting
B. Composite molda
C. Rammed graphite molding
D. Expendable pattern

The answer is: D


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44
MEMBERS
44. Are usually square, with a cross-sectional are
smaller than blooms and further rolled into round
rods and bars.
A Bloom or slab
B. Bloom
C. Slab
D. Billets

The answer is: D


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45
MEMBERS
45. is a cold-forming process by which straight or
tapered threads are formed on round rods, by
passing them between dies.
A. Ring-rolling
B. Thread rolling
C. Forming tap
D. Rotary tube piercing

The answer is: B


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46
MEMBERS
46. Material is distributed away from an area.
A. Impression-die forging
B. Flash
C. Fullering
D. Edging

The answer is: C


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47
MEMBERS
47. Rotary swaging is also known as:
A. Incremental forging
B. Isothermal forging or hot-die forging
C. Swaging
D. Radial forging or swaging
The answer is: D
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48
MEMBERS
48. The die moves toward the billet.
A Drawing
B. Indirect extrusion
C. Hydrostatic extrusion
D. Lateral or side extrusion

The answer is: B


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49
MEMBERS
49. In the sheared slug is discarded.
A. Burr
B. Punching
C. Shearing
D. Blanking

The answer is: B


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50
MEMBERS
49. In the sheared slug is discarded.
A. Burr
B. Punching
C. Shearing
D. Blanking

The answer is: B


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51
MEMBERS
50. Is actually a finishing operation in which a
small amount of metal is sheared away from the
edge of an already blanked part.
A. Nibbling
B. Shaving
C. Cutoff
D. Dinking

The answer is: B


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52
MEMBERS
51. An important development in testing the
formability of sheet metal is the_______
A. Stretch forming
B. Anisotropy
C. Forming-limit diagram
D. Bend allowance

The answer is: C


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53
MEMBERS
52. The process of thinning the walls of a drawn
cylinder by passing it between a punch and die whose
separation is less than the original wall thickness
A. Drawbeads
B. Ironing
C. Redrawing
D. Embossing

The answer is: B


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54
MEMBERS
53. Certain operations can be carried out using lasers as
a localized heat source, to reduce the flow stress of the
sheet metal at specific locations and to improve
formability and increase process flexibility.
A. Laser-assisted forming
B. Electrohydraulic forming
C. Honeycomb structure
D. Dents

The answer is: A


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55
MEMBERS
54. The powder is encased in a metal container
and extruded.
A. Hot isostatic pressing
B. Injection molding
C. Roll compaction
D. Compacted by extrusion

The answer is: D


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56
MEMBERS
55. Can be sintered at lower temperature to give
the ceramic part its final shape.
A. Jiggering
B. Hot pressing or pressure sintering
C. Firing
D. Nanophase ceramics

The answer is: D


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57
MEMBERS
56. This is a process in which the resin and fibers
are combined at the time of curing.
A. Centrifugal casting
B. Potting
C. Encapsulation
D. Filament winding

The answer is: D


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58
MEMBERS
57. The _______in turning on a lathe is found to be
proportional to the cutting speed and feed.
A. Shaving
B. Dynamometers or force transducers
C. Mean temperature
D. Thermocouples

The answer is: C


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59
MEMBERS
58. A ______ with positive rake angle at the tool tip may
also be used to reduce cutting forces without reducing
the overall strength of the insert significantly.
A. Tool steels
B. Diamond grinding
C. Chip groove
D. Carbide inserts

The answer is: C


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60
MEMBERS
59. To meet the challenge of higher speeds for
higher production rates, ________ introduced in
1930's.
A. Molybdenum and Tungsten
B. Cast-cobalt alloys
C. Cast-cobalt alloys
D. Carbide or cemented of sintered carbide

The answer is: D


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61
MEMBERS
60. Types of cutting fulds commonly used in
machining operations:
A. Oils
B. Emulsions
C. Semisynthetics and Synthetics
D. All of these

The answer is: D


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62
MEMBERS
61. Control interference and rubbing at the tool
workpiece interference.
A. Rake angles
B. Back rake angle
C. Relief angles
D. Cutting-edge angles

The answer is: C


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63
MEMBERS
62. Is usually equipped with three or four jaws.
A. Engine lathe
B. Gap bed lathe
C. Special-purpose lathes
D. Chuck

