AME 8 End of Unit – SVE Study

AME 8 End Of Unit Quiz

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What is a typical transition joint used to attach an aluminum superstructure to a steel hull?

C. A riveted joint with aluminum and steel rivets, where no insulating material is used, relying solely on the mechanical strength of the rivets.

B. A welded joint where aluminum and steel are joined directly using conventional welding techniques, despite the differences in their melting points.

A. A mechanical joint that uses a non-corrosive insulating material between the aluminum and steel, such as a plastic or rubber gasket, to prevent galvanic corrosion and ensure a secure connection.

D. A bonded joint using epoxy adhesive to attach the aluminum superstructure to the steel hull, without any additional protection against corrosion.

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What are cracks in a weld produced using the covered electrode welding process?

C. Defects involving gas bubbles trapped within the weld metal, which result in a porous structure and rough surface appearance.

B. Defects where non-metallic materials, such as slag or oxide, are trapped within the weld metal, leading to weakened weld strength and potential for failure.

A. Defects characterized by visible fissures or separations in the weld metal, caused by rapid cooling, high stresses, or improper welding parameters, which can significantly weaken the weld.

D. Defects where molten metal is expelled from the weld pool, creating irregular droplets of metal around the weld area.

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Question:

Which welding/brazing/soldering process is best suited for attaching a 1.0 mm steel section to a 10 mm thick deckhead plate, and why?

B. TIG Welding: Offers precise control and high-quality welds but may not be the most efficient for welding thin sections to much thicker plates due to the slower process and potential difficulties with heat management.

D. Soldering: Employs a low-temperature filler metal, which is not suitable for joining different thicknesses of steel sections due to its insufficient strength and durability for such applications.

C. Brazing: Uses a filler metal with a lower melting point but may not provide sufficient penetration and strength for welding thin sections to much thicker plates, especially in structural applications.

A. MIG Welding: Provides a good balance of speed and control, making it suitable for welding thin sections to thicker plates while offering consistent results and effective penetration.

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What is the process of explosion welding, and how is it used to join a steel hull to an aluminum superstructure?

A. Explosion welding involves detonating a high-explosive charge to force two metal surfaces together, creating a strong bond without melting the metals. This process is suitable for joining dissimilar metals like steel and aluminum due to its ability to handle different material properties.

B. Explosion welding uses a high-temperature flame to melt and fuse metal surfaces together, ensuring a seamless joint. It is ideal for joining metals with similar thermal expansion rates.

C. Explosion welding employs a laser to precisely weld metal surfaces by focusing high energy on the joining area, effectively merging dissimilar metals.

D. Explosion welding involves applying an electric arc between two metal electrodes to create a weld, which is then treated with a protective coating to prevent corrosion.

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What is the TIG welding process?

C. TIG welding involves melting the workpiece with a high-powered laser while simultaneously feeding in a solid filler material, with the weld shielded by a nitrogen gas to protect it from contamination.

A. TIG welding (Tungsten Inert Gas welding) involves using a tungsten electrode to create an electric arc between the electrode and the workpiece, with the weld area protected by an inert gas, usually argon or helium. The process may or may not include a filler rod, which is added separately to the weld pool.

D. TIG welding utilizes a rotating arc between a copper electrode and the workpiece, with the weld area shielded by a liquid flux, which helps to clean and protect the weld zone during the process.

B. TIG welding uses a consumable electrode that is continuously fed into the weld pool, while the workpiece is shielded by a combination of carbon dioxide and oxygen gases to facilitate the weld.

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What is lack of penetration in a weld produced using the covered electrode welding process?

B. A defect characterized by the formation of gas bubbles within the weld metal, leading to a porous structure and rough surface.

D. A defect where there are visible fissures or separations in the weld metal, often caused by rapid cooling or high stresses.

A. A defect where the weld metal does not fully penetrate the base metal, resulting in a shallow weld and poor fusion, which weakens the joint.

