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Progress test Nr.

001 Defects

1. What are main factors for defects to occur?


Answer:- The main factors for defects is change in :-
Size chemical composition,
structure and mechanical properties
of parts
Surface structure

2. Definition of defect is
Answer: - Defect is a physical, aesthetic, or functional attribute of a product or
service that exhibits that the product or service failed to meet one of the desired
specification.

3. How defects are classified?


Answer:- Classification of defect are:-
Based on Location:
External
Internal
Based on Type:
Geometric
Integrity
Based on Size/Severity:
Small/Minor
Large/Major
Based on Process:
Moulding-related
Filling-related
Solidification-related

Based on Cause:
Raw materials
Product design
Tooling design
Process parameters
Process Control
Based on stage:
Casting
Rough Machining
Finish Machininhg
Service
Based on Reparability:
Repairable
Irreparable

4. What are casting defects? Describe their nature and name examples.
Answer:- Casting defect is an undesired irregularity in a metal casting process.
Some defects can be tolerated while others can be repaired, otherwise they must be
eliminated. They are broken down into five main categories: gas
porosity, shrinkage defects, mold material defects, pouring metal defects,
and metallurgical defects.

5. What are rolling and forging defects? Describe their nature and name examples.
Forging The initial shape is squeezed and shaped between two opposing dies.
Rolling A slab or plate is squeezed between two rotating rolls to reduce the
height so as to produce thinner shapes like sheets.

6. What welded defects do you know?


Answer:- The defects in the weld can be defined as irregularities in the weld metal
produced due to incorrect welding parameters or wrong welding procedures or
wrong combination of filler metal and parent metal.
Weld defect may be in the form of variations from the intended weld bead shape,
size and desired quality. Defects may be on the surface or inside the weld metal.
Certain defects such as cracks are never tolerated but other defects may be
acceptable within permissible limits. Welding defects may result into the failure of
components under service condition, leading to serious accidents and causing the
loss of property and sometimes also life.
Various welding defects can be classified into groups such as cracks, porosity, solid
inclusions, lack of fusion and inadequate penetration, imperfect shape and
miscellaneous defects.

7. Name what welded defects do you see on the Picture?


Answer:-
A. Lack of Fusion and Inadequate or incomplete penetration.
B. Solid Inclusion
C. Porosity
D. Porosity
E. Cracks
F. Imperfect Shape or Miscellaneous Defects

Lecturer__K.Carjova__
Mark_____________

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