The answer is: D


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64
MEMBERS
63. Are capable of performing multiple cutting
operations, such as turning, boring, drilling, thread
cutting, and facing, on the same workpiece.
A. Tracer lathes
B. Automatic lathes
C. Automatic Bar Machines
D. Turret lathe

The answer is: D


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65
MEMBERS
64. Are mass-production machines with as many s
50 spindles driven by a single powerhead and fed
simultaneously into the work.
A. Gang-drilling machine
B. Turret-type drilling machines
C. Radial drilling machine tools
D. Multiple-spindle drilling machines

The answer is: D


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66
MEMBERS
65. Has nicks along the cutting edge to break up
the heavy chips that result as a cylindrical hole is
cut to a taper.
A. Expansion reamers
B. Adjustable reamers
C. Taper reamers
D. Roughing reamers

The answer is: B


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67
MEMBERS
66. Cutting starts at the surface of the workpiece
where the chip is at its thickest.
A. Slab milling or peripheral milling
B. Conventional milling or up milling
C. Climb milling or down milling
D. Face milling

The answer is: C


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68
MEMBERS
67. Is a relatively simple cutting operation by which flat
surfaces, as well as various CTOSS sections with
grooves and notches, are produced along the length of
the workpiece.
A. Planning
B. Shaping
C. Slotters or Vertical shapers
D. Broaching

The answer is: A


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69
MEMBERS
68. Tooth spacing is usually in the range of
A. 0.08 to 0.25 teeth per mm
B. 0.08 to 1.25 teeth per mm
C. 0.08 to 1.35 teeth per mm
D. 0.08 to 1.45 teeth per mm

The answer is: B


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70
MEMBERS
69. Are mixture of crushed concrete and plastic.
A. Gray iron
B. Polymer concrete
C. Ceramic
D. Composites

The answer is: B


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71
MEMBERS
70. The common bond types for bonded are:
A. Grit number
B. Vetrified, resinoid, rubber and metal
C. Ceramic bond
D. Resinoid

The answer is: B


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72
MEMBERS
71. Is the process of producing sharp new edges on
grains, conditioning worn grains on the surface of a
grinding wheel, and truing an out-of-round wheel.
A. Grinding wheel
B. Attritious wear
C. Dressing
D. Loading

The answer is: C


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73
MEMBERS
72. Parts with diameters as small as______ can
be ground.
A. 0.10 mm
B. 0.20 mm
C. 0.30 mm
D. 0.40 mm

The answer is: A


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74
MEMBERS
73. The tip of the tool of ultrasonic machining
vibrates at a frequency of:
A. 5 Khz
B. 10 Khz
C. 15 Khz
D. 20 Khz

The answer is: D


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75
MEMBERS
74. Is the oldest of the non-traditional machining process,
and has been used to engrave metals and hard stones, in
deburring, and more recently in the production of printed-
circuit boards and microprocessor chips.
A. Chemical machining
B. Chemical milling
C. Chemical blanking
D. Photochemical blanking
The answer is: B
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76
MEMBERS
75. Can be used for very accurate cutting of a wide
variety of metals.
A. Electron-beam machining
B. Laser-beam machining
C. Plasma-arc cutting
D. Abrasive water-jet machining

The answer is: A


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77
MEMBERS
76. This method of welding two components starts with
the heating of the interface by means of a torch using,
typically, oxyacetylene gas.
A. Filler materials
B. Pressure gas welding
C. Arc welding
D. Sheilded metal-arc welding

The answer is: B


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78
MEMBERS
77. Electroslag welding is capable of welding plates.. with
thicknesses ranging from:
A.50 mm to more than 600 mm
B. 50 mm to more than 700 mm
C. 50 mm to more than 800 mm
D. 50 mm to more than 900 mm

The answer is: D


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79
MEMBERS
78. The energy required for frictional heating is supplied
by the kinetic energy of flywheel.
A. Cold welding
B. Ultrasonic welding
C. Friction welding
D. Inertia friction welding

The answer is: D


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80
MEMBERS
79. Results from the melting away of the base metal and
the consequent generation of a groove in the shape of a
sharp recess or nothch.
A. Weld profile
B. Undercutting
C. Overlap
D. Cracks

The answer is: D


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81
MEMBERS
80. The parts in______ are first precleaned, and then
preload with brazing metal in appropriate configurations,
before being placed in a furnace.
A. Furnace brazing
B. Induction brazing
C. Resistance brazing
D. Dip brazing