C. A defect where non-metallic materials, such as slag or oxide, are trapped within the weld metal, leading to reduced weld strength and potential for failure.

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What are the design safety features and inspections to be carried out on the oxy-acetylene welding torch and cylinders before commencing welding?

C. Verify that the welding torch is heated to the proper temperature, check the color of the cylinders, and ensure that hoses are free of kinks.

B. Ensure that the welding torch is painted for visibility, check that the cylinders are fully filled with gas, and confirm that the hoses are the correct color.

A. Inspect for gas leaks, ensure pressure gauges are functional, check the integrity of hoses, and verify that regulators are properly calibrated.

D. Confirm that the welding torch is equipped with an automatic shut-off feature, check for cylinder labels, and ensure the hoses are of the correct length.

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What are the particular problems associated with an aluminum superstructure when it is bonded to a steel hull?

D. The paint and coating systems applied to the aluminum and steel can react chemically, causing surface deterioration and reduced adhesion.

B. The aluminum superstructure often becomes too heavy for the steel hull, causing balance and stability issues for the vessel.

A. The formation of galvanic corrosion due to the electrical difference between aluminum and steel, which can lead to accelerated degradation of the aluminum and potential structural issues.

C. The differing thermal expansion rates between aluminum and steel lead to frequent joint failures and require special joint designs.

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Which welding/brazing/soldering process is best suited for joining two lengths of aluminium bronze seawater pipe with the same diameter, and why?

C. Brazing: Uses a filler metal with a lower melting point than the base metal, allowing for a strong bond between the aluminium bronze pipes without melting the base material.

A. TIG Welding: Provides precise control over the welding process and produces high-quality welds with minimal spatter, making it ideal for the thin-walled aluminium bronze pipes.

B. MIG Welding: Suitable for thicker materials but may not be the best choice for aluminium bronze pipes due to the potential for excessive spatter and the need for a more controlled environment.

D. Soldering: Utilizes a low-temperature filler metal and is not suitable for high-strength applications like aluminium bronze pipes due to its lower strength and durability.

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Why is an explosion-welded joint considered superior to an insulated bolt joint for joining a steel hull to an aluminum superstructure?

D. Explosion welding is more cost-effective and faster than using insulated bolts, which require precise torque settings and additional maintenance.

A. Explosion welding provides a continuous, seamless joint with high strength and minimal thermal distortion, whereas an insulated bolt joint may suffer from mechanical weaknesses and potential galvanic corrosion.

C. Explosion welding requires less surface preparation compared to insulated bolt joints, which need extensive surface cleaning and alignment.

B. Explosion welding allows for easy disassembly and reassembly, unlike insulated bolt joints which are permanent and difficult to modify.

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What are the advantages of TIG welding compared to other welding methods?

A. TIG welding provides high-quality welds with precise control over the heat and filler material, making it ideal for welding thin materials and producing aesthetically pleasing welds.

C. TIG welding is less expensive than methods like MIG or stick welding, making it a cost-effective choice for large-scale production.

D. TIG welding uses a wide range of filler materials, including plastic and ceramic, which makes it versatile for various applications.

B. TIG welding is faster than other welding methods and does not require any post-weld cleaning or finishing work, reducing overall labor time.

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Which welding/brazing/soldering process is best suited for re-attaching a section of a broken flange on a cast iron pump casing, and why?

A. Brazing: Utilizes a filler metal with a lower melting point than the base metal, which can effectively join cast iron without the need for high temperatures that could cause further damage to the pump casing.

D. Soldering: Employs a low-temperature filler metal, which is not suitable for high-strength or high-temperature applications such as re-attaching a broken flange on a cast iron pump casing.

C. MIG Welding: Typically used for thinner materials and may not be suitable for cast iron due to potential difficulties in managing heat and avoiding cracks.

B. TIG Welding: Provides high precision and control but may not be ideal for cast iron due to the high temperatures involved, which could lead to further cracking or thermal stress in the cast iron.

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