INSPECTION AND QUALITY CONTROL IN MANUFACTURING

Solution for Assignment-03

1. Which inspection technique necessitates stress during the inspection process and
identifies the movement of defects when loading a test component?
(a) Acoustic emission inspection
(b) Magnetic particle inspection
(c) Dye penetrant inspection
(d) None of these.

Sol. Acoustic emission inspection method is considered as quite unique among the non-
destructive testing methods. Using Acoustic Emission equipment, we can “listen” to
the sounds of cracks growing, fibers breaking, and many other modes of active damage
in the stressed material. In contrast to other NDT methods, Acoustic Emission Testing
(AET) is usually applied during loading, while most others are applied before or after
loading of a structure.

2. Which non-destructive inspection technique relies on the physical phenomenon that any
body with a temperature above absolute zero (-273.15 °C) emits electromagnetic
radiation?
(a) Radiography inspection
(b) Magnetic particle inspection
(c) Thermographic inspection
(d) Eddy current inspection

Sol. Principle of thermography is based on the physical phenomenon that any body of a
temperature above absolute zero (-273.15 °C) emits electromagnetic radiation. The
emitted infrared energy is a function of the object’s temperature and its relative
efficiency of thermal radiation, known as emissivity.

3. In acoustic emission inspection, the increase in the amplitude of the acoustic emission
(AE) signal is attributed to:
(a) Plastic deformation
(b) Mechanically induced twinning
(c) Small grain size
(d) Ductile failure
Sol. Factors which tend to increase the amplitude of AE signal are: high strength, high strain
rate, low temperature, anisotropy, martensitic phase transformations, crack propagation, large
grain size, mechanically induced twinning, etc.

4. What factors typically lead to an increase in the amplitude of acoustic emission (AE)?

(a) Isotropy
(b) High strain rate
(c) Homogeneity
(d) High temperature
Sol. Factors that tend to increase the amplitude of AE are: high strength, high strain rate,
low temperature, anisotropy, heterogeneity, etc. Factors that tend to decrease the amplitude of
AE are: low strength, low strain rate, high temperature, isotropy, homogeneity, etc.

5. In which of the following thermographic inspection techniques is an energy source

needed to create a thermal contrast between the feature of interest and the background?

(a) Active thermography

(b) Passive thermography
(c) Passive and active thermography
(d) None of these

Sol. In active thermography, an energy source is required to produce a thermal contrast

between the feature of interest and the background, whereas in passive thermography,
the features of interest are naturally at a higher or lower temperature than the
background.

6. What statements are true regarding cooled infrared detectors (thermographic cameras)
among the following?
(a) Cooled infrared cameras exhibit lower sensitivity compared to uncooled infrared
detectors.
(b) Cooled infrared detectors employ a sensor stabilized at a temperature near ambient
using small temperature control elements.
(c) Typical operating temperatures range from 4 Kelvin to slightly below room
temperature.
(d) None of these.

Sol. Thermographic cameras can be divided into two types: cooled infrared detectors, and
uncooled infrared detectors. Cooled IR detectors are typically contained in a vacuum-
sealed case and cryogenically cooled. The cooling is necessary for the operation of the
 semiconductor materials used. Typical operating temperatures for cooled IR detectors
range from 4 K to just below room temperature.

7. Which of the following statements are not accurate concerning accelerator-type neutron
sources?
(a) The DD reaction is preferred over the DT reaction because the yield of the DD
reaction is 50–100 times higher than that of the DT reaction.
(b) The fusion of a deuterium and a tritium atom (D + T) leads to the creation of a He-
4 ion and a neutron with a kinetic energy of around 14 MeV.
(c) The fusion of deuterium atoms (D + D) produces a He-3 ion and a neutron with a
kinetic energy of approximately 2.5 MeV.
(d) In these systems, deuterium and tritium ions are accelerated toward a target that
also contains the same isotopes.

Sol. The correct statement is:

The DT reaction is used more than the DD reaction because the yield of the DT reaction is 50–
100 times higher than that of the DD reaction.

8. What is the alternative name for modulated thermography among the following
thermographic inspection methods?
(a) Burst Vibrothermography
(b) Lock-in Thermography
(c) Pulsed Thermography
(d) None of these

Sol. Lock-in thermography (LT) is also known as modulated thermography. In this method,
a small surface spot is periodically illuminated by an intensity modulated laser beam to
inject thermal waves into the specimen.

9. Which layer of the radiographic film is employed to prevent film curling caused by
emulsion swelling during processing?
(a) Emulsion layer
(b) Top coat layer
(c) Film base
(d) Backing layer

Sol. The function of backing layer is to prevent film curling due to swelling of emulsion
during processing. It also helps to prevent reflection of stray light from the film support
material back into the light-sensitive area.

10. What does MARSE stand for?

(a) Measured Area under the Rectified Sensitive Envelope
 (b) Mean Acoustic Ringdown Signal Envelope
(c) Measured Area under the Rectified Signal Envelope
(d) None of these.

Sol. MARSE (Measured Area under the Rectified Signal Envelope) is the measure of the
area under the envelope of the rectified linear voltage time signal from the transducer. It is
sensitive to the duration and amplitude of the signal, but does not use counts or user defined
thresholds and operating frequencies.