The answer is: A


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82
MEMBERS
81. Are difficult to solder.
A. Copper and gold
B. Aluminum and stainless steels
C. Adhesive bonding
D. Natural adhesive

The answer is: B


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83
MEMBERS
82. They are economical, and they permit easy and rapid
component assembly.
A. Crimping
B. Snap-In fasteners
C. Shrink and Press Fits
D. Ultrasonic welding

The answer is: B


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84
MEMBERS
83. The techniques used to calculate the coefficient of
friction generally involve measurement of either:
A. Ultrasonic vibrations
B. Forces or dimensional changes
C. Ring compression test
D. Wear

The answer is: B


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85
MEMBERS
84. Are used for stainless steels and high temperature
alloys.
A. Molybdenum Disulfide
B. Oxalate
C. Shot peening
D. Laser peening

The answer is: B


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86
MEMBERS
85. lons are introduced into the surface of the workpiece.
A. Chemical vapour deposition
B. Ton implant
C. Diffusion coating
D. Electroplating

The answer is: B


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87
MEMBERS
86. Of these inter-layer dielectrics is critical in the
reduction of metal shorts and of the linewidth variation of
the interconnect.
A. Etching
B. Planarization
C. Diamond sawing
D. All of these

The answer is: B


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88
MEMBERS
87. Is a substance with metallic properties, composed of
two or more elements of which at least one is a metal.
A. Age hardening
B. Artificial aging
C. Alloy
D. Alloying element

The answer is: C


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89
MEMBERS
88. Is a temper produced in a wire, rod, or tube by cold
drawing.
A. Free Carbon
B. Hard Drawn
C. Homogeneous Material
D. Izod test

The answer is: B


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90
MEMBERS
89. Are those not due to applied loads or temperature
gradients,
A. Red Shortness
B. Relaxation
C. Residual Stress
D. Rimmed Steel

The answer is: C


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91
MEMBERS
90. Is an annealing process whereby combined carbon in
white cast iron is transformed wholly or in part to temper
carbon.
A. Graphitizing
B. Hardening
C. Malleabilizing
D. Normalizing

The answer is: C


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92
MEMBERS
91. Load of 100 kg with diamond indenter used for case-
hardened metal.
A. Rockwell B
B. Rockwell C
C. Rockwell A
D. Rockwell D

The answer is: D


EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW
93
MEMBERS
92. Molybdenum steels with Nickel
A. 43XX
B. 46XX
C. 46XX and 48XX
D. 47XX

The answer is: B


EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW
94
MEMBERS
93. Nickel - chromium - molybdenum
A. 33XX
B. 40XX
C. 41XX
D. 43XX

The answer is: D


EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW
95
MEMBERS
94. Low-carbon alloy steels used chiefly
for______carburizing
A. 0.10 - 0.25%C
B. 0.25 -0.50%C
C. 250 and 400 Brinell
D. 0.50 - 0.70%C or more

The answer is: A


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96
MEMBERS
95. Improves machinability of stainless steel.
A. Nickel
B. Selenium
C. Silicon
D. Tantalum

The answer is: B


EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW
97
MEMBERS
96. For crankshafts, axles, gears, landing gear parts
A. AIS14063
B. AISI4130,4140
C. AISI 4340
D. AISI 4640

The answer is: C

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98
MEMBERS
97. The carbon content of the nitralloys falls within the
approximate range of
A. 0.20 to 0.10% carbon
B. 0.20 to 0.20% carbon
C. 0.20 to 0.30% carbon
D. 0.20 to 0.40% carbon

The answer is: D

EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW


99
MEMBERS
98. Induction hardening, as for gears teeth, may
produced a surface hardness of
A. Rc~ 50
B. Rc~55
C. RC ~ 60
D. Rc~ 65

The answer is: B

EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW


100
MEMBERS
99. Is the oldest known metals.
A. Cold working
B. Age hardening
C. Copper Alloys
D. Copper

The answer is: D

EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW


101
MEMBERS
100. Has a tin base and is a general purpose bearing
material for light and moderate service in various
machines.
A. Titanium
B. Babbit B23-46T
C. Babbit23-49
D. Hastelloy B
The answer is: B

EXCLUSIVE ONLY TO ES MECHANICAL ENGINEERING REVIEW


102
MEMBERS

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