Exam Replica Version 1

Replica Metallography Training Exam

Exam Paper

Date

Time Allowed

Total Questions

Course Title

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Replica Metallography Training Exam 60 Mins

40

In-Situ Metallography

Instructions: There are 40 questions in this exam and all questions carry equal weightage. There is no negative marking for the wrong answers. Make sure to encircle on tick on single option only for each question.

Candidate Name ……………………………

Petromster ID ……………………………….

1) Which of the following is the main purpose of In-situ metallography? a) b) c) d)

To measure the wall thickness of the component To identify the type of corrosion operating in the system To study the microstructural features of the component at the surface To measure the crack length in any equipment

2) In which of the following condition field metallography is utilized mainly? a) b) c) d)

Material under high temperature exposure Equipment under highly corrosive environment Equipment exposed to H2S environment Components under highly stressed condition

3) Which of the following non-intrusive inspection technique is utilized for assessment of fire damage? a) b) c) d)

Long range ultrasonic thickness (LRUT) Hardness Testing Metallography Both (B) & (C)

4) Which of the following NDT technique cannot be utilized to identify creep damage which is limited to internal surface of the boiler tube? a) In-situ metallography b) hardness Testing c) Radiography d) All of above

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Replica Metallography Training Exam

5) Which of the following is the main disadvantage of in-situ metallography? a) It covers very small area of the component. b) It is non-intrusive technique C) It can detect micro-cracks if present in any component d) It is labor-intensive

6) What is the temperature range of the surfaces where replica metallography can be utilized? a) -100oC to 0oC b) 0 oC to 50 oC C) 50 oC to 100 oC d) 100 oC to 0 oC

7) Selection of the initial grit size for grinding depends on a) the initial condition of the surface (oxidized, pits etc) b) the ease of operator c) the location where replica is to be performed d) All of above

8) Which of the following chemicals can be utilized for cleaning before and after grinding and polishing for surface examination? a) Acetone b) Ethanol c) Both (a) & (b) d) Nital

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Replica Metallography Training Exam

9) What is the prime purpose of utilizing portable microscope on site after etching the surface? a) It serves as a quality check tool b) to evaluate the microstructural integrity c) to identify the crack locations d) to measure the grain size

10) which of the following features can result from shallow grinding? a) Decarburized microstructure b) Stress corrosion cracks c) Carburized microstructure d) None of the above

11) Too long an etching can result in which of the following microstructural features? a) Thick or stepped grain boundaries b) More pearlite phase in the carbon steels c) Inter-granular corrosion d) Grain dissolution

12) Direct pressure on the acetate film during mounting can result in? a) Cracks in the film b) Flattened microstructure c) Bubbles in the microstructure d) Creep damage

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Replica Metallography Training Exam

13) Which of the following damage mechanism can be identified by field metallography? a) Spherodization b) Creep damage c) Micro cracks d) All of the above

14) Is it possible to utilize field metallography for the curves surface? a) No, it can be used only for flat surface b) Yes, it can be used for both flat and curved surface c) It cannot be used for either flat or curved surface d) All of the above

15) When performing replica in equipment fired with Vanadium containing fuels it is mandatory to use a) Adequate respiratory protection b) Chemical gloves c) Hard Hat d) Disposable coveralls

16) Which of the following is the correct method for handling solvent containing cotton swabs? a) Placing them in plastic garbage bag after usage b) keeping them on the site after usage c) Burning them after usage d) None of the above

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Replica Metallography Training Exam

17) which etchant can be utilized for revealing sigma phase in carbon steels a) 2 % nital solution b) aqua-regia c) Kalling solution d) None of the above

18) Which of the following etchants cannot be utilized for revealing general structure of carbon steels a) Aqua-regia b) Kallings solution c) Vilella reagent d) All of above

19) While performing replication on the weld which areas need to be included in the replicated surface a) Only weld region b) Only heat affected zone c) only base metal d) weld region, HAZ & base metal

20) Which of the following is the most appropriate etchant for SA 213-T22 material a) Kalling solution b) 2% Nital c) Vilella reagent d) None of the above

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Replica Metallography Training Exam

21) which of the following is the commonly used etchant for SS 304 stainless steels a) Electrolytic etchant b) aqua-regia c) Nital d) Picral

22) Which of the following is the recommended action during inter-stage grinding? a) Etching b) Taking replica after each grinding step c) Cleaning and surface examination d) (a) & (C)

23) What are the commonly encountered phases in the carbon steel microstructure? a) Austenite b) Martensite c) Ferrite and pearlite d) All of the above

24) Which of the following chemical is utilized as lubricating during polishing stage? a) Aerosol b) Acetone c) Ethanol d) None of the above

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Replica Metallography Training Exam

25) Which of the following etchant can be utilized for low alloy steels a) Nital or kalling b) Aqua-regia c) electrolytic etching d) All of the above

26) The microstructure shown below has quality issues . What could be the reason for this.

a) Over-etching b) Shallow Grinding c) Over-polishing d) All of the above

27) Which etchant can be utilized for HP-40 (Nickel based alloy) reformer tubes? a) Nital b) Picral c) Vilella d) waterless Kalling solution

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Replica Metallography Training Exam 28) What is the minimum number of sample which need to be taken for each replica location? a) 2 b) 1 c) 4 d) 3

29) Which of the following PPEs should be utilizing while rough grinding? a) Gloves b) Face Shield c) Hard Hat d) All of above

30) What is the main microstructural constituent of SS 304 stainless steel? a) Martensite b) Austenite c) Ferrite d) Martensite

31) Which of the following is the correct interpretation of the following micrograph

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Replica Metallography Training Exam

a) Spherodised carbides in the ferrite matrix b) under-etched microstructure c) Unidentifiable microstructure due to severe quality issues d) None of the above

32) Which of the below statement correctly describes the microstructure below

a) Micro-cracks can be observed at the grain boundaries b) Carbides present at the grain boundaries c) Under etched microstructure d) All of the above 33) Which of the following statements correctly identifies the phases in the below micrograph

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Replica Metallography Training Exam

a) Ferrite and Pearlite b) Austenite c) Martensite d) The microstructure cannot be interpreted due to severe quality issues

34) The below micrograph belongs to ASTM A53 flange. What is the correct identification of the microstructure?

a) Ferrite and pearlite b) Ferrite and martensite c) Austenite and pearlite d) Ferrite and Bainite

35) Which of the following statement correctly identifies the phases in the below micrograph which belongs to carbon steel grade.

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Replica Metallography Training Exam

a) Ferrite and Pearlite b) Ferrite and bainite c) Ferrite and martensite d) Ferrite and austenite

36) What is the correct statement with regard to etching of cast and wrought Nickel based superalloys? a) Kalling solution can be utilized for both of the types b) Both of them will be etched by electrolytic etchant c) They cannot be etched with the same etchant d) None of the above

37) What is the probable phase(s) in the weld metal of ferritic steels? a) Martensite b) Bainite c) Ferrite and martensite d) All of the above 38) Which of the following correctly describes the micrograph below which belongs to SS 347 HFG?

a) Austenite grains with few grain boundary carbides b) Ferrite and spherodized carbides Tel: +966138967124 Fax: +966138967153, Email: [email protected]

Replica Metallography Training Exam c) Pearlite d) None of the above

39) While replicating the butt weld what is the correct orientation of placing replica film on surface? a) Replicas should be placed across the fusion line to cover WM, HAZ and PM b) Replica should be placed along the fusion line to cover part of WM, HAZ and PM c) Replica should be placed only on the weld region d) Replica should be placed only on the HAZ

40) Placing the wrong side of the acetate film on the slide will result in a) No microstructure will be observed if the other side is shaded black b) A dim microstructure with poorly defined features is observed if other side is not shaded c) Will make interpretation difficult d) All of the above

-------------------------------------- Nothing as follows ----------------------------------------------